Front suspension hub motor wheel edge integrated structure, assembly method and automobile

Abstract

The application relates to the technical field of automobile part structures, in particular to a front suspension hub motor wheel edge integrated structure, an assembling method and an automobile. The front suspension hub motor wheel edge integrated structure comprises a rim, a hub motor, a front suspension and a brake, the rim is a hollow ring structure; the hub motor is located on the inner side of the rim and comprises an outer rotor shell fixed at one end of the rim away from the vehicle body and a stator shell arranged on the outer rotor shell; one end of the stator shell close to the vehicle body is located on the inner side of the rim in the axial direction; the front suspension comprises a steering knuckle fixedly connected with one end of the stator shell close to the vehicle body; and the brake comprises a brake caliper fixedly connected with the steering knuckle and a brake disc connected with one end of the outer rotor shell close to the vehicle body. The front suspension hub motor wheel edge integrated structure of the application completely integrates the hub motor in the rim, reserves sufficient assembling space for the wheel edge, facilitates the arrangement of the front suspension and pipelines, and reserves multiple interfaces, which greatly facilitates the assembling of the front suspension and the pipelines.

Description

Technical Field

[0001] This invention relates to the field of automotive component structure technology, specifically to a front suspension hub motor wheel-side integrated structure, assembly method, and automobile. Background Technology

[0002] Currently, hub motors are mainly used in small electric vehicles, such as electric cars, electric bicycles, electric scooters, and special vehicles. However, existing hub motors still have certain defects due to their structure. These defects include, but are not limited to, space ratio, load capacity, output reliability, and working stability. In particular, in terms of space ratio, they need to occupy most of the chassis space to meet the installation requirements of the hub motor, resulting in too little battery installation space and a significant reduction in range.

[0003] To address the aforementioned issues, existing technology has proposed a hub motor structure. This hub motor includes a motor rotor, a motor stator, a spindle assembly, a steering knuckle, and a brake. The motor rotor includes a first spoke portion, and the motor stator includes a second spoke portion. The first and second spoke portions are coaxially mounted on the spindle assembly, both located at the first end of the spindle assembly. The steering knuckle is located at the second end of the spindle assembly and is fixedly connected to the motor stator. The brake is located inside the steering knuckle facing the first end of the spindle assembly. This hub motor has a simple and compact structure, occupying little space. The motor rotor and stator are coaxially mounted on the first end of the spindle assembly via the first and second spoke portions, respectively. The brake is located inside the steering knuckle at the second end of the spindle assembly. Therefore, when the steering knuckle is removed, the brake is exposed, allowing for maintenance and replacement without separating the motor stator and rotor. This simplifies operation and reduces the difficulty and cost of brake maintenance in hub motors.

[0004] However, this structure also has some problems. It does not make full use of the wheel-side space. The connection between the hub motor and the wheel is through the hub flange interface. Because the motor rotor housing protrudes outward from the vehicle, the entire vehicle will shift outward when the wheel is installed. The wheel-side space is not used compactly, which restricts the layout space of the vehicle chassis suspension and makes the chassis suspension layout extremely difficult. Further improvements are needed to improve the utilization rate of the wheel-side space. Summary of the Invention

[0005] The purpose of this application is to address the shortcomings of the aforementioned background technology and to provide a front suspension hub motor wheel-side integrated structure, assembly method, and automobile.

[0006] The technical solution of this application is: a front suspension hub motor wheel-side integrated structure, comprising,

[0007] The rim is a hollow annular structure;

[0008] A hub motor, located inside the wheel rim, includes an outer rotor housing fixed to the end of the wheel rim away from the vehicle body and a stator housing disposed on the outer rotor housing; the end of the stator housing closest to the vehicle body is located axially inside the wheel rim.

[0009] A front suspension, the front suspension including a steering knuckle fixedly connected to the stator housing near one end of the vehicle body;

[0010] The brake includes a brake caliper fixed to the steering knuckle and a brake disc connected to the outer rotor housing near the vehicle body.

[0011] According to the front suspension hub motor wheel-side integrated structure provided in this application, the wheel rim is provided with spokes at the end away from the vehicle body; the spokes are provided with screw holes for fixed connection with the outer rotor housing.

[0012] According to the front suspension hub motor wheel-side integrated structure provided in this application, the stator housing is provided with a plurality of first mounting holes at one end near the vehicle body; the steering knuckle is provided with a plurality of second mounting holes corresponding to the first mounting holes.

[0013] According to the front suspension hub motor wheel-side integrated structure provided in this application, the stator housing is provided with two sets of first mounting holes at one end near the vehicle body. The two sets of first mounting holes are symmetrically arranged with the axis of the stator housing as the center, and each set includes at least two first mounting holes arranged at intervals in the vertical or horizontal direction.

