Electric assembly and vehicle

Abstract

The invention relates to an electric assembly and a vehicle, the electric assembly comprises a shell assembly, a first flow channel and a second flow channel, the first flow channel is suitable for cooling a motor, the second flow channel is suitable for cooling a power supply assembly and an electric control assembly, the first flow channel and the second flow channel are both arranged in the shell assembly, and the first flow channel and the second flow channel are arranged in the shell assembly. The first flow channel and the second flow channel are integrated in the shell assembly, the second flow channel is communicated with the first flow channel, so that the power supply assembly, the electric control assembly and the motor share the heat dissipation flow channel, the first flow channel for cooling the motor and the second flow channel for cooling the power supply assembly and the electric control assembly are integrated in the shell assembly, and the first flow channel and the second flow channel are communicated; therefore, the whole electric assembly is effectively cooled, the structural size is reduced, and the structural weight is reduced.

Description

Technical Field

[0001] The present application relates to the field of vehicle technology, and in particular to an electric assembly and a vehicle. Background Art

[0002] With the development of social technology, electric vehicles are becoming more and more popular. The controller functions of electric vehicles are becoming more and more integrated, and the volume and weight requirements are getting smaller and smaller. The existing controller functions are relatively single and the integration is not high. The motor controller, power charging all-in-one machine, vehicle controller, etc. are independent boxes. The cooling water channels of each box are independent and need to be connected by water pipes. Such a structure occupies a large space and is relatively bulky and costly. Summary of the invention

[0003] The embodiments of the present application provide an electric assembly and a vehicle that can effectively perform cooling, reduce the structure volume, and reduce the structure weight, so as to at least partially solve the above-mentioned technical problems.

[0004] In order to achieve the above-mentioned object, according to a first aspect of the present application, an electric assembly is provided, comprising:

[0005] Shell assembly;

[0006] a first flow channel, the first flow channel being suitable for cooling the motor; and,

[0007] A second flow channel, wherein the second flow channel is suitable for cooling the power supply component and the electronic control component;

[0008] The first flow channel and the second flow channel are both arranged in the housing component, and the second flow channel is communicated with the first flow channel, so that the power supply component, the electronic control component and the motor share a heat dissipation flow channel.

[0009] Optionally, the second flow channel includes a first branch and a second branch that are interconnected, the first branch is suitable for dissipating heat for the power supply component, and the second branch is suitable for dissipating heat for the electronic control component.

[0010] Optionally, the power supply assembly is arranged in the shell assembly, and the power supply assembly includes a transformer and a MOS tube. The first branch is arranged around the outer periphery of the transformer, and the transformer and the MOS tube are both arranged adjacent to the first branch.

[0011] Optionally, the shell assembly is provided with a power supply cavity, which accommodates the power supply assembly. A first shielding rib is provided in the power supply cavity, which is arranged around the outer periphery of the transformer. The first shielding rib is hollow to form the first branch therein, and the MOS tube is arranged along the side of the first shielding rib facing away from the transformer.

[0012] Optionally, the housing assembly is provided with the electric control assembly, the electric control assembly includes an IGBT assembly, and the IGBT assembly is arranged adjacent to the second branch.

[0013] Optionally, the housing assembly is further provided with an electric control cavity, the electric control cavity accommodates the electric control assembly, and the IGBT assembly and the cavity wall of the electric control cavity are spaced apart to define the second branch.

[0014] Optionally, the power supply cavity and the electric control cavity are arranged separately;

[0015] Alternatively, the power cavity and the electric control cavity are respectively arranged on different sides of the housing assembly;

[0016] Alternatively, the housing assembly is further provided with a power distribution cavity for accommodating a power distribution assembly, and the power distribution cavity, the power supply cavity and the electric control cavity are separated from each other.

[0017] Optionally, the shell assembly includes a shell and a cover plate, the shell is provided with a groove to facilitate processing of the second flow channel, and the cover plate closes the groove.

[0018] Optionally, the groove includes a first groove, the bottom of which is provided with the first branch, and the cover plate includes a first cover plate, and the first cover plate covers the first groove.

[0019] Optionally, the second flow channel further includes an inflow branch;

[0020] The groove includes a second groove, the second groove is connected to the inflow branch and the first branch, and the cover plate includes a second cover plate, the second cover plate covers the notch of the second groove.

[0021] Optionally, the groove includes a third groove, the third groove connects the first branch and the second branch, and the cover plate includes a third cover plate, and the third cover plate at least partially covers a notch of the third groove.

[0022] Optionally, a mounting groove is provided on the plate surface of the third cover plate facing away from the third groove, an IGBT assembly is provided in the shell assembly, the IGBT assembly is installed at the notch of the mounting groove to close the mounting groove and define the second branch, and a first channel and a second channel are provided at the bottom of the mounting groove, the first channel connects the first branch and the second branch, and the second channel connects the second branch and the first flow channel.

[0023] Optionally, the second flow channel further includes an outflow branch;

[0024] The groove includes a fourth groove, the fourth groove is connected to the first flow channel and the outflow branch, and the cover plate includes a fourth cover plate, and the fourth cover plate covers a part of the notch of the fourth groove.

[0025] Optionally, the first flow channel includes a plurality of motor flow channel segments extending along the axial direction of the motor, and the plurality of motor flow channel segments are interconnected.

[0026] Optionally, the second flow channel also includes an inlet branch and an outflow branch, the inlet branch is connected to the first branch, the outflow branch is connected to the first flow channel, the heat dissipation flow channel has an inlet and an outlet, the inlet is connected to the inlet branch, the outlet is connected to the outflow branch, and the inlet and the outlet are arranged on the same side of the shell assembly.

[0027] Optionally, the electric assembly further includes a DC charging terminal, a capacitor assembly, a DC bus, and a first shellless contactor and a second shellless contactor;

[0028] The capacitor assembly comprises a capacitor and a housing, wherein the housing is provided with a first mounting cavity and a second mounting cavity, the first housing-less contactor is mounted in the first mounting cavity, and the second housing-less contactor is mounted in the second mounting cavity.

[0029] Optionally, the controller further includes a three-phase magnetic ring assembly, and the three-phase magnetic ring assembly includes:

[0030] a magnetic core having a central hole; and,

[0031] A three-phase conductive bar is passed through the central hole, one end of the three-phase conductive bar is used to be connected to the IGBT component, and the other end of the three-phase conductive bar is used to be connected to the three-phase coil of the motor;

[0032] Among them, three conductive bars in the three-phase conductive bar are arranged in sequence along the first direction.

[0033] According to a second aspect of the present application, a vehicle is provided, comprising the electric assembly as described above.

[0034] In the electric assembly of the embodiment of the present application, by integrating the first flow channel for cooling the motor and the second flow channel for cooling the power supply component and the electronic control component into the housing component, and connecting the first flow channel and the second flow channel, a single cooling medium (such as liquid coolant or air) can be used to cool the motor, the power supply component and the electronic control component at the same time, thereby improving the cooling efficiency and reducing the system cost. The motor, the power supply component and the electronic control component share the heat dissipation flow channel, which simplifies the structure of the heat dissipation system, reduces the demand for cooling medium, and ensures the thermal balance of the entire electric assembly. That is, by connecting the first flow channel for cooling the motor with the second flow channel of the cooling controller (including the power supply component and the electronic control component), a unified heat dissipation flow channel is formed, thereby achieving effective cooling of the entire electric assembly, reducing the structural volume, and reducing the structural weight.

[0035] Other features and advantages of the present application will be described in detail in the subsequent detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application, and those skilled in the art can obtain other drawings based on these drawings without creative work.

[0037] In order to more completely understand the present application and its beneficial effects, the following description will be given in conjunction with the accompanying drawings, wherein the same figure numbers represent the same parts in the following description.

[0038] Figure 1 is a schematic diagram of the overall structure of an electric assembly provided in an exemplary embodiment of the present disclosure;

[0039] Figure 2 yes Figure 1 A schematic diagram of the overall structure of the electric assembly from another perspective;

[0040] Figure 3 yes Figure 1 Schematic diagram of the partial structure of the box body (the second cover plate and the third cover plate are not covered);

[0041] Figure 4 yes Figure 1 Schematic diagram of the partial structure of the box body (the second cover plate and the third cover plate have been covered);

[0042] Figure 5 for Figure 4 A partial cutaway schematic diagram of a box in FIG.

