Three-in-one oil cooling electric drive assembly

Abstract

The invention belongs to the technical field of automobile power assemblies, and particularly relates to a three-in-one oil cooling electric drive assembly. Comprising a speed reducer, a motor, a controller and an integrated shell. The speed reducer and the motor are installed on the two adjacent sides of the integrated shell correspondingly. A mounting groove is formed in the integrated shell; the controller is mounted in the mounting groove; a cooling oil channel is formed in the integrated shell; the cooling oil duct is communicated with the speed reducer, the motor, the controller and the integrated shell; one end of the cooling oil duct is communicated with the oil pump, and the other end of the cooling oil duct is communicated with the first main oil duct, the second main oil duct and the third main oil duct; the controller, the motor and the speed reducer share an oil duct, the heat dissipation efficiency of the controller is improved, the complex staggered cooling paths are avoided, and the size of an electric drive assembly is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile powertrain, and in particular relates to a three-in-one oil-cooled electric drive assembly. Background Art

[0002] The electric drive three-in-one assembly is an important technology in new energy vehicles. It refers to a comprehensive component consisting of a motor, a reducer and a controller. Power transmission is achieved through the motor and the reducer, and the output of the motor is controlled and adjusted through the controller, so as to achieve the purpose of improving the efficiency of the electric drive and reducing energy consumption. Its function is to convert electrical energy into mechanical energy to drive the new energy vehicle to travel; the controller is the brain of the electric drive system, controlling and adjusting the output of the motor to ensure the smooth and efficient operation of the electric drive system.

[0003] The traditional three-in-one electric drive assembly integrates the motor controller, motor and reducer into one, reducing the overall volume of the product, making the product smaller and lighter. At present, the mainstream electric drive assembly mainly uses water-cooled motor controllers and oil-cooled motors and reducers. Among them, the motor controller uses a water-cooled plate structure to cool the IGBT module, and the motor and reducer use an oil channel structure for cooling oil circulation and heat dissipation, ultimately achieving the heat dissipation requirements of the three-in-one electric drive assembly. Summary of the invention

[0004] In view of the above problems, the present invention proposes a three-in-one oil-cooled electric drive assembly, comprising a reducer, a motor, a controller and an integrated housing; the reducer and the motor are respectively mounted on two adjacent sides of the integrated housing; a mounting groove is provided on the integrated housing; the controller is mounted in the mounting groove;

[0005] A cooling oil passage is provided on the integrated housing; the cooling oil passage is connected with the reducer, the motor, the controller and the integrated housing; one end of the cooling oil passage is connected with the oil pump, and the other end of the cooling oil passage is connected with the first main oil passage, the second main oil passage and the third main oil passage; the first main oil passage is provided at the integrated housing at a position corresponding to the reducer; the second main oil passage is provided at the integrated housing at a position corresponding to the motor; the third main oil passage is provided in the mounting groove; the first main oil passage is connected with the oil passage inside the reducer, the second main oil passage and the third main oil passage; the second main oil passage is connected with the oil passage inside the motor; the third main oil passage is connected with the oil passage inside the controller;

[0006] A motor oil return passage is provided at one end of the motor away from the reducer; one end of the motor oil return passage is connected to the first main oil passage, the second main oil passage and the third main oil passage, and the other end of the motor oil return passage is connected to the oil pump.

[0007] Furthermore, a No. 1 groove is provided in the installation groove; a first branch oil inlet is provided at one end of the No. 1 groove close to the third main oil passage, and a first branch oil outlet is provided at one end away from the third main oil passage; a No. 1 copper bar assembly is installed on the No. 1 groove, and a first branch oil passage is provided in the No. 1 copper bar assembly; the third main oil passage is connected with the first branch oil inlet; the first branch oil inlet is connected with the first branch oil outlet via the first branch oil passage; the first branch oil inlet is provided at one end of the No. 1 groove close to the third main oil passage; the first branch oil outlet is provided at one end of the No. 1 groove away from the third main oil passage.