[0014] According to the wheel-side integrated structure of the front suspension hub motor provided in this application, the middle portion of the stator housing near the vehicle body is recessed axially away from the vehicle body, and the edge portion away from the axis is bent axially towards the vehicle body.

[0015] According to the front suspension hub motor wheel-side integrated structure provided in this application, the brake disc is an annular structure, and a first connecting structure is provided on the outer circumference of the brake disc; the first connecting structure corresponds to a second connecting structure at the end of the outer rotor housing near the vehicle body, and the brake disc is fixedly connected to the outer rotor housing through the first connecting structure and the second connecting structure.

[0016] According to the present application, a front suspension hub motor wheel-side integrated structure is provided, wherein the first connecting structure includes a plurality of bosses arranged at equal intervals along the circumference on the outer side of the brake disc; the second connecting structure includes an annular flange disposed on the inner side of the outer rotor housing near the vehicle body; the bosses are fixedly connected to the flange by bolts passing through the bosses and the flange along the axial direction.

[0017] According to the front suspension hub motor wheel-side integrated structure provided in this application, the front suspension includes,

[0018] The shock absorber has its lower end fixedly connected to the clamping and fixing hole on the portion of the steering knuckle that extends axially outward from the outer side of the wheel rim, and its upper end fixedly connected to the vehicle body via an upper support seat.

[0019] A control arm, which is connected to the steering knuckle via a ball joint structure;

[0020] The bracket is connected to the triangular arm via a bushing structure;

[0021] The steering gear is provided with multiple connection points fixed to the bracket, and the steering gear includes a steering tie rod connected to the steering knuckle via a tie rod ball pin;

[0022] The lifting lug is fixedly connected at one end to the outer cylinder support of the shock absorber.

[0023] A stabilizing bar, one end of which is hinged to the other end of the lifting lug, and the stabilizing bar is provided with multiple connection points for fixing to the bracket.

[0024] This application also provides a method for assembling a front suspension hub motor wheel-side integrated structure. The assembly method is used to assemble the aforementioned front suspension hub motor wheel-side integrated structure, including:

[0025] A brake is installed at the end of the hub motor closest to the vehicle body;

[0026] The front suspension is installed at the end of the stator housing of the hub motor that is closest to the vehicle body;

[0027] Insert the outer rotor housing of the hub motor axially into the wheel rim and fix the outer rotor housing to the wheel rim.

[0028] According to the assembly method of the wheel-side integrated structure of the front suspension hub motor provided in this application, the method of fixing the outer rotor housing to the wheel rim includes: inserting the end of the outer rotor housing away from the vehicle body into the wheel rim along the axial direction from the end of the wheel rim close to the vehicle body, so that the end of the outer rotor housing away from the vehicle body is closely fitted with the spoke of the wheel rim away from the vehicle body, and driving bolts into the spoke and the outer rotor housing to fix the two together as one.

[0029] According to the assembly method of the front suspension hub motor wheel-side integrated structure provided in this application, the method of installing the brake at the end of the hub motor near the vehicle body includes: fixing the annular brake disc in the brake to the end of the outer rotor housing near the vehicle body, aligning the screw holes on the multiple circumferentially equidistant bosses on the outer circumference of the brake disc with the screw holes on the flange of the outer rotor housing near the vehicle body, driving bolts into the aligned screw holes to fix the brake disc to the outer rotor housing; and fixing the brake caliper in the brake disc to the steering knuckle to complete the assembly of the brake.

[0030] This application also provides a car equipped with the aforementioned front suspension hub motor wheel-side integrated structure.

[0031] The advantages of this application are: 1. This application integrates the hub motor into the wheel rim. The outer rotor housing of the hub motor is fixedly connected to the wheel rim at a point away from the vehicle body. The connection point does not encroach on the internal space of the wheel rim, resulting in extremely high utilization of the internal space of the wheel rim. Moreover, the hub motor of this application is entirely located inside the wheel rim, so the hub motor does not encroach on the wheel side space, leaving sufficient space for the arrangement of the front suspension and pipelines. This solves the problem of limited wheel side space in the prior art. The entire wheel side integrated structure has abundant interfaces, which facilitates the rapid installation of pipelines and the front suspension. This solves the difficulties in wheel side integration caused by hub motors being installed in mature passenger vehicles, the complexity of the interface between the hub motor front suspension system and the vehicle body, and the problem of insufficient performance of the hub motor front suspension.

[0032] 2. The rim structure of this application is simple. By pre-drilling screw holes on the spokes, it is easy to fix and connect with the outer rotor housing in the hub motor. The overall assembly operation is very simple. When assembling the hub motor and the rim, you only need to insert the outer rotor housing of the hub motor into the rim and drive in the bolts to fix the outer rotor housing on the rim.