[0043] Figure 6 yes Figure 1A schematic diagram of a local structure of the box body from another perspective (the first cover plate and the fourth cover plate are not covered);

[0044] Figure 7 yes Figure 1 A schematic diagram of a local structure of the box body from another perspective (the first cover plate and the fourth cover plate are already covered);

[0045] Figure 8 for Figure 7 A schematic cross-sectional view of a local structure of a box;

[0046] Fig. 9 for Figure 1 A schematic diagram of the local structure of the motor;

[0047] Fig.10 for Fig. 9 Schematic diagram of formation of the first flow channel of the motor;

[0048] Fig.11 for Figure 1 A cross-sectional schematic diagram of an electric powertrain assembly;

[0049] Fig.12 for Figure 1 A schematic diagram of the structure of the capacitor component of the electric assembly;

[0050] Fig.13 for Figure 1 A schematic diagram of the structure of a three-phase magnetic ring assembly of an electric assembly;

[0051] Fig.14 for Fig.13 A schematic cross-sectional view of a three-phase magnetic ring assembly;

[0052] Fig.15 for Figure 1 Schematic diagram of the structural assembly of the electric assembly.

[0053] Description of reference numerals: 100, electric assembly; 1, motor; 11, first flow channel; 111, motor flow channel section; 2, controller; 21, power supply component; 211, transformer; 212, MOS tube; 22, electronic control component; 221, IGBT component; 3, housing; 31, second flow channel; 311, first branch; 3111, connecting section; 3112, extension section; 312, second branch; 313, inflow branch; 3131, liquid inlet; 314, second groove; 315, outflow branch; 3151, liquid outlet; 316, fourth groove; 317, first groove; 318, third groove; 32, cover plate; 321, first cover plate; 322, second cover plate; 323, third cover plate; 3231, First channel; 3232, second channel; 3233, mounting slot; 324, fourth cover; 33, power distribution cavity; 34, power cavity; 341, AC inductor cavity; 342, transformer shielding cavity; 343, MOS tube shielding cavity; 344, DC inductor cavity; 35, electric control cavity; 36, first box part; 361, first cover; 37, second box part; 371, second cover; 38, integrated box body; 4, gearbox; 5, DC charging terminal; 6, DC bus; 63, power board assembly; 67, IGBT driver board; 68, shielding board bracket; 69, control board; 71, capacitor assembly; 72, bus positive electrode lap point; 73, bus negative electrode lap point; 74, power negative electrode lap point; 75, PT C / air conditioner negative electrode connection point; 76, capacitor DC positive terminal; 77, capacitor DC negative terminal; 78, first installation cavity; 79, first shellless contactor; 80, shellless contactor signal connection point a; 81, shellless contactor signal connection point b; 82, contactor signal socket; 83, contactor control PCB board; 84, second shellless contactor; 85, second shellless contactor current input point; 86, second shellless contactor current output point; 87, first shellless contactor current input point; 88, first shellless contactor current output point; 89, second installation cavity; 90, second contactor positive input current sampling conductive row; 91, second contactor positive output current sampling conductive row; 92, second contactor positive output connection Point; 93, the second contactor positive input connection point; 94, the contactor positive output transfer conductive bar; 95, the DC charging positive connection conductive bar; 96, the DC charging negative connection conductive bar; 97, the first contactor negative input current sampling conductive bar; 98, the first contactor negative input connection point; 99, the capacitor output conductive bar; 146, the contactor negative output transfer conductive bar; 101, the capacitor grounding conductive bar; 102, the first contactor negative output connection point; 103, the first contactor negative output current sampling conductive bar; 104, the three-phase magnetic ring seat; 105, the magnetic core; 106, the three-phase conductive bar a; 107, the three-phase conductive bar b; 108, the three-phase conductive bar c; 109, the Hall magnetic concentrator; 110, the motor three-phase connection point a;151. Motor three-phase junction b; 112. Motor three-phase junction c; 113. IGBT junction a; 114. IGBT junction b; 115. IGBT junction c; 116. DC inductor; 117. Power signal harness; 118. Small magnetic ring; 119. DC filter magnetic ring assembly; 120. AC inductor; 121. Small insurance; 122. Busbar magnetic ring assembly; 123. Small insurance installation position; 124. DC charging small cover; 125. DC charging filter assembly; 126. Xuan transformer socket; 127. Power signal line electrical control end socket; 128. PWM line socket; 129. Contactor signal harness; 13 0. Xuanbian wiring harness connector; 131. Xuanbian component; 133. Hall sensor chip; 134. PWM signal wiring harness; 136. Motor end cover sealing surface; 137. Power supply wiring harness; 138. Half shaft; 139. Ball cage; 140. Power distribution connector; 141. AC charging connector; 142. DC connector; 1431. First shielding rib; 1432. Second shielding rib; 144. First via; 145. Second via; 146. Signal connector; 147. Power distribution connector via; 148. DC output shielding cavity; 149. DC charging connector guard position; 150. Contactor negative output transfer conductive bar. ; DETAILED DESCRIPTION

[0054] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present application.

[0055] This application provides an electric assembly, please refer to Figure 1 and Figure 2 , Figure 1 A schematic diagram of the structure of the electric assembly provided in an embodiment of the present application.

[0056] The electric assembly 100 includes a motor 1, a controller 2, and a housing component. The housing component is not only a physical container for the components of the electric assembly 100, but also undertakes the important task of thermal management. By setting a first flow channel 11 and a second flow channel 31 in the housing component, the first flow channel 11 cools the motor 1, and the second flow channel 31 cools the power supply component 21 and the electric control component 22. The first flow channel 11 is connected with the second flow channel 31 to form a unified heat dissipation flow channel. The housing component can effectively guide the cooling medium to flow between the components to achieve comprehensive cooling of the entire electric assembly 100. This design not only simplifies the complexity of the cooling system, improves the cooling efficiency, but also reduces the overall weight and cost of the system. Specifically, the housing component includes a housing and a housing 3 of the motor 1. The first flow channel 11 is formed in the housing of the motor 1, and the second flow channel 31 is formed in the housing 3. The housing of the motor 1 and the housing 3 are connected to achieve the connection between the first flow channel 11 and the second flow channel 31.

[0057] The motor 1 is a component in the electric assembly 100 that is responsible for generating power. It drives the vehicle by converting electrical energy into mechanical energy. In order to ensure that the motor 1 can still maintain efficient operation under high load, a first flow channel 11 is designed inside the housing component (specifically, the housing of the motor 1) (see Fig. 9 and Fig.10 ) is used to guide the cooling medium (such as liquid coolant or air) to flow through the motor 1, promptly remove the heat generated during operation, prevent the motor 1 from overheating, and thus ensure the performance and life of the motor 1.

[0058] The controller 2 includes a power supply component 21 and an electric control component 22, which are responsible for providing stable power to the motor 1 and controlling the operating state of the motor 1 to ensure the best performance of the motor 1 under different driving conditions. During operation, these modules will also generate heat, especially when the power supply component 21 is converting power and the electric control component 22 is processing complex control logic. Therefore, a second flow channel 31 is designed in the housing component (specifically, the box 3) (see Figure 5 ), taking away the heat of the power supply component 21 and the electronic control component 22, and maintaining the normal operating temperature of the controller 2. Specifically, the second flow channel 31 runs through or is arranged near the power supply component 21 and the electronic control component 22, further ensuring that these high-heat generating components can quickly dissipate heat, maintain the normal operating temperature of the controller 2, and avoid performance degradation or damage caused by overheating.

[0059] In the technical solution of the present application, by integrating the first flow channel 11 for cooling the motor 1 and the second flow channel 31 for cooling the power supply component 21 and the electronic control component 22 into the housing component, and connecting the first flow channel 11 and the second flow channel 31, a single cooling medium (such as liquid coolant or air) can be used to cool the motor 1, the power supply component 21 and the electronic control component 22 at the same time, thereby improving the cooling efficiency and reducing the system cost. The motor 1, the power supply component 21 and the electronic control component 22 share a heat dissipation flow channel, which simplifies the structure of the heat dissipation system, reduces the demand for cooling medium, and ensures the thermal balance of the entire electric assembly 100. That is, by connecting the first flow channel 11 for cooling the motor 1 with the second flow channel 31 of the cooling controller 2 (including the power supply component 21 and the electronic control component 22), a unified heat dissipation flow channel is formed, thereby achieving effective cooling of the entire electric assembly 100, reducing the structural volume and reducing the structural weight.