[0008] Furthermore, the third main oil channel is connected to the second branch oil inlet channel; the second branch oil inlet channel is connected to the second branch oil outlet channel via the second branch oil circuit; the second branch oil circuit flows through the IGBT module; one end of the IGBT module is connected to the second branch oil inlet channel, and the other end of the IGBT module is connected to the second branch oil outlet channel.

[0009] Furthermore, a sealing groove is provided at the top of the No. 1 groove; the sealing groove cooperates with the No. 1 copper busbar assembly to achieve internal sealing of the No. 1 groove.

[0010] Furthermore, a first oil return channel is provided at one end of the integrated housing away from the controller; one end of the first oil return channel is connected to a first branch oil outlet channel; and the first oil return channel is connected to the motor oil return channel.

[0011] Furthermore, the second branch oil outlet passage is communicated with the middle portion of the first oil return passage.

[0012] Furthermore, one end of the first oil return flow channel away from the first branch oil outlet channel is connected to the second oil return flow channel.

[0013] Furthermore, the first oil return flow channel and the second oil return flow channel are arranged perpendicularly.

[0014] Furthermore, the second oil return channel is provided with a plurality of oil outlet holes; the No. 1 oil hole connected to the oil outlet hole is provided on the No. 2 copper busbar assembly; the No. 2 oil hole is provided on the rear end cover of the motor; the No. 1 oil hole is connected to the motor oil return channel via the No. 2 oil hole.

[0015] Furthermore, an oil pump port is provided on the integrated housing; the oil pump port is connected to the oil filter via a cooling oil channel; the oil filter is connected to an oil cooler; the oil cooler is connected to the first main oil channel, the second main oil channel and the third main oil channel.

[0016] Beneficial Effects

[0017] The beneficial effects of the present invention compared to the prior art are as follows:

[0018] 1. The present application sets a first main oil channel, a second main oil channel and a third main oil channel, and the second main oil channel and the third main oil channel are connected to the first main oil channel, so that the controller, the motor and the reducer share the same oil channel design, thereby improving the heat dissipation efficiency of the controller, avoiding the complexity of the cooling path, and reducing the volume of the electric drive assembly.

[0019] 2. In the present application, an oil cooling structure is adopted for the IGBT (Insulated Gate Bipolar Transistor) module through the second branch oil circuit to directly dissipate the heat of the chip in the IGBT module and improve product performance.

[0020] 3. The present application designs the first branch oil circuit and the second branch oil circuit on the No. 1 copper busbar assembly and the No. 2 copper busbar assembly to improve the heat dissipation of the copper busbar, reduce the heat of the DC copper busbar, the film capacitor copper busbar and the three-phase copper busbar, and increase the current density.

[0021] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0023] Figure 1 An overall schematic diagram of an embodiment of the present invention is shown.

[0024] Figure 2 A schematic diagram of the internal structure in an embodiment of the present invention is shown.

[0025] Figure 3 A schematic diagram of the internal structure in another direction of an embodiment of the present invention is shown.

[0026] Figure 4 A schematic diagram of the first branch oil outlet passage in an embodiment of the present invention is shown.

[0027] Figure 5 A schematic structural diagram of the bottom of the integrated housing in an embodiment of the present invention is shown.

[0028] Figure 6 A schematic diagram of the flow path after the cooling oil in an embodiment of the present invention is shown.

[0029] Figure 7 A schematic diagram of the flow path of the cooling oil during the cooling process in an embodiment of the present invention is shown.

[0030] Figure 8 A schematic diagram of the flow path of cooling oil for cooling a three-phase copper busbar in an embodiment of the present invention is shown.

[0031] Fig. 9 A schematic diagram of three-phase copper row oil cooling in an embodiment of the present invention is shown.