[0033] 3. This application designs the installation structure of the stator housing and the steering knuckle. By setting a first mounting hole at the end of the stator housing near the vehicle body to form a docking interface, and designing a corresponding second mounting hole on the steering knuckle, the steering knuckle and the stator housing can be fixedly connected by docking the first mounting hole and the second mounting hole. The overall connection method is very simple.

[0034] 4. This application optimizes the arrangement of the first mounting holes. By designing multiple sets of the first mounting holes, the connection between the stator housing and the steering knuckle can be improved, and the anti-torsion effect in the axial direction is better.

[0035] 5. The stator housing of this application has a structure in which the middle is recessed away from the vehicle body and the edge is bent towards the vehicle body. The inward recess in the middle part facilitates the installation and arrangement of the steering knuckle, giving the steering knuckle and other structures sufficient installation space. The edge extending towards the vehicle body can create more space between the outer rotor housing and the stator housing, which is convenient for arranging other components of the hub motor.

[0036] 6. The fixing method of the brake disc and the outer rotor housing in this application is very simple. The brake disc adopts a ring structure, which will not encroach on the installation space of the front suspension and the wheel hub motor. The front suspension can be easily connected with the stator housing. In addition, the ring brake disc is easy to install and can effectively ensure the contact area with the brake friction pad. The brake disc volume is greatly reduced, which effectively reduces the weight of the entire wheel-side integrated structure.

[0037] 7. This application designs a special boss and flange structure for the installation of the outer rotor housing and brake disc. By matching the screw holes on the flange and the boss one by one, the outer rotor housing and brake disc can be fixed together in a good and convenient way. The outer circumference of the brake disc is connected to the inner circumference of the outer rotor housing near the vehicle body. The connection is tight and stable, and will not encroach too much on the inner space of the wheel rim, which facilitates the subsequent layout of the front suspension and pipeline structure.

[0038] 8. The front suspension structure of this application is simple, easy to install and assemble, and can make full use of the wheel side space. It can maintain good matching with traditional vehicles. The bracket of the front suspension structure is not affected in any way and can be directly used to connect with the body. The KC characteristics of the front suspension meet the performance indicators of passenger cars and can provide a good solution for the future vehicle installation and mass production application of hub motors.

[0039] 9. This application also provides an assembly method for assembling a wheel-side integrated structure. Based on the structure of the wheel rim, hub motor and front suspension, the required wheel-side integrated structure can be quickly formed. The assembly is orderly, the wheel-side space is sufficient, and the difficulty of front suspension assembly is greatly reduced.

[0040] 10. The assembly method of the hub motor and the rim in this application is very simple. The outer rotor housing of the hub motor is inserted into the rim along the axial direction, which makes it easy to assemble the two. Bolts can be driven from the outside of the rim spokes into the spokes and the outer rotor housing to fix the two together as one, which is convenient to operate.

[0041] 11. The present application makes the assembly of the brake very easy. The brake disc of the brake is a ring structure. The brake disc can be easily fixed to the outer rotor housing directly through the corresponding structure of the flange and the boss. The brake caliper of the brake is fixed to the steering knuckle. The interface design is rich, which greatly facilitates the assembly.

[0042] The front suspension hub motor wheel-side integrated structure of this application fully integrates the hub motor inside the wheel rim, reserving sufficient assembly space for the wheel side, facilitating the layout of the front suspension and pipelines. At the same time, it reserves multiple interfaces, greatly facilitating the assembly of the front suspension and pipelines. It solves the problems of difficult integration, complex interfaces and insufficient performance of existing hub motors, and has great promotional value. Attached Figure Description

[0043] Figure 1 Axial view of the front suspension hub motor wheel-side integrated structure of this application;

[0044] Figure 2 Axial view (another view) of the front suspension hub motor wheel-side integrated structure of this application;

[0045] Figure 3 : Exploded view of the front suspension hub motor wheel-side integrated structure of this application;

[0046] Figure 4 : A schematic diagram of the hub motor structure of this application;

[0047] Figure 5 This application includes a schematic diagram of the hub motor structure and brake assembly.

[0048] Figure 6 This application includes an exploded view of the hub motor structure and brake assembly.

[0049] Figure 7 This application includes a schematic diagram of the hub motor structure, brake, and steering knuckle assembly.

[0050] Figure 8 This application includes exploded schematic diagrams of the hub motor structure, brake, and steering knuckle assembly.

[0051] Figure 9 This application includes a schematic diagram of the hub motor structure, brake, steering knuckle, and control arm assembly.