[0060] In some embodiments, the second flow channel 31 includes a first branch 311 and a second branch 312 that are interconnected, the first branch 311 is suitable for dissipating heat for the power component 21, and the second branch 312 is suitable for dissipating heat for the electronic control component 22. In these embodiments, the second flow channel 31 is subdivided into two interconnected branches, namely the first branch 311 and the second branch 312, the first branch 311 is used to cool the power component 21, and the second branch 312 is used to cool the electronic control component 22. Since the power component 21 and the electronic control component 22 may have different heat dissipation requirements and characteristics, the first branch 311 and the second branch 312 can be optimized according to the characteristics and working conditions of the components to be cooled, so as to better adapt to the specific cooling requirements of different components, and achieve the best cooling effect without affecting the efficiency of the overall cooling system.

[0061] The present application does not limit the specific connection method between the first branch 311 and the second branch 312. The first branch 311 and the second branch 312 can be connected in parallel. For example, the second flow channel 31 includes a first confluence trunk connected to one end of the first branch 311 and the second branch 312, and a second confluence trunk connected to the other end of the first branch 311 and the second branch 312. The first confluence trunk and / or the second confluence trunk are connected to the first flow channel 11. The cooling medium can enter the first branch 311 and the second branch 312 from the first confluence trunk, respectively, and then be collected through the second confluence trunk, flow into the first flow channel 11, and finally discharged to the external circulation system or other designated return path. In some embodiments, the first branch 311, the second branch 312 and the first flow channel 11 are connected in sequence, or the second branch 312, the first branch 311 and the first flow channel 11 are connected in sequence. In these embodiments, the second flow channel 31 is subdivided into a first branch 311 and a second branch 312 which are interconnected, wherein the first branch 311 is specifically used to dissipate heat from the power component 21. Since the power component 21 generates a large amount of heat during the power conversion process, this branch ensures that the cooling medium can cool the power component 21 and quickly take away the heat to prevent overheating. The second branch 312 is used to dissipate heat from the electronic control component 22. The electronic control component 22 also generates heat when processing complex control logic. The second branch 312 is also set to cool in time to keep the operating temperature of the module within a safe range. There are two possible layouts for the connection of the two flow channels: the first branch 311, the second branch 312 and the first flow channel 11 are connected in sequence, which means that the cooling medium first cools the power component 21 through the first branch 311, then flows through the second branch 312 to cool the electronic control component 22, and finally enters the first flow channel 11 of the motor 1 to complete the cooling cycle of the entire electric assembly 100; and the second branch 312, the first branch 311 and the first flow channel 11 are connected in sequence, which is slightly different from the above method. The flow order of the cooling medium is to cool the electronic control component 22 first, then the power component 21, and finally Entering motor 1 for cooling, it is understandable that the heat load of motor 1 is usually the highest in the electric assembly 100, so it needs to be cooled in the final stage of the cooling process to ensure that all previous components will not be affected by the high temperature of motor 1. By allowing the cooling medium to flow into motor 1 after passing through the power supply component 21 and the electronic control component 22, the overall cooling efficiency can be improved, so that the cooling medium can achieve the best cooling effect before leaving the system, that is, it not only ensures that the temperature of each key component of the electric assembly 100 is effectively controlled, but also improves the thermal management efficiency of the entire system by optimizing the flow direction of the cooling medium.

[0062] Understandable, see Fig.11The power supply assembly 21 generally includes a transformer 211 for adjusting the input voltage to a level suitable for driving the motor 1, and a MOS tube 212 (metal oxide semiconductor field effect transistor) as a switch element for controlling the on and off of the current. In some embodiments, the power supply assembly 21 is installed in a housing assembly, and the power supply assembly 21 includes a transformer 211 and a MOS tube 212. The first branch 311 is arranged around the outer periphery of the transformer 211 (see Figure 5 , it is understood that the transformer 211 is arranged in the transformer shielding cavity 342), and the transformer 211 and the MOS tube 212 are both arranged adjacent to the first branch 311. In these embodiments, the first branch 311 is arranged around the outer periphery of the transformer 211, so that the transformer 211 is surrounded by the first branch 311 (cooling channel), the heat dissipation area of ​​the transformer 211 is increased, and the transformer 211 is adjacent to the cooling channel, which improves the heat exchange efficiency. At the same time, the MOS tube 212 is arranged adjacent to the first branch 311. This layout makes full use of the path of the cooling medium to ensure that the transformer 211 and the MOS tube 212 can both be effectively cooled to prevent performance degradation or damage caused by overheating. It should be supplemented that the first branch 311 is arranged around the outer periphery of the transformer 211, which means that the first branch 311 forms an enclosing cooling structure on the periphery of the transformer 211. The first branch 311 can be arranged around the outer periphery of the transformer 211 in a full circle, or it can be arranged around the outer periphery of the transformer 211 ( Figure 5 In the figure, the first branch 311 has a connecting section 3111 and two extending sections 3112 extending in the same direction from the sides of the two ends of the connecting section 3111, which are roughly arranged to form a U shape (schematically shown). The cooling medium can exchange heat with the transformer 211 from multiple directions and can cover more surfaces of the transformer 211, thereby increasing the heat exchange area and ensuring that the heat of the transformer 211 can be evenly distributed and effectively dissipated. Regardless of whether the first branch 311 is arranged around the outer periphery of the transformer 211 in a full circle or only around a portion of the outer periphery, this design can significantly improve the heat dissipation efficiency of the transformer 211, thereby protecting the transformer 211 from overheating and extending its service life.

[0063] In some embodiments, the MOS tube 212 is arranged on the side of the first branch 311 away from the transformer 211. In these embodiments, the first branch 311 is still arranged around the outer periphery of the transformer 211 to form an enclosing or semi-enclosing cooling structure, thereby improving the heat dissipation area and heat exchange efficiency of the transformer 211. The MOS tube 212 is located on the other side of the first branch 311, so that it can use the other side of the first branch 311 for heat dissipation. By reasonably arranging the positional relationship between the cooling channel and the heating element, effective heat dissipation management of different heating elements in the power supply component 21 is achieved while maintaining the compactness of the layout.

[0064] In some embodiments, the shell assembly is provided with a power supply cavity 34, the power supply cavity 34 accommodates the power supply assembly 21, and a first shielding rib 1431 is provided in the power supply cavity 34. The first shielding rib 1431 is arranged around the outer periphery of the transformer 211. The first shielding rib 1431 is hollow to form a first branch 311 therein, and the MOS tube 212 is arranged along the side of the first shielding rib 1431 away from the transformer (211). In these embodiments, the first shielding rib 1431 can reduce the impact of electromagnetic interference generated by the transformer 211 on other electronic components. The MOS tube 212 is arranged along the side of the first shielding rib 1431 that is away from the transformer 211, that is, one side of the first shielding rib 1431 faces the MOS tube 212, and the other side faces the transformer 211. The hollow portion of the first shielding rib 1431 forms a first branch 311, so that the first branch 311 can cool the transformer 211 and the MOS tube 212 at the same time, making the entire electric assembly 100 more compact, and the transformer 211 and the MOS tube 212 can be kept within a safe operating temperature range, thereby extending the system life and improving the overall performance.

[0065] It is also understandable that the electronic control component 22 generally includes an IGBT component 221 (see the attached Fig.11 ), the IGBT component 221 (insulated gate bipolar transistor) is responsible for more precise current control, and is usually used to adjust the speed and torque of the motor 1. The IGBT component 221 generates a large amount of heat when working. If this heat is not effectively managed, it will cause the device performance to decline, reduce the overall efficiency of the system, and increase the risk of failure. In some embodiments, the electronic control component 22 is installed in the housing component, and the electronic control component 22 includes an IGBT component 221. The IGBT component 221 is arranged adjacent to the second branch 312. By placing the IGBT component 221 close to the cooling channel, the heat exchange area can be maximized, ensuring that the generated heat can be quickly absorbed and dissipated by the cooling medium, thereby avoiding performance degradation or failure caused by overheating of the IGBT component 221.