[0032] In the figure, 10, reducer; 20, motor; 21, rear end cover of the motor;

[0033] 30, controller; 301, DC copper busbar; 302, film capacitor copper busbar; 303, IGBT module; 304, No. 2 copper busbar assembly; 3041, three-phase copper busbar; 3042, No. 1 oil hole;

[0034] 40. Integrated housing; 41. Cooling oil passage; 411. First main oil passage; 412. Second main oil passage;

[0035] 413, third main oil passage; 4131, first branch oil passage; 4132, second branch oil passage; 4134, second oil return passage; 4135, No. 1 groove; 4136, first branch oil inlet passage; 4137, second branch oil inlet passage; 4138, second branch oil outlet passage; 4139, first branch oil outlet passage; 4140, first oil return passage; 4141, oil outlet hole; 4142, sealing groove;

[0036] 42. Motor oil return channel;

[0037] 50. Oil pump port; 60. Oil filter; 70. Oil cooler. DETAILED DESCRIPTION

[0038] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] The controller in the traditional electric drive assembly adopts water cooling for heat dissipation; however, water cooling is an indirect cooling method with poor cooling effect, which can hardly meet the heat dissipation requirements of the controller; at the same time, the water channel structure and oil channel structure in the traditional electric drive assembly are designed independently, and the wall thickness between the water channel and the oil channel needs to be sufficient to prevent leakage, which leads to a complex heat dissipation structure and a larger electric drive assembly.

[0040] Therefore, this application provides a three-in-one oil-cooled electric drive assembly, such as Figure 1 As shown, the reducer 10 is installed on the front side of the integrated housing 40, and the motor 20 is installed on the left side of the integrated housing 40; it includes a reducer 10, a motor 20, a controller 30 and an integrated housing 40; the reducer 10 and the motor 20 are respectively installed on both sides of the integrated housing 40; the integrated housing 40 is provided with a mounting groove; the controller 30 is installed in the mounting groove;

[0041] like Figure 2 and Figure 6 As shown; a cooling oil passage 41 is provided on the integrated housing 40; the cooling oil passage 41 is connected to the reducer 10, the motor 20, the controller 30 and the integrated housing 40; the cooling oil passage 41 is connected to the first main oil passage 411, the second main oil passage 412 and the third main oil passage 413; the first main oil passage 411 is connected to the oil passage inside the reducer 10, the second main oil passage 412 and the third main oil passage 413; the second main oil passage 412 is connected to the oil passage inside the motor 20; the third main oil passage 413 is connected to the oil passage inside the controller 30;

[0042] refer to Figure 8 The motor 20 is provided with a motor oil return passage 42; one end of the motor oil return passage 42 is connected to the first main oil passage 411, the second main oil passage 412 and the third main oil passage 413, and the other end of the motor oil return passage 42 is connected to the oil pump.

[0043] During the implementation process, the cooling oil channel 41 is integrated into the integrated housing 40 to avoid the use of hose connections, reduce the use of parts, and simplify the structure; the cooling oil flows from the oil pump through the cooling oil channel 41 to the first main oil channel 411, and flows into the oil circuit through the first main oil channel 411 to lubricate the gears and bearings inside the reducer 10; then flows to the second main oil channel 412 and the third main oil channel 413 through the first main oil channel 411 respectively; flows into the oil circuit inside the motor 20 through the second main oil channel 412 to cool the stator and rotor inside the motor 20; because the cooling oil has good insulation, the cooling oil enters the controller 30 through the third main oil channel 413 to cool the components inside the controller 30; finally, after the cooling oil of the first main oil channel 411, the second main oil channel 412 and the third main oil channel 413 is completed, it is collected into the oil pump through the motor return oil channel 42 to form a complete electric drive assembly oil circuit cooling circuit;

[0044] The present application sets a third main oil channel 413 so that the controller 30, the motor 20 and the reducer 10 share the same oil channel design, thereby improving the heat dissipation efficiency of the controller 30 and reducing the volume of the electric drive assembly.