[0052] Figure 10 : A schematic diagram of the triangular arm structure of this application;

[0053] Figure 11 : A schematic diagram of the steering knuckle structure of this application;

[0054] Figure 12 Schematic diagram of wheel rim structure;

[0055] Wherein: 1—rim; 11—spoke;

[0056] 2—Outer rotor housing; 21—Flange;

[0057] 3—Stator housing; 31—First mounting hole;

[0058] 4—Front suspension; 41—Steering knuckle; 411—Second mounting hole;

[0059] 42—Shock absorber; 43—Triangular arm; 44—Bracket; 45—Steering gear; 46—Steering tie rod; 47—Helmet; 48—Stabilizer bar;

[0060] 5—Brake; 51—Brake disc; 511—Boss; 52—Brake caliper; Detailed Implementation

[0061] The embodiments of this application are described in detail below, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0062] In the description of this application, it should be understood that the terms "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0063] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0064] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0065] This application relates to a wheel hub motor integrated structure for a front suspension. The wheel hub motor is integrated into the wheel rim, remaining completely within the rim and not encroaching on the vehicle body. This provides sufficient space for the front suspension and wiring without changing the wheel's position, solving the problem of limited wheel hub space in existing technologies. The integrated structure incorporates numerous interfaces on the wheel hub motor, wheel rim, and suspension, making assembly very convenient. This solves the difficulties of wheel hub motor integration in mature passenger vehicles, the complexity of the interface between the wheel hub motor front suspension system and the vehicle body, and the insufficient performance of the wheel hub motor front suspension.

[0066] Specifically, such as Figures 1-11As shown, a front suspension hub motor wheel-side integrated structure of this application includes a rim 1, a hub motor, a front suspension 4 (identified in the figure), and a brake 5 (identified in the figure). The rim 1 is a hollow annular structure. The hub motor is located inside the rim 1 and includes an outer rotor housing 2 fixed to the end of the rim 1 away from the vehicle body and a stator housing 3 disposed on the outer rotor housing 2. The end of the stator housing 3 near the vehicle body is located axially inside the rim 1. The hub motor also has many other structures, but since these structural components are not involved here, they will not be discussed further. No further description is provided; the outer rotor housing 2 and the stator housing 3 together form the outer shell of the hub motor. The outer rotor housing 2 is fixedly connected to the wheel rim 1 and is a structure that rotates together with the wheel rim 1. The stator housing 3 is fixedly connected to the front suspension 4 and to the subframe and is a structure that does not rotate. The hub motor of this application is completely located inside the wheel rim 1, and neither end of the hub motor extends beyond the axial sides of the wheel rim 1. Therefore, sufficient space is reserved for the subsequent installation of the front suspension 4 and corresponding pipelines, which facilitates the arrangement of the front suspension 4 and pipelines.

[0067] The front suspension 4 includes a steering knuckle 41 fixedly connected to the stator housing 3 near the vehicle body. The stator housing 3 near the vehicle body has a reserved interface for connecting to the steering knuckle 41. The steering knuckle 41 can be easily fixed to the stator housing 3 through this interface. The steering knuckle is provided with a structure extending towards the vehicle body to facilitate connection with other structural components on the front suspension 4. That is, part of the structure of the steering knuckle 41 is inside the rim 1, and part of the structure is outside the rim 1. The part outside the rim 1 will be connected to other structures of the front suspension 4.

[0068] The brake 5 includes a brake caliper 52 fixedly connected to the steering knuckle 41 and a brake disc 51 connected to the end of the outer rotor housing 2 near the vehicle body. The brake 5 is a braking device installed between the wheel hub motor and the front suspension 4. The brake disc 51 of the brake 5 is fixedly connected to the outer rotor housing 2 and rotates around the axis of the entire outer rotor housing 2. The brake caliper 52 is fixedly connected to the steering knuckle 41. When braking is required, the friction pads in the brake caliper 52 are attached to the brake disc 51, and the outer rotor housing 2 is braked and decelerated through friction.

[0069] During actual assembly, the following method can be used: install the brake 5 at the end of the hub motor near the vehicle body; install the front suspension 4 at the end of the stator housing 3 of the hub motor near the vehicle body; axially attach the wheel rim to the outer rotor housing 2 of the hub motor, and fix the outer rotor housing 2 to the wheel rim 1.

[0070] The assembly of this application is carried out in a specific order. First, the hub motor is connected to the side of the vehicle body, including the connection with the brake 5 and the front suspension 4, and the assembly is carried out from the outside to the inside. Then, the hub motor is assembled with the wheel rim 1.

[0071] In some embodiments of this application, the connection structure between the rim 1 and the outer rotor housing 2 described above has been optimized. Specifically, as follows: Figure 12 As shown, in this embodiment, the rim 1 is provided with spokes at the end away from the vehicle body. Multiple spokes are distributed in a divergent manner with the axis of the rim 1 as the center. Multiple spokes are connected as one piece at the axis position of the rim 1. Screw holes are reserved on the spokes for fixed connection with the outer rotor housing 2. Multiple screw holes are arranged at equal intervals along the circumference with the axis of the rim 1 as the center.