[0066] In some embodiments, the housing assembly is further provided with an electric control cavity 35, the electric control cavity 35 accommodates the electric control assembly 22, and the IGBT assembly 221 and the cavity wall of the electric control cavity 35 are spaced apart to define a second branch 312. In these embodiments, a certain gap is left between the IGBT assembly 221 and the cavity wall of the electric control cavity 35, and this gap constitutes the second branch 312, which is used to cool the IGBT assembly 221. By directly defining the second branch 312 using the IGBT assembly 221, a more compact design is achieved, so that the cooling medium flows through the IGBT assembly 221, ensuring that the IGBT assembly 221 is effectively cooled, thereby making the entire electric assembly 100 more compact, and the IGBT assembly 221 can be kept within a safe operating temperature range, thereby extending the system life and improving the overall performance.

[0067] In some embodiments, the power cavity 34 and the electronic control cavity 35 are separated and arranged. In this way, through physical isolation, electrical interference between the power supply component 21 and the electronic control component 22 can be prevented, the risk of short circuit and fire can be reduced, and it helps to enhance the structural stability and sealing, and prevent the external environment from affecting the internal components, such as dust, moisture and vibration. The independent cavity design can optimize the heat dissipation requirements of each component, improve the heat dissipation efficiency, adapt to the different thermal characteristics of each component, and improve the overall thermal efficiency of the system. Each component in each cavity can be installed and disassembled independently, which simplifies the assembly and maintenance process, and is also conducive to separate replacement and upgrading. Placing components with different functions in independent cavities helps to reduce electromagnetic interference (EMI) and improve the system's EMC (Electromagnetic Compatibility).

[0068] In some embodiments, the power cavity 34 and the electronic control cavity 35 are respectively arranged on different sides of the shell assembly. In these embodiments, arranging the two cavities on different sides can make each cavity close to the external environment, have better ventilation conditions, and improve its own heat dissipation efficiency. The design of different sides also makes each cavity more independent, which is convenient for maintenance personnel to inspect and repair their respective parts, reducing the difficulty of maintenance. By arranging the cavities on different sides, the space in the shell assembly can be more reasonably utilized, making the overall design more compact and less crowded.

[0069] The present application does not limit the specific side of the housing assembly where the power cavity 34 and the electric control cavity 35 are arranged. In some embodiments, the power cavity 34 is arranged on the top surface of the housing assembly, and the electric control cavity 35 is arranged on the side of the housing assembly. It can be understood that the power cavity 34 is usually provided with power conversion and management components such as transformers, rectifiers, filters, etc., which process high voltages and large currents and generate a lot of heat, while the electric control cavity 35 is usually provided with power semiconductor devices. Although it also generates heat, it usually processes relatively low voltages and currents, and its heat generation is usually less than that of the power cavity 34. Since the electric control cavity 35 contains more control logic and complex circuit design, it may require more frequent inspection and maintenance. Therefore, the power cavity 34 with a larger heat generation is arranged on the top surface of the housing assembly, which can better utilize the natural rising characteristics of hot air and help dissipate heat. The electric control cavity 35 with a higher maintenance frequency is arranged on the side of the housing assembly, which is more convenient for maintenance personnel to inspect and operate.

[0070] It can be understood that the controller 2 with integrated power distribution components can simplify system design, reduce external connections, improve electrical isolation, thereby reducing failure rates, and simplify maintenance work. In some embodiments, refer to Figure 3The controller 2 also includes a power distribution component, and the housing component (specifically, the box 3) is provided with a power distribution cavity 33 and a power cavity 34 ( Figure 5 In these embodiments, the interior of the housing 3 is divided into three mutually spaced cavities, namely, the power distribution cavity 33, the power cavity 34 and the electric control cavity 35. In this way, through physical isolation, electrical interference between components with different functions can be prevented, the risk of short circuit and fire can be reduced, and it is helpful to enhance the structural stability and sealing, and prevent the influence of the external environment on the internal components, such as dust, moisture and vibration. The independent cavity design can optimize the heat dissipation requirements of each component, improve the heat dissipation efficiency, adapt to the different thermal characteristics of each component, and improve the overall thermal efficiency of the system. Each component in each cavity can be independently installed and disassembled, which simplifies the assembly and maintenance process, and is also conducive to separate replacement and upgrading. Placing components with different functions in independent cavities helps to reduce electromagnetic interference (EMI) and improve the EMC (Electromagnetic Compatibility) of the system.

[0071] In some embodiments, the housing assembly includes a housing and a cover plate 32. The housing is provided with a groove to facilitate the processing of the second flow channel 31, and the cover plate 32 closes the groove. It can be understood that the design of the flow channel sections of the second flow channel 31 in different extension directions helps to ensure that the cooling medium can cover the various heat sources of the electric assembly 100 and achieve more uniform heat dissipation. In this way, the housing assembly will contain complex flow channel features to form a hollow flow channel with bends, turns or branches. In the injection molding or casting process, if a hollow flow channel with complex bends and branches is to be formed directly on a part, the design of the mold will become extremely complicated. This is because the mold needs to be able to be separated after the part is formed in order to remove the finished product. If the flow channel is hollow and has complex turns inside, then the traditional two-half mold (upper mold) And lower mold) is difficult to achieve this, because when the mold is opened, the unsupported hollow runner part may be stuck in the mold, causing damage to the parts or the mold cannot be opened normally. By introducing the cover plate 32, the originally complex single structure is decomposed into two or more simpler parts. Specifically in the runner design, an open groove is preset on the shell, and then the cover plate 32 is used to close the groove. The complete runner structure is formed by the close combination of the cover plate 32 and the shell. Since the runner part of the shell does not need to form a cavity in the mold, the design of the mold can be simpler, and only needs to consider how to form the external shape and the groove. This greatly reduces the complexity and cost of the mold. During the molding process, since the flow channel is not a cavity formed directly in the mold, there will be no jamming problem caused by the hollow flow channel when the mold is opened, which simplifies the demolding steps and improves production efficiency. The addition of the cover plate 32 provides additional processing freedom. Drilling, cutting and other operations can be performed on the cover plate 32 to form the inlet and outlet of the flow channel, or add additional structural features without worrying about affecting the integrity of the shell. The design of the cover plate 32 makes the assembly, maintenance and replacement of the flow channel section more convenient. When maintenance is required, only the cover plate 32 needs to be removed, which reduces maintenance time and cost and improves the maintainability of the electric assembly 100. That is, the shell assembly includes the design of the shell and the cover plate 32, and the layout of the flow channel sections in two different extension directions, which optimizes the thermal management of the electric assembly 100, improves the system integration and structural compactness, reduces the manufacturing difficulty, and improves the product quality and production efficiency. It should be emphasized that, from the above description, it can be seen that the shell is provided with a groove to facilitate the processing of the second flow channel 31, which not only refers to the situation where the groove forms the flow channel, but also includes the situation where the flow channel is connected through the groove, and this application does not limit it.

[0072] It can be understood that the first branch 311 is arranged around the outer periphery of the transformer 211, that is, the first branch 311 forms a surrounding cooling structure around the outer periphery of the transformer 211, that is, the second flow channel 31 has a bend at the first branch 311. In some embodiments, refer to Figure 6 to Figure 7The groove includes a first groove 317, and the bottom of the first groove 317 is provided with a first branch 311 ( Figure 6 The extension section 3112 of the first branch 311 is identified in the figure, and the cover plate 32 includes a first cover plate 321, and the first cover plate 321 covers the first groove 317. In these examples, the first groove 317 is provided on the shell, and the first branch 311 is provided at the bottom of the first groove 317. The first cover plate 321 is independently provided, and the first cover plate 321 is filled in the first groove 317 as a whole. The plate surface of the first cover plate 321 facing the first groove 317 abuts against the bottom of the first groove 317, thereby completing the construction of the first branch 311, which can simplify the production and processing process of the second flow channel 31 at the first branch 311, reduce the complexity of mold design and manufacturing, and thus reduce production costs. The shell and the first cover plate 321 can be formed by different molds respectively, and then assembled, avoiding the difficulty of forming complex flow channels in a single mold, and improving production efficiency and cost-effectiveness.