[0045] In one embodiment of the present invention, Figure 3 and Figure 7As shown; a groove No. 1 4135 is provided in the installation groove; a copper bar assembly No. 1 is installed in the groove No. 1 4135; the third main oil passage 413 is connected with the first branch oil inlet passage 4136; the first branch oil inlet passage 4136 is connected with the first branch oil outlet passage 4139 via the first branch oil passage 4131; the first branch oil inlet passage 4136 is provided in the groove No. 1 4135 near one end of the third main oil passage 413; as shown Figure 4 As shown; the first branch oil outlet channel 4139 is opened in the first groove 4135 at one end away from the third main oil channel 413.

[0046] In one embodiment of the present invention, a sealing groove 4142 is formed on the top of the No. 1 groove 4135 ; the sealing groove 4142 cooperates with the No. 1 copper busbar assembly to achieve internal sealing of the No. 1 groove 4135 .

[0047] During the implementation process, the cooling oil flows into the third main oil channel 413 through the cooling oil channel 41, and then flows into the No. 1 groove 4135 through the first branch oil inlet channel 4136. The No. 1 copper bar assembly in the No. 1 groove 4135 is a DC copper bar 301 and a film capacitor copper bar 302; the DC copper bar 301 and the film capacitor copper bar 302 are installed on the top of the No. 1 groove 4135, and a sealing ring is arranged in the sealing groove 4142. The cooling oil in the No. 1 groove 4135 is sealed by the sealing groove 4142, the sealing ring and the No. 1 copper bar assembly; wherein the first branch oil circuit 4131 includes the No. 1 copper bar assembly; the connecting terminals of the DC copper bar 301 assembly and the film capacitor copper bar 302 extend to the inside of the No. 1 groove 4135 and contact with the cooling oil; the cooling oil flows into the No. 1 groove 4135 to fully dissipate the heat of the DC copper bar 301 assembly and the film capacitor copper bar 302, thereby reducing the heat of the DC copper bar 301 and the film capacitor copper bar 302 and increasing the current density;

[0048] Then, the cooling oil flows into the first oil return channel 4140 through the first branch oil outlet channel 4139 ; the cooling oil returns to the oil pump through the motor oil return channel 42 .

[0049] In one embodiment of the present invention, Figure 7 As shown; the third main oil channel 413 is connected to the second branch oil inlet channel 4137; the second branch oil inlet channel 4137 is connected to the second branch oil outlet channel 4138 via the second branch oil channel 4132; the second branch oil channel 4132 flows through the IGBT module 303; one end of the IGBT module 303 is connected to the second branch oil inlet channel 4137, and the other end of the IGBT module 303 is connected to the second branch oil outlet channel 4138.

[0050] During the implementation, the first branch oil circuit 4131 and the second branch oil circuit 4132 are arranged in parallel and staggered; and the first branch oil circuit 4131 and the second branch oil circuit 4132 are arranged perpendicular to the third main oil channel 413; part of the cooling oil in the third main oil channel 413 flows into the second branch oil circuit 4132 through the second branch oil inlet channel 4137 (the second branch oil circuit 4132 includes the IGBT module 303 oil circuit, the IGBT module 303 oil circuit is opened in the IGBT module 303, and the IGBT module 303 is provided with an oil inlet and an outlet. The oil port is connected to the second branch oil inlet channel 4137 and the second branch oil outlet channel 4138 respectively, and is in direct contact with the chip of the IGBT module 303; the IGBT module 303 is fully cooled and dissipated to improve product performance; and then flows into the first return oil channel 4140 through the second branch oil outlet channel 4138, and merges with the cooling oil in the first branch oil outlet channel 4139; an oil heat dissipation channel is provided for the IGBT module 303 through the second branch oil inlet channel 4137, the second branch oil circuit 4132 and the second branch oil outlet channel 4138.

[0051] In one embodiment of the present invention, Figure 5 and Figure 7 As shown, the end of the integrated housing 40 away from the controller 30 is provided with a first oil return channel 4140; one end of the first oil return channel 4140 is connected to the first branch oil outlet channel 4139; the first oil return channel 4140 is connected to the motor oil return channel 42. The first oil return channel 4140 is opened at the bottom of the integrated housing 40.