[0072] The outer rotor housing 2 has multiple screw holes corresponding to the wheel spokes at the end away from the vehicle body. By inserting bolts into the screw holes on the outer rotor housing 2 and the wheel spokes, the outer rotor housing 2 and the wheel spokes can be fixedly connected as one, thereby completing the connection between the outer rotor housing 2 of the hub motor and the wheel rim 1.

[0073] During assembly, the end of the outer rotor housing 2 away from the vehicle body is inserted axially into the wheel rim 1 from the end of the wheel rim 1 closest to the vehicle body, so that the end of the outer rotor housing 2 away from the vehicle body fits tightly with the spoke of the wheel rim 1 away from the vehicle body. Bolts are driven into the spoke and the outer rotor housing 2 to fix them together as one.

[0074] In other embodiments of this application, the structure of the stator housing 3 described above has been optimized, specifically, as follows: Figures 1-9 As shown, in this embodiment, the stator housing 3 is fixedly connected to the steering knuckle 41. The stator housing 3 has multiple first mounting holes 31 at its end near the vehicle body, and the steering knuckle 41 has multiple second mounting holes 411 corresponding to the first mounting holes 31. The stator housing 3 has two sets of first mounting holes 31 at its end near the vehicle body. These two sets of first mounting holes 31 are symmetrically arranged around the axis of the stator housing 3, and each set includes at least two first mounting holes 31 spaced apart vertically or horizontally. Similarly, the second mounting holes 411 on the steering knuckle 41 are arranged in the same way. The main body of the steering knuckle 41 has two sets of second mounting holes 411, symmetrically arranged around the center of the main body of the steering knuckle 41, and each set includes at least two second mounting holes 411 spaced apart vertically or horizontally.

[0075] The stator housing 3 has a recessed structure at the end near the vehicle body. The middle portion of the stator housing 3 near the vehicle body, close to the axis, is recessed axially away from the vehicle body. The circumferential edge of the stator housing 3 at the end near the vehicle body bends and extends axially towards the vehicle body, forming a stepped end face structure. A first mounting hole 31 is arranged at the middle position of the stator housing 3 at the end near the vehicle body for fixed connection with the steering knuckle 41. Because the middle portion is recessed away from the vehicle body, the steering knuckle 41 and other suspension structures can be inserted deeper into the wheel rim 1, bringing the steering knuckle 41 closer to the wheel center. The wheel center is also closer to the kingpin of the front suspension, greatly enhancing the vehicle's handling. The circumferential edge of the stator housing 3 at the end near the vehicle body is closer to the side of the vehicle body, creating a larger space between the stator housing 3 and the outer rotor housing 2, facilitating the arrangement of other structural components of the hub motor.

[0076] During actual assembly, the main body of the steering knuckle 41 is attached to the middle part of the stator housing 3 near the vehicle body. The second mounting hole 411 on the steering knuckle 41 is adjusted to align with the first mounting hole 31 on the stator housing 3 near the vehicle body in the axial direction. Then, bolts are driven into the aligned first mounting hole 31 and second mounting hole 411 to complete the fixed connection between the stator housing 3 and the steering knuckle 41.

[0077] In other embodiments of this application, the structure of the brake disc 51 described above has been optimized, specifically, as follows: Figures 4-9 As shown, the brake disc 51 in this embodiment has an annular structure. A first connecting structure is provided on the outer circumference of the brake disc 51. The first connecting structure corresponds to the second connecting structure at the end of the outer rotor housing 2 near the vehicle body. The brake disc 51 is fixedly connected to the outer rotor housing 2 through the first connecting structure and the second connecting structure.

[0078] The brake disc 51 is an annular structure connected to the outer circumference of the outer rotor housing 2 near the vehicle body. This annular structure allows the axial position of the stator housing 3 to remain unobstructed, without affecting the installation of the steering knuckle 41 and other front suspension components 4. Furthermore, the annular structure provides a large friction area, resulting in excellent braking performance. Compared to traditional circular brake discs, the overall structure of the brake disc 51 is significantly smaller, reducing its space and weight, thus lowering the overall wheel weight and unsprung weight, and enhancing handling performance. In this embodiment, the brake disc 51 is made of carbon ceramic material, ensuring good resistance to heat fading.

[0079] Specifically, such as Figures 4-9As shown, the first connection structure includes a plurality of bosses 511 arranged at equal intervals along the circumference on the outer side of the brake disc 51, and the second connection structure includes an annular flange 21 arranged on the inner side of the outer rotor housing 2 near the vehicle body. The bosses 511 are fixedly connected to the flange 21 by bolts passing through the bosses 511 and the flange 21 along the axial direction.