[0073] In some embodiments, see Figures 3 to 5 The second flow channel 31 also includes an inflow branch 313, ( Figure 5 In the figure, the inflow branch 313 flows in horizontally, and the extension section 3112 on the right side of the first branch 311 flows longitudinally, that is, the second flow channel 31 is bent at the connection between the inflow branch 313 and the first branch 311); wherein the groove includes a second groove 314, the second groove 314 connects the inflow branch 313 and the first branch 311, and the cover plate 32 includes a second cover plate 322, and the second cover plate 322 is installed in the notch of the second groove 314. In these embodiments, the inflow branch 313 and the first branch 311 extend in different directions, ensuring that the cooling medium can be evenly distributed to various heat sources of the electric assembly 100, thereby improving the heat exchange efficiency. The setting of the inlet of the entire heat dissipation channel (the inflow branch 313) can be more flexible. The cooperation between the second cover plate 322 and the shell closes the second groove 314, thereby achieving the connection between the inflow branch 313 and the first branch 311, and can simplify the production and processing process of the second channel 31 at the connection between the inflow branch 313 and the first branch 311, thereby reducing the complexity of mold design and manufacturing, thereby reducing production costs. The shell and the second cover plate 322 can be formed by different molds respectively and then assembled, thereby avoiding the problem of forming complex channels in a single mold and improving production efficiency and cost-effectiveness.

[0074] In some embodiments, please refer to Figures 3 to 5 , ( Figure 5The extension section 3112 on the left side of the first branch 311 flows longitudinally, and the second branch 312 flows from top to bottom, that is, the second flow channel 31 is bent at the connection between the second branch 312 and the first branch 311) the groove includes a third groove 318, and the third groove 318 connects the first branch 311 and the second branch 312. The cover plate 32 includes a third cover plate 323, and the third cover plate 323 at least partially covers the notch of the third groove 318. In this way, the cooperation between the third cover plate 323 and the shell body closes the third groove 318, thereby realizing the connection between the second branch 312 and the first branch 311, which can simplify the production and processing process of the second flow channel 31 at the connection between the second branch 312 and the first branch 311, reduce the complexity of mold design and manufacturing, and thus reduce production costs. The shell and the third cover plate 323 can be formed by different molds respectively and then assembled, avoiding the problem of forming complex flow channels in a single mold, thereby improving production efficiency and cost-effectiveness.

[0075] The present application does not specifically limit the formation method of the second branch 312. For example, a groove structure can be processed on the surface of the shell, and then the third cover plate 323 covers the notch of the groove structure and defines the second branch 312. That is, the groove structure and the third groove 318 are connected, a part of the third cover plate 323 covers the third groove 318, and another part of the third cover plate 323 covers the groove structure, thereby simplifying the production and processing process of the second flow channel 31 at the second branch 312.

[0076] In some embodiments, please refer to Figures 3 to 5 The plate surface of the third cover plate 323 which is away from the third groove 318 is provided with a mounting groove 3233, and the housing assembly is provided with an IGBT assembly 221, which is installed at the notch of the mounting groove 3233 to close the mounting groove 3233 and define the second branch 312 (combined with Fig.11Understanding), the bottom of the mounting groove 3233 is provided with a first channel 3231 and a second channel 3232, the first channel 3231 connects the second branch 312 and the third groove 318 (thereby connecting the first branch 311), and the second channel 3232 connects the second branch 312 and the first flow channel 11. In these embodiments, the third cover plate 323 is independently designed and is provided with a mounting groove 3233, a first channel 3231 and a second channel 3232. The mounting groove 3233 and the IGBT component 221 define a second branch 312. The first channel 3231 connects the second branch 312 and the third groove 318 (thereby connecting the first branch 311). The second channel 3232 connects the second branch 312 and the first flow channel 11. The production and processing process of the second flow channel 31 at the second branch 312, the connection between the second branch 312 and the first branch 311, and the connection between the second branch 312 and the first flow channel 11 can be simplified, the complexity of mold design and manufacturing can be reduced, and thus the production cost can be reduced. The shell and the third cover plate 323 can be formed by different molds respectively and then assembled, thereby avoiding the problem of forming complex flow channels in a single mold and improving production efficiency. The third cover plate 323 is provided with a first mounting groove 3233, and the IGBT component 221 is directly mounted at the notch of the mounting groove 3233, thereby closing the mounting groove 3233 and defining the second branch 312. This design also realizes the integration of the IGBT component 221 with the cooling system, simplifies the assembly process of the electric assembly 100, and improves the assembly efficiency. The IGBT component 221 is directly mounted at the notch of the mounting groove 3233 of the third cover plate 323, and the cooling medium can directly contact the heat exchange structure of the IGBT component 221 (such as a cooling plate or a cooling kit), thereby further enhancing the heat exchange efficiency and ensuring stable operation under extreme conditions. Specifically, the IGBT component 221 is provided with a heat sink, one surface of the heat sink is provided with components, and the other surface is provided with heat sink pins. The surface of the heat sink provided with the heat sink pins and the bottom of the mounting groove 3233 are spaced apart to form a second branch 312, so that the heat sink pins are located in the second branch 312, so that the heat on the heat sink pins is taken away by the coolant, thereby achieving heat dissipation of the IGBT component 221. For details, see the attached Fig.11 , above the IGBT assembly 221 are the IGBT driving board 67, the shielding board bracket 68, the control board 69 and the second cover 371, and the control board 69 is provided with a PWM line socket 128. Specifically, in order to achieve the communication between the second channel 3232 and the first flow channel 11 on the motor 1, the shell is further provided with a first via hole 144, which passes through the shell and is arranged opposite to the second channel 3232, and the cooling medium flowing out of the first via hole 144 enters the first flow channel 11 of the motor 1.

[0077] In some embodiments, see Figures 6 to 8 The second flow channel 31 also includes an outflow branch 315 (the outflow branch 315 extends in the transverse direction, and the first flow channel 11 extends in the longitudinal direction, that is, the second flow channel 31 is bent at the connection between the outflow branch 315 and the first flow channel 11), the groove includes a fourth groove 316, and the fourth groove 316 connects the first flow channel 11 and the outflow branch 315. The cover plate 32 includes a fourth cover plate 324, and the fourth cover plate 324 is installed at the notch of the fourth groove 316 to close a part of the notch of the fourth groove 316. The outflow branch 315 and the first flow channel 11 extend in different directions, ensuring that the cooling medium can be evenly distributed to the electric The heat exchange efficiency is improved at each heat source of the dynamic assembly 100, and the setting of the outlet (outflow branch 315) of the entire heat dissipation channel is more flexible. The cooperation between the fourth cover plate 324 and the shell closes part of the notch of the fourth groove 316, which can simplify the production and processing process of the second channel 31 at the connection between the outflow branch 315 and the first channel 11, reduce the complexity of mold design and manufacturing, and thus reduce production costs. The shell and the fourth cover plate 324 can be formed by different molds respectively and then assembled, avoiding the problem of forming complex channels in a single mold, thereby improving production efficiency and cost-effectiveness. Specifically, in order to allow the fourth groove 316 to communicate with the first flow channel 11, when the fourth cover plate 324 is matched with the housing, the fourth cover plate 324 does not completely close the notch of the fourth groove 316, and a second through hole 145 is reserved. The cooling medium flowing out of the first flow channel 11 enters the fourth groove 316 through the second through hole 145, passes through the outflow branch 315, and finally exits the electric assembly 100. That is, in this embodiment, the second through hole 145 and the first through hole 144 are both arranged on the sealing surface 136 of the motor end cover. By such an arrangement, the first flow channel 11 of the motor 1 is connected with the second flow channel 31 of the housing 3. Specifically, see Figure 5 , Figure 6 and Fig.11 In some embodiments, the cooling medium enters the housing 3 from the inflow branch 313, enters the first branch 311 (located in the first groove 317) through the second groove 314, flows through the third groove 318 and the first channel 3231 in sequence to enter the second branch 312, and then flows out of the housing 3 through the second channel 3232 and the first through hole 144 in sequence, thereby entering the first flow channel 11 of the motor 1, and then enters the fourth groove 316 from the second through hole 145, and finally is discharged from the outflow branch 315, completing a cooling cycle.