[0052] In one embodiment of the present invention, Figure 7 As shown; the second branch oil outlet channel 4138 is connected to the middle part of the first oil return channel 4140.

[0053] In one embodiment of the present invention, one end of the first oil return channel 4140 away from the first branch oil outlet channel 4139 is connected to the second oil return channel 4134 .

[0054] In one embodiment of the present invention, Figure 5 As shown; the first oil return channel 4140 and the second oil return channel 4134 are arranged vertically.

[0055] In one embodiment of the present invention, Figure 8 and Fig. 9 As shown; the second oil return channel 4134 is provided with a plurality of oil outlet holes 4141; the No. 1 oil hole 3042 connected with the oil outlet hole 4141 is provided on the No. 2 copper busbar assembly 304; the No. 2 oil hole is provided on the rear end cover 21 of the motor; the No. 1 oil hole 3042 is connected with the motor oil return channel 42 via the No. 2 oil hole.

[0056] During the implementation process, the cooling oil in the first branch oil circuit 4131 and the second branch oil circuit 4132 flows through the first oil return channel 4140 and the second oil return channel 4134; after flowing through the second oil return channel 4134, the cooling oil flows out from the No. 1 oil outlet hole 4141; flows into the No. 2 copper busbar assembly 304 through the No. 1 oil outlet hole 4141, and cools the three-phase copper busbar 3041; then it is collected from the No. 2 oil hole on the rear end cover 21 of the motor to the motor return oil channel 42 at the bottom of the motor 20, and finally collected to the oil pump.

[0057] In one embodiment of the present invention, Figure 6 As shown, the integrated housing 40 is provided with an oil pump port 50; the oil pump port 50 is connected to the oil filter 60 through the cooling oil passage 41; the oil filter 60 is connected to the oil cooler 70; the oil cooler 70 is connected to the first main oil passage 411, the second main oil passage 412 and the third main oil passage 413. The oil pump port 50 is also provided at the bottom of the integrated housing 40.

[0058] During the implementation process, the cooling oil is in the oil circuit inside the reducer 10, the motor 20 and the controller 30. After working, the cooling oil passes through the motor oil return channel 42 and the oil pump port 50 to be collected in the oil pump; then it flows into the oil filter 60 through the cooling oil channel 41, and the cooling oil is filtered by the oil filter 60 to filter out the impurities in the cooling oil after the cooling work; then it flows through the oil cooler 70, because the cooling oil will absorb heat after the cooling work, so the temperature rises, so it needs to lower the temperature, and then enter the first main oil channel 411, the second main oil channel 412 and the third main oil channel 413 again for cooling work; forming a complete oil circuit cooling circuit of the three-in-one oil-cooled electric drive assembly; ensuring the working effect of the cooling oil.

[0059] Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent substitutions for some of the technical features therein; and these modifications or substitutions do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A three-in-one oil-cooled electric drive assembly, characterized in that: The invention comprises a reducer (10), a motor (20), a controller (30) and an integrated housing (40); the reducer (10) and the motor (20) are respectively mounted on two adjacent sides of the integrated housing (40); a mounting groove is provided on the integrated housing (40); and the controller (30) is mounted in the mounting groove; The integrated housing (40) is provided with a cooling oil passage (41); the cooling oil passage (41) is connected to the reducer (10), the motor (20), the controller (30) and the integrated housing (40); one end of the cooling oil passage (41) is connected to the oil pump, and the other end of the cooling oil passage (41) is connected to the first main oil passage (411), the second main oil passage (412) and the third main oil passage (413); the first main oil passage (411) is opened in the integrated housing (40) at a position corresponding to the reducer (10) The second main oil passage (412) is opened at a position of the integrated housing (40) corresponding to the position of the motor (20); the third main oil passage (413) is opened in the mounting groove; the first main oil passage (411) is in communication with the oil passage inside the reducer (10), the second main oil passage (412) and the third main oil passage (413); the second main oil passage (412) is in communication with the oil passage inside the motor (20); the third main oil passage (413) is in communication with the oil passage inside the controller (30); A motor oil return passage (42) is provided at one end of the motor (20) away from the reducer (10); one end of the motor oil return passage (42) is connected to the first main oil passage (411), the second main oil passage (412) and the third main oil passage (413), and the other end of the motor oil return passage (42) is connected to the oil pump.