[0080] The brake disc 51 is assembled to the outer circumference of the outer rotor housing 2 near the vehicle body through the boss 511 structure. This assembly structure is simple, and the brake disc 51 is tightly and stably connected to the outer rotor housing 2.

[0081] During actual assembly, the annular brake disc 51 in the brake 5 is fixed to the outer rotor housing 2 near the vehicle body. The screw holes on the boss 511 on the outer circumference of the brake disc 51 are aligned with the screw holes on the flange 21 near the vehicle body of the outer rotor housing 2. Bolts are driven into the aligned screw holes to fix the brake disc 51 to the outer rotor housing 2, thus completing the installation of the brake disc 51.

[0082] After the brake disc 51 is installed, the brake caliper 52 in the brake 5 is installed. Since the brake disc 51 is a moving structure that rotates with the outer rotor housing 2, while the brake caliper 52 is a non-rotating structure, in this embodiment, the brake caliper 52 is fixedly connected to the steering knuckle 41. Figure 5 , 6 As shown in Figure 8, the brake caliper 52 is designed with two connection points (such as...). Figure 5 , 6 As shown in Figure 8 (A and B), the steering knuckle 41 has two corresponding connection points (such as A and B). Figure 11 As shown in a) and b), during actual assembly, align the two connection points on the brake caliper 52 with the two connection points on the steering knuckle 41, and drive in the bolts to complete the assembly of the brake caliper 52 and the steering knuckle 41. This completes the assembly of the brake 5.

[0083] In a preferred embodiment of this application, the front suspension 4 structure described above has been optimized. The front suspension 4 structure in this embodiment has been adapted to the hub motor. In order to adapt to the vehicle body, the bracket 44 structure connected to the vehicle body in the front suspension 4 has not been changed. Only some structural components connected to the hub motor in the front suspension 4 have been specifically adjusted. This can adapt to various vehicle structures and reduce subsequent development costs.

[0084] Specifically, such as Figure 3 and 11As shown, the front suspension 4 in this embodiment includes a shock absorber 42, a control arm 43, a bracket 44, a steering gear 45, a hanger 47, and a stabilizer bar 48. The lower end of the shock absorber 42 is fixedly connected to the clamping and fixing hole on the portion of the steering knuckle 41 that extends axially outward from the outer side of the rim 1. The shock absorber 42 has two connection points, such as... Figure 3 As shown in C and D, the shock absorber 42 is a structure that provides damping. The lower end of the shock absorber 42 is connected to the steering knuckle 41 via connection point C. The steering knuckle 41 has a corresponding connection point c. The upper end of the shock absorber 42 is fixed to the vehicle body via an upper support seat. The triangular arm 43 is connected to the steering knuckle 41 via a ball joint structure. The triangular arm 43 has three connection points, such as... Figure 3 and 10 As shown, the connection points are E, F, and G, respectively. The steering knuckle 41 has a corresponding connection point e for connection point E. Connection point E on the control arm 43 is connected to connection point e on the steering knuckle 41 via a ball joint structure. Connection point e is located at the lower end of the steering knuckle 41 body. The bracket 44 is connected to the control arm 43 via a bushing structure. The X-direction side of the bracket 44 has corresponding connection points f and g on the control arm 43 for connection points F and G. The control arm 43 is assembled onto the bracket 44 via connection points F, G, f, and g. The bracket 44 also has connection points h, i, j, and k. The steering gear 45 is connected to the steering knuckle 41 and is used to control the rotation of the wheels. The steering gear 45 has two connection points, as shown... Figure 3 As shown, connection points H and I are respectively. The body of the steering gear 45 is assembled onto the bracket 44 via connection points H and I, and connection points h and i on the bracket 44. Steering tie rods 46 are provided at both ends of the steering gear 45 body. The two steering tie rods 46 at both ends of the steering gear 45 body correspond to the steering knuckles 41 on the wheels on both sides, that is, the rotation of the wheels on both sides is controlled by one steering gear 45. Connection point L is provided at the end of the steering tie rod 46, and corresponding connection point l is provided on the side of the main body of the steering knuckle 41. Figure 3As shown, the connection point L of the steering tie rod 4 is connected to the connection point l on the steering knuckle 41 via a tie rod ball pin; the lug 47 is a rod-shaped structure connecting the shock absorber 42 and the stabilizer bar 48. Connection points d and m are provided at both ends of the lug 47. The lug 47 is connected to the shock absorber 42 via connection point d and connection point D on the cylinder of the shock absorber 42; the stabilizer bar 48 is a U-shaped rod-shaped structure. Both ends of the stabilizer bar 48 are connected to the lugs 47 on both sides. Connection point M is provided at the end of the stabilizer bar 48, corresponding to connection point m at the end of the lug 47. The stabilizer bar 48 is connected to the lug 47 via the connection of connection points M and m. Two symmetrically arranged connection points J and K are also provided on the straight rod of the stabilizer bar 48, corresponding to connection points j and k on the bracket 44. The stabilizer bar 48 is assembled to the bracket 44 via the connection of connection points J and K with connection points j and k. See below for the specific distribution of connection points. Figure 3 As shown.