[0078] In some embodiments, see Fig. 9 and Fig.10The first flow channel 11 includes a plurality of motor flow channel sections 111 extending along the axial direction of the motor 1, and the plurality of motor flow channel sections 111 are interconnected. In these embodiments, through the plurality of motor flow channel sections 111 distributed along the axial direction, the cooling medium can evenly cover the entire length of the motor 1, ensuring that all parts inside the motor 1 can be effectively dissipated. Such uniform heat dissipation helps to reduce the temperature gradient inside the motor and avoid local overheating, thereby improving the thermal stability and efficiency of the motor 1. The interconnected design of the motor flow channel sections 111 increases the contact area and time between the cooling medium and the motor 1, thereby enhancing the heat exchange efficiency. When the cooling medium flows through each flow channel section, it can more fully absorb the heat generated by the motor 1, ensuring that the motor 1 operates within a suitable operating temperature range.

[0079] The present application does not limit the manner in which the plurality of motor flow path segments 111 are interconnected. For example, one end (head end) of the plurality of motor flow path segments 111 is interconnected, and the other end (tail end) of the plurality of motor flow path segments 111 is interconnected. In a specific embodiment, the head end and the tail end of the plurality of motor flow path segments 111 are interconnected to form a circuitous flow path ( Fig.10 The arrow in the middle indicates the flow direction). In the circuitous flow channel design, the cooling medium must pass through the entire flow channel network. The cooling medium will circulate between different parts of the motor 1 and have a longer contact with the heat-generating parts of the motor 1, increasing the effective area and time of heat exchange, thereby improving the heat exchange efficiency and ensuring that all parts of the motor 1 can be evenly and fully cooled. The circuitous flow channel design can prevent certain middle areas of the motor 1 from not being sufficiently cooled due to the fast flow rate of the cooling medium or the short residence time, ensuring that the temperature distribution inside the motor 1 is more uniform, reducing the risk of local overheating, and making the temperature of the entire medium more balanced, avoiding the situation where the front-stage medium is overcooled and the rear-stage medium is overheated, thereby improving the overall utilization rate and cooling effect of the cooling medium. The circuitous flow channel design can better control fluid dynamics, reduce unnecessary pressure losses, and make the cooling system run more efficiently.

[0080] In some embodiments, see Figure 5 and Figure 8, the second flow channel 31 further includes an inflow branch 313 and an outflow branch 315, the inflow branch 313 is connected to the first branch 311, the outflow branch 315 is connected to the first flow channel 11, the heat dissipation flow channel has an inlet 3131 and a liquid outlet 3151, the inlet 3131 is connected to the inflow branch 313, the liquid outlet 3151 is connected to the outflow branch 315, the inlet 3131 and the liquid outlet 3151 are arranged on the same side of the shell component, in these embodiments, the coolant enters the shell component from the inlet 3131, and flows through the inflow branch 313, the first branch 311, the second branch 312, the first flow channel 11, the outflow branch 315, and the cooling channel 3131. 15, the liquid flows out of the shell assembly from the liquid outlet 3151. The liquid inlet 3131 and the liquid outlet 3151 are located on the same side. The pipelines connecting the liquid inlet 3131 and the liquid outlet 3151 to the external system can be arranged more directly without bypassing the entire shell assembly, thereby reducing the length and complexity of the pipeline. When the liquid inlet 3131 and the liquid outlet 3151 are on one side, it is easier to perform regular inspections and maintenance work because there is no need to approach these interfaces from different sides of the shell assembly. It is also helpful to quickly replace or clean the pipeline. Such a design is conducive to the layout of the entire heat dissipation flow channel, can simplify the installation process and reduce the complexity of the pipeline layout.

[0081] In some embodiments, see Figure 1 and Figure 2 The electric assembly 100 also includes a gearbox 4, and the box body 3 includes a first box part 36 and a second box part 37; wherein the first box part 36 is arranged on one side of the radial direction (i.e., longitudinal direction) of the motor 1, the second box part 37 is arranged at one end of the axial direction of the motor 1, and the gearbox 4 is arranged at the other end of the axial direction of the motor 1, the first box part 36 and the second box part 37 are connected, the power distribution cavity 33 and the power supply cavity 34 are arranged in the first box part 36, and the electric control cavity 35 is arranged in the second box part 37. In these embodiments, the first box part 36 is arranged on one side of the radial direction of the motor 1, the second box part 37 is arranged at one end of the axial direction of the motor 1, and the gearbox 4 is arranged at the other end of the axial direction of the motor 1. This layout can make full use of the space inside the electric assembly 100, and realize a compact design by reasonably arranging the positions of various components, thereby reducing the overall volume of the electric assembly 100.

[0082] In some embodiments, in conjunction with Figure 3The power cavity 34 includes an AC inductor cavity 341, a transformer shielding cavity 342, a MOS tube shielding cavity 343, and a DC inductor cavity 344 which are spaced apart from each other. The power distribution cavity 33, the AC inductor cavity 341, the transformer shielding cavity 342, the MOS tube shielding cavity 343, and the DC inductor cavity 344 are distributed along the radial direction of the motor 1; the power supply component 21 includes a transformer 211 and a MOS tube 212, the transformer 211 is arranged in the transformer shielding cavity 342, and the MOS tube 212 is arranged in the MOS tube shielding cavity 343. In these embodiments, by placing the transformer 211 and the MOS tube 212 in the power supply component 21 in independent shielding cavities respectively, high voltage and high current components can be effectively isolated, the risk of short circuit and electrical failure can be reduced, and electrical safety can be improved. The independent shielding cavity can effectively reduce electromagnetic interference (EMI) and improve the electromagnetic compatibility of the system. The design of the independent cavity allows key components such as the transformer 211 and the MOS tube 212 to be installed and disassembled independently, simplifying the assembly and maintenance process. It also helps to enhance the structural stability and sealing of the electric assembly 100 and prevent the external environment from affecting the internal module, such as dust, moisture and vibration. The cavity design distributed radially along the motor 1 makes full use of the radial space of the electric assembly 100, reduces the axial length, and realizes a compact layout. The cavity design arranged radially enables the built-in module to be connected more directly from the axial direction of the motor 1, simplifies the interface design between the module and other vehicle systems, reduces the length and complexity of the external connection cables, reduces the risk of electromagnetic interference, and also facilitates the installation, maintenance and upgrading of the module. Specifically, the AC inductor cavity 341, the transformer shielding cavity 342, the MOS tube shielding cavity 343, and the DC inductor cavity 344 are separated and formed by shielding ribs, wherein the first shielding rib 1431 defining the transformer shielding cavity 342 is hollowly arranged to form a first branch 311 in the first shielding rib 1431, and the first shielding rib 1431 and the second shielding rib 1432 are spaced apart to define the MOS tube shielding cavity 343.

[0083] In some embodiments, see Figure 2The first box part 36 includes a first main body and a first cover 361. The first main body is open on one side away from the motor 1 to place the power supply assembly 21 and the power distribution assembly. The first cover 361 is covered on the open side of the first main body to cover the power supply assembly 21 and the power distribution assembly. The second box part 37 includes a second main body and a second cover 371. The second main body is open on one side away from the motor 1 to place the electric control assembly 22. The second cover 371 is covered on the open side of the second main body to cover the electric control assembly 22. The first main body and the second main body are integrally arranged. In these embodiments, the integral arrangement of the first main body and the second main body helps to enhance the structural strength of the box 3 and improve the durability and reliability of the electric assembly 100. The arrangement of the cover allows the cover to be quickly opened for operation when maintaining or replacing a module without affecting the normal operation of other modules, thereby simplifying the maintenance process and reducing maintenance costs and time. Specifically, the first main body and the second main body are integrally arranged to form an integrated box body 38, see attached Figure 1 , the electric assembly 100 also has a DC bus 6, a DC charging terminal 5, an AC charging connector 141, and a DC connector 142 on both sides of the axial direction, and a power distribution connector 140 on the other side. It can be seen that this electric assembly 100 is an electric assembly 100 that integrates at least multiple functions such as MPU, PDU, DC / OBC, etc. There are two covers on the electric assembly 100, namely the first cover body 361 and the second cover body 371, and the signal connector 146 of the integrated controller 2 is led out from the second cover body 371 in the axial direction of the electric assembly 100; it can be further seen from the figure that the DC charging terminal 5 is above the half shaft 138 and the ball cage 139 of the electric assembly 100, and the space above the entire half shaft 138 is fully utilized by the integrated box body 38.