2. A three-in-one oil-cooled electric drive assembly according to claim 1, characterized in that: A No. 1 groove (4135) is provided in the installation groove; a first branch oil inlet channel (4136) is provided in the No. 1 groove (4135) at one end close to the third main oil channel (413), and a first branch oil outlet channel (4139) is provided at one end away from the third main oil channel (413); a No. 1 copper bar assembly is installed on the No. 1 groove (4135), and a first branch oil passage (4131) is provided in the No. 1 copper bar assembly; the third main oil channel (413) is connected with the first branch oil inlet channel (4136); the first branch oil inlet channel (4136) is connected with the first branch oil outlet channel (4139) via the first branch oil passage (4131); the first branch oil inlet channel (4136) is provided in the No. 1 groove (4135) at one end close to the third main oil channel (413); the first branch oil outlet channel (4139) is provided in the No. 1 groove (4135) at one end away from the third main oil channel (413).

3. The three-in-one oil-cooled electric drive assembly according to claim 2, characterized in that: The third main oil channel (413) is connected to the second branch oil inlet channel (4137); the second branch oil inlet channel (4137) is connected to the second branch oil outlet channel (4138) via the second branch oil circuit (4132); the second branch oil circuit (4132) flows through the IGBT module (303); one end of the IGBT module (303) is connected to the second branch oil inlet channel (4137), and the other end of the IGBT module (303) is connected to the second branch oil outlet channel (4138).

4. The three-in-one oil-cooled electric drive assembly according to claim 3, characterized in that: A sealing groove (4142) is provided at the top of the No. 1 groove (4135); the sealing groove (4142) cooperates with the No. 1 copper bar assembly to achieve internal sealing of the No. 1 groove (4135).

5. The three-in-one oil-cooled electric drive assembly according to claim 4, characterized in that: A first oil return channel (4140) is provided at one end of the integrated housing (40) away from the controller (30); one end of the first oil return channel (4140) is connected to a first branch oil outlet channel (4139); and the first oil return channel (4140) is connected to the motor oil return channel (42).

6. A three-in-one oil-cooled electric drive assembly according to claim 5, characterized in that: The second branch oil outlet channel (4138) is connected to the middle part of the first oil return channel (4140).

7. The three-in-one oil-cooled electric drive assembly according to claim 6, characterized in that: One end of the first oil return channel (4140) away from the first branch oil outlet channel (4139) is connected to the second oil return channel (4134).

8. The three-in-one oil-cooled electric drive assembly according to claim 7, characterized in that: The first oil return channel (4140) and the second oil return channel (4134) are arranged vertically.

9. The three-in-one oil-cooled electric drive assembly according to claim 8, characterized in that: The second oil return channel (4134) is provided with a plurality of oil outlet holes (4141); the second copper busbar assembly (304) is provided with a first oil through hole (3042) connected to the oil outlet hole (4141); the motor rear end cover (21) is provided with a second oil through hole; the first oil through hole (3042) is connected to the motor oil return channel (42) via the second oil through hole.

10. A three-in-one oil-cooled electric drive assembly according to claim 9, characterized in that: The integrated housing (40) is provided with an oil pump port (50); the oil pump port (50) is communicated with an oil filter (60) via a cooling oil passage (41); the oil filter (60) is communicated with an oil cooler (70); the oil cooler (70) is communicated with a first main oil passage (411), a second main oil passage (412) and a third main oil passage (413).

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