[0085] While enabling hub-drive technology, the suspension structure design also maintains its load-bearing, guiding, shock-absorbing, and vibration-damping functions. 。

[0086] During front suspension assembly, the lower end of the shock absorber 42 is connected to the connection point c of the steering knuckle 41 via connection point C. The connection point E on the triangular arm 43 is connected to the connection point e on the steering knuckle 41 via a ball joint structure. The triangular arm 43 is assembled onto the bracket 44 via connection points F, G, f, and g. The body of the steering gear 45 is assembled onto the bracket 44 via connection points I and H, connected to connection points i and h on the bracket 44. The connection point L of the steering tie rod 4 is connected to the connection point l on the steering knuckle 41 via a tie rod ball joint. The lug 47 is assembled onto the shock absorber 42 via connection point d, connected to the connection point D on the shock absorber 42 cylinder. The stabilizer bar 48 is connected to the lug 47 via connection points M and m. The stabilizer bar 48 is assembled onto the bracket 44 via connection points J, K, j, and k.

[0087] Specifically, the assembly method of the front suspension hub motor wheel-side integrated structure of this application is as follows: The main body of the steering knuckle 41 is fitted to the middle part of the stator housing 3 near the vehicle body. The second mounting hole 411 on the steering knuckle 41 is adjusted to align with the first mounting hole 31 on the stator housing 3 near the vehicle body in the axial direction. Bolts are then driven into the aligned first mounting hole 31 and second mounting hole 411 to complete the fixed connection between the stator housing 3 and the steering knuckle 41. The annular brake disc 51 in the brake 5 is fixed to the outer rotor housing. With the brake disc 51 aligning the screw holes on the multiple circumferentially spaced bosses 511 on the outer circumference of the brake disc 51 with the screw holes on the flange 21 of the outer rotor housing 2 near the vehicle body, the brake disc 51 is fixed to the outer rotor housing 2 by driving bolts into the aligned screw holes, thus completing the installation of the brake disc 51. The two connection points on the brake caliper 52 are aligned with the two connection points on the steering knuckle 41, and bolts are driven in to complete the assembly of the brake caliper 52 and the steering knuckle 41. Thus, the assembly of the brake 5 is completed.

[0088] The lower end of the shock absorber 42 is connected to the connection point c of the steering knuckle 41 via connection point C. The connection point E on the triangular arm 43 is connected to the connection point e on the steering knuckle 41 via a ball joint structure. The triangular arm 43 is assembled onto the bracket 44 via connection points F, G, f, and g. The body of the steering gear 45 is assembled onto the bracket 44 via connection points I and H, and the connection points i and h on the bracket 44. The connection point L of the steering tie rod 4 is connected to the connection point l on the steering knuckle 41 via a tie rod ball joint. The lug 47 is assembled onto the shock absorber 42 via connection point d, and the shock absorber 42 via connection point D on the shock absorber 42 cylinder. The stabilizer bar 48 is connected to the lug 47 via connection points M and m. The stabilizer bar 48 is assembled onto the bracket 44 via connection points J, K, j, and k, thus completing the assembly of the front suspension 4.

[0089] Insert the outer rotor housing 2 away from the vehicle body into the wheel rim 1 along the axial direction from the end of the wheel rim 1 closest to the vehicle body, so that the end of the outer rotor housing 2 away from the vehicle body is tightly fitted with the spoke of the wheel rim 1 away from the vehicle body. Drive bolts into the spoke and the outer rotor housing 2 to fix the two together as one.

[0090] This completes the assembly of the front suspension hub motor wheel-side integrated structure.

[0091] In this application, the X direction refers to the front-to-back direction of the vehicle, the Y direction refers to the left-to-right direction of the vehicle, and the Z direction refers to the up-to-down direction of the vehicle.

[0092] The foregoing has shown and described the basic principles, main features, and advantages of this application. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this application. Various changes and modifications can be made to this application without departing from the spirit and scope thereof, and all such changes and modifications fall within the scope of this application as claimed. The scope of protection of this application is defined by the appended claims and their equivalents.