[0084] It can be understood that when the vehicle is running normally, the battery pack supplies power to the IGBT component 221 (insulated gate bipolar transistor) through the DC bus 6. The IGBT component 221 converts DC power into AC power, and then supplies it to the motor 1 to drive the vehicle. When charging the vehicle, the current at the DC charging terminal needs to flow to the battery pack through the DC bus 6, but the distance from the DC charging port to the DC bus 6 interface needs to be connected by a wiring harness or a copper coin bus, which requires additional line connections, increasing costs and potential failure points.

[0085] In some embodiments, see Fig.12, the controller 2 also includes a DC charging terminal 5, a capacitor assembly 71, a DC bus 6, and a first shellless contactor 79 and a second shellless contactor 84; the capacitor assembly 71 includes a capacitor and a housing, the housing is provided with a first mounting cavity 78 and a second mounting cavity 89, the first shellless contactor 79 is mounted in the first mounting cavity 78, and the second shellless contactor 84 is mounted in the second mounting cavity 89; the current input point 87 of the first shellless contactor is connected to the negative pole of the DC charging terminal 5, and the current output point 88 of the first shellless contactor is connected to the negative pole of the DC bus 6 through the capacitor; the current input point 85 of the second shellless contactor is connected to the positive pole of the DC bus 6 through the capacitor, and the current output point 86 of the second shellless contactor is connected to the positive pole of the DC charging terminal 5. In this way, by directly connecting the DC charging terminal 5 to the capacitor assembly 71 and the DC bus 6 connection, eliminating additional wiring harnesses or copper bars, reducing connection points and wiring complexity, simplifying system architecture, reducing potential failure points, and improving system reliability and durability. The shellless contactor is directly installed in the housing of the capacitor assembly 71, reducing space occupancy and simplifying the assembly process. This integrated design helps to achieve a more compact controller 2 layout, saves space, and reduces external connections, reducing electromagnetic interference (EMI) risks. In charging mode, current flows directly from the DC charging terminal 5 through the shellless contactor and capacitor assembly 71 to the DC bus 6, and finally reaches the battery pack, optimizing the current path, reducing energy loss, and improving charging efficiency. At the same time, the capacitor assembly 71 plays a role in smoothing current fluctuations during the charging process and protects the battery pack from transient current shocks.

[0086] In some embodiments, continue to refer to Fig.12The housing is provided with a first contactor negative pole input connection point 98, a first contactor negative pole output connection point 102, a second contactor positive pole input connection point 93, a second contactor positive pole output connection point 92, a DC charging positive pole bridging conductive bar 95, a DC charging negative pole bridging conductive bar 96, a capacitor DC positive pole 76, a capacitor DC negative pole 77, a bus positive pole bridging point 72, and a bus negative pole bridging point 73; wherein, the current input point 87 of the first shellless contactor is connected to the first contactor negative pole input connection point 98, the first contactor negative pole input connection point 98 is connected to the DC charging negative pole bridging conductive bar 96, and the DC charging negative pole bridging conductive bar 96 is used to connect to the negative pole of the DC charging terminal 5; the current output point 88 of the first shellless contactor is connected to the first contactor negative pole output connection point 10 2 connection, the first contactor negative output connection point 102 is connected to the bus negative electrode lap point 73 through the capacitor DC terminal negative electrode 77, and the bus negative electrode lap point 73 is used to connect to the negative electrode of the DC bus 6; the second shellless contactor current input point 85 is connected to the second contactor positive output connection point 92, the second contactor positive output connection point 92 is connected to the bus positive electrode lap point 72 through the capacitor DC terminal positive electrode 76, and the bus positive electrode lap point 72 is used to connect to the positive electrode of the DC bus 6; the second shellless contactor current output point 86 is connected to the second contactor positive input connection point 93, the second contactor positive input connection point 93 is connected to the DC charging positive electrode lap conductive bar 95, and the DC charging positive electrode lap conductive bar 95 is used to connect to the positive electrode of the DC charging terminal 5. In these embodiments, a clearly planned current path ensures that the current can efficiently and safely flow from the DC charging terminal 5 to the capacitor assembly 71, and then reach the DC bus 6 through the contactor. The contactor and capacitor are integrated inside the housing, and electrical connection is achieved through internal connection points and conductive bars. This integrated design not only saves space, but also simplifies the overall structure of the system. The compact layout helps to achieve a smaller controller 2, which is beneficial to the rational use of the internal space of the electric vehicle.

[0087] In some embodiments, the controller 2 also includes a contactor control PCB board 83, and the contactor control PCB board 83 is equipped with a contactor signal socket 82; the housing is also provided with a first contactor negative input current sampling conductive row 97, a first contactor negative output current sampling conductive row 103, a second contactor positive input current sampling conductive row 90, and a second contactor positive output current sampling conductive row 91; the first contactor negative input current sampling conductive row 97 is connected to the first contactor negative input connection point 98, and is used for welding with the contactor control PCB board 83; the first contactor negative output current sampling conductive row 103 is connected to the first contactor negative output connection point 102, and is used for welding with the contactor control PCB board 83; the second contactor positive input current sampling conductive row 90 is connected to the second contactor positive input connection point 93, and is used for welding with the contactor control PCB board 83; the second contactor The positive output current sampling conductive bus 91 is connected to the second contactor positive output connection point 92 and is used for welding with the contactor control PCB board 83. In these embodiments, by arranging a current sampling conductive bus directly connected to the current input and output points of the first shellless contactor 79 and the second shellless contactor 84 in the shell, the design realizes direct sampling of the contactor current. This design avoids additional current sampling wiring harnesses and reduces the complexity of internal wiring. The contactor control PCB board 83 is not only responsible for the control signal processing of the contactor, but also integrates the current signal receiving and processing functions. By integrating the contactor signal socket 82 on the contactor control PCB board 83, centralized processing and transmission of current sampling data and control signals are realized. By directly welding the current sampling conductive bus to the contactor control PCB board 83, the design concentrates the current sampling signal and the contactor control signal on the contactor signal socket 82. In this way, all signals can be transmitted to the main control board 69 through a set of wiring harnesses, greatly reducing the number and complexity of internal wiring harnesses. Reducing the internal wiring harnesses not only simplifies the system structure and reduces the risk of electromagnetic interference and signal attenuation, but also reduces potential failure points and improves the overall reliability of the system. At the same time, the centralized signal processing design facilitates maintenance and fault diagnosis, reduces maintenance costs and time, that is, the design integrates the current sampling conductive bus, the contactor control PCB board 83 and the contactor signal socket 82 to achieve efficient centralized processing and transmission of current sampling signals and contactor control signals, which not only simplifies the internal wiring harness layout, improves the reliability and efficiency of the system, but also optimizes cost-effectiveness and production efficiency.Furthermore, the busbar negative electrode bonding point 73 also has a power supply negative electrode bonding point 74 and a PTC / air conditioner negative electrode bonding point 75, which are used for drawing power from the negative electrodes of the power supply and the PTC / air conditioner, respectively. The capacitor assembly 71 also has a capacitor grounding conductive bar 101, a capacitor output conductive bar 99, a contactor positive output transfer conductive bar 94, and a contactor negative output transfer conductive bar 150. The combination of the shellless contactor and the shell of the capacitor assembly 71 not only saves the contactor installation space and circuit connection, but also facilitates the signal harness connection and sampling connection, thereby making the entire electric control structure more compact and saving space and weight.