Claims

1. A front suspension hub motor wheel-side integrated structure, characterized in that: include, The rim (1) is a hollow annular structure; The hub motor is located inside the wheel rim (1) and includes an outer rotor housing (2) fixed to the end of the wheel rim (1) away from the vehicle body and a stator housing (3) disposed on the outer rotor housing (2); the end of the stator housing (3) near the vehicle body is located axially inside the wheel rim (1); The front suspension (4) includes a steering knuckle (41) fixedly connected to the stator housing (3) near the vehicle body. The brake (5) includes a brake caliper (52) fixed to the steering knuckle (41) and a brake disc (51) connected to the outer rotor housing (2) near the vehicle body. The middle part of the stator housing (3) near the axis of the vehicle body is recessed axially away from the vehicle body, and the edge part away from the axis of the vehicle body is bent axially towards the vehicle body. The brake disc (51) has an annular structure, and a first connecting structure is provided on the outer circumference of the brake disc (51). The first connecting structure corresponds to the second connecting structure at the end of the outer rotor housing (2) near the vehicle body. The brake disc (51) is fixedly connected to the outer rotor housing (2) through the first connecting structure and the second connecting structure. The first connecting structure includes a plurality of bosses (511) arranged at equal intervals along the circumference on the outer side of the brake disc (51); the second connecting structure includes an annular flange (21) arranged on the inner side of the outer rotor housing (2) near the vehicle body; the bosses (511) are fixedly connected to the flange (21) by bolts passing through the bosses (511) and the flange (21) along the axial direction.

2. The front suspension hub motor wheel-side integrated structure as described in claim 1, characterized in that: The rim (1) is provided with spokes at the end away from the vehicle body; the spokes are provided with screw holes for fixed connection with the outer rotor housing (2).

3. The front suspension hub motor wheel-side integrated structure as described in claim 1, characterized in that: The stator housing (3) has a plurality of first mounting holes at one end near the vehicle body; the steering knuckle (41) has a plurality of second mounting holes corresponding to the first mounting holes.

4. The front suspension hub motor wheel-side integrated structure as described in claim 3, characterized in that: The stator housing (3) is provided with two sets of first mounting holes at one end near the vehicle body. The two sets of first mounting holes are arranged symmetrically with the axis of the stator housing (3) as the center. Each set includes at least two first mounting holes arranged at intervals in the vertical or horizontal direction.

5. The front suspension hub motor wheel-side integrated structure as described in claim 1, characterized in that: The front suspension (4) includes, The shock absorber (42) is fixedly connected at its lower end to the clamping and fixing hole on the part of the steering knuckle (41) that extends axially out of the outer side of the rim (1), and at its upper end to the vehicle body through the upper support seat. The triangular arm (43) is connected to the steering knuckle (41) via a ball joint structure; The bracket (44) is connected to the triangular arm (43) via a bushing structure; Steering gear (45), the steering gear (45) is provided with multiple connection points fixed to the bracket (44), the steering gear (45) includes a steering tie rod (46) connected to the steering knuckle (41) through a tie rod ball pin; Lifting lug (47), one end of which is fixedly connected to the outer cylinder support of the shock absorber (42); A stabilizer bar (48) is provided, one end of which is hinged to the other end of the lug (47), and multiple connection points are provided on the stabilizer bar (48) to be fixed to the bracket (44).

6. A method for assembling a front suspension hub motor wheel-side integrated structure, characterized in that: The assembly method is used to assemble a front suspension hub motor wheel-side integrated structure as described in any one of claims 1 to 5, including: A brake is installed at the end of the hub motor near the vehicle body (5); A front suspension (4) is installed at one end of the stator housing (3) of the hub motor near the vehicle body; Insert the outer rotor housing (2) of the hub motor into the wheel rim (1) along the axial direction and fix the outer rotor housing (2) to the wheel rim (1).

7. The assembly method of the front suspension hub motor wheel-side integrated structure as described in claim 6, characterized in that: The method for fixing the outer rotor housing (2) to the rim (1) includes: inserting the end of the outer rotor housing (2) away from the vehicle body into the rim (1) along the axial direction from the end of the rim (1) close to the vehicle body, so that the end of the outer rotor housing (2) away from the vehicle body is closely fitted with the spoke of the rim (1) away from the vehicle body, and driving bolts into the spoke and the outer rotor housing (2) to fix the two together as one.

8. The assembly method of the front suspension hub motor wheel-side integrated structure as described in claim 6, characterized in that: The method of installing the brake (5) at the end of the hub motor near the vehicle body includes: fixing the annular brake disc (51) in the brake (5) to the end of the outer rotor housing (2) near the vehicle body, aligning the screw holes on the multiple circumferentially spaced bosses (511) on the outer circumference of the brake disc (51) with the screw holes on the flange (21) of the outer rotor housing (2) near the vehicle body, driving bolts into the aligned screw holes to fix the brake disc (51) to the outer rotor housing (2); and fixing the brake caliper (52) in the brake disc (51) to the steering knuckle (41) to complete the assembly of the brake (5).

9. A car, characterized in that: The vehicle is equipped with a front suspension hub motor wheel-side integrated structure as described in any one of claims 1 to 5.

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