[0088] In some embodiments, see Fig.13 and Fig.14 , the controller 2 also includes a three-phase magnetic ring component, the three-phase magnetic ring component includes a magnetic core 105 and a three-phase conductive row (specifically see three-phase conductive row a106, three-phase conductive row b107, three-phase conductive row c108, three-phase magnetic ring seat 104), the magnetic core 105 has a central hole, the three-phase conductive row is inserted into the central hole, one end of the three-phase conductive row is used to connect with the IGBT component 221 (specifically see IGBT bridging point a113, IGBT bridging point b114, and IGBT bridging point c115), and the other end of the three-phase conductive row is used to connect with the three-phase coil of the motor 1 (specifically see the motor three-phase bridging point a110, the motor three-phase bridging point b151, and the motor three-phase bridging point c112); wherein, three conductive rows in the three-phase conductive row are connected along the first direction In these embodiments, the three-phase conductive bars (also called three-phase copper bars) are arranged in sequence along the first direction (usually the axial direction of the magnetic ring) in the center hole of the magnetic ring to form a stacked structure. This layout minimizes the space occupied by the conductive bars, thereby reducing the diameter of the center hole of the magnetic ring. The reduction in the aperture not only saves physical space, but also may reduce manufacturing costs and material consumption. The smaller the aperture, the smaller the magnetic resistance of the magnetic circuit, making the magnetic flux more concentrated, thereby improving the inductance performance of the magnetic ring. The stray inductance is caused by the non-ideal electromagnetic coupling between conductors, which usually leads to additional energy loss and electromagnetic interference. The stacking of the conductive bars can reduce this non-ideal coupling effect and help reduce the stray inductance of the three-phase copper bars themselves. Furthermore, there are three Hall magnetism sheets 109 on the three-phase magnetic ring seat 104, and the three-phase conductive bars pass over these three Hall magnetism sheets 109, which facilitates the Hall sensing chip 133 on the IGBT driver board 67 to sense and monitor the three-phase current.

[0089] According to a second aspect of the present application, a vehicle is provided, including an electric assembly 100. The electric assembly 100 is as described above. Since the vehicle adopts all the technical solutions of all the above embodiments, it at least has the beneficial effects brought by the technical solutions of the above embodiments, which will not be described one by one here.

[0090] The vehicle may be a pure electric vehicle (BEV), a plug-in hybrid electric vehicle (PHEV), a hybrid electric vehicle (HEV), a fuel cell electric vehicle (FCEV), etc., and this application does not make any specific limitations on this.

[0091] See also Fig.15The present disclosure exemplarily describes the assembly process of the electric assembly 100, firstly assemble and connect the motor 1 and the integrated box body 38 (the first main body and the second main body are formed by an integrated arrangement), and then respectively install the DC connector 142, the small magnetic ring 118, the DC magnetic ring filter component 119 and the DC charging filter component 125 in the integrated box body 38, and then respectively install the variable component 131, the IGBT component 221 and the IGBT driving board 67, the capacitor component 71 and the three-phase magnetic ring seat 104, so that one end of the IGBT component 221 is connected to the capacitor output conductive bar 99 of the capacitor component 71, and the other end is connected to the IGBT overlap point of the three-phase magnetic ring seat 104, and the Hall sensor chip 133 of the IGBT driving board 67 is located directly above the Hall magnetic focusing plate 109 to sense and monitor the three-phase current. Then install the shielding plate bracket 68 and the control board 69 in sequence, connect the contactor signal harness 129 of the control board 69 to the contactor signal socket 82, connect the variable harness connector 130 of the variable assembly 131 to the variable line connector 126 on the control board 69, and connect the IGBT drive board 67 to the control board 69 through the PWM signal harness 134. Install the busbar magnetic ring assembly 122 (the busbar magnetic ring assembly 122 is provided with a small fuse installation position 123) with the small fuse 121 installed into the integrated box body 38, and connect the positive and negative ends of the busbar magnetic ring assembly 122 to the busbar positive electrode lap point 72 and the busbar negative electrode lap point 73 of the capacitor assembly 71, and the other end is connected to the DC bus 6 for conduction. After the power distribution connector 140 is installed and passed through the small magnetic ring 118, the positive end is connected to a small fuse 121, and the negative end is connected to the PTC / air conditioner negative electrode lap point 75. At this time, the power board assembly 63 can be installed, and the two groups of MOS tubes 212 on the power board assembly 63 are respectively installed in the MOS tube shielding cavity 343, and the DC inductor 116 and the AC inductor 120 are respectively installed in the DC inductor cavity 344 and the AC inductor cavity 341, and the power board assembly 63 is connected to the DC magnetic ring filter assembly 119, the positive pole of one end of the power supply harness 137 is connected to the small fuse 121, and the negative pole is connected to the power negative pole lap point 74 of the capacitor assembly 71, and the other end is connected to the power board assembly 63, the power signal harness 117 and the power signal line electrical control end socket 127, and then the first cover 361 and the second cover 371 are installed respectively, and then the DC charging end 5 passes through the DC charging filter assembly 125 and is connected to the DC charging positive pole lap conductive bar 95 of the capacitor assembly 71 and the DC charging negative pole lap conductive bar 96 of the capacitor assembly 71, and finally the DC charging small cover 124 is installed, and the integrated controller 2 is assembled. Finally, the assembled integrated controller 2 and the transmission are connected to form Figure 1 The integrated electric powertrain 100 in the style.

[0092] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0093] In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0094] The embodiments, implementation methods and related technical features of the present application can be combined and replaced with each other without conflict.

[0095] The above are only preferred embodiments of the present application and do not constitute any form of limitation to the present application. However, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present application without departing from the content of the technical solution of the present application are still within the scope of the technical solution of the present application.

Claims

1. An electric assembly, characterized in that: include: Shell assembly; a first flow channel, the first flow channel being suitable for cooling the motor; and, A second flow channel, wherein the second flow channel is suitable for cooling the power supply component and the electronic control component; The first flow channel and the second flow channel are both arranged in the housing component, and the second flow channel is communicated with the first flow channel, so that the power supply component, the electronic control component and the motor share a heat dissipation flow channel.

2. The electric assembly according to claim 1, characterized in that: The second flow channel includes a first branch and a second branch that are interconnected, the first branch is suitable for dissipating heat for the power supply component, and the second branch is suitable for dissipating heat for the electronic control component.

3. The electric assembly according to claim 2, characterized in that: The power supply component is arranged in the housing component, and the power supply component includes a transformer and a MOS tube. The first branch is arranged around the outer periphery of the transformer, and the transformer and the MOS tube are both arranged adjacent to the first branch.

4. The electric assembly according to claim 3, characterized in that: The shell assembly is provided with a power supply cavity, and the power supply cavity accommodates the power supply assembly. A first shielding rib is provided in the power supply cavity, and the first shielding rib is arranged around the outer periphery of the transformer. The first shielding rib is hollow to form the first branch therein, and the MOS tube is arranged along a side of the first shielding rib away from the transformer.

5. The electric assembly according to claim 4, characterized in that: The housing assembly is provided with the electric control assembly, the electric control assembly includes an IGBT assembly, and the IGBT assembly is arranged adjacent to the second branch.

6. The electric assembly according to claim 5, characterized in that: The housing component is further provided with an electric control cavity, which accommodates the electric control component. The IGBT component and the cavity wall of the electric control cavity are spaced apart to define the second branch.

7. The electric assembly according to claim 6, characterized in that: The power supply cavity and the electric control cavity are arranged separately; Alternatively, the power cavity and the electric control cavity are respectively arranged on different sides of the housing assembly; Alternatively, the housing assembly is further provided with a power distribution cavity for accommodating a power distribution assembly, and the power distribution cavity, the power supply cavity and the electric control cavity are separated from each other.

8. The electric assembly according to claim 2, characterized in that: The housing assembly comprises a housing and a cover plate. The housing is provided with a groove to facilitate the processing of the second flow channel, and the cover plate closes the groove.

9. The electric assembly according to claim 8, characterized in that: The groove includes a first groove, the groove bottom of which is provided with the first branch, and the cover plate includes a first cover plate, and the first cover plate covers the first groove.

10. The electric assembly according to claim 8, characterized in that: The second flow channel also includes an inflow branch; The groove includes a second groove, the second groove is connected to the inflow branch and the first branch, and the cover plate includes a second cover plate, the second cover plate covers the notch of the second groove.

11. The electric assembly according to claim 8, characterized in that: The groove includes a third groove, the third groove is connected to the first branch and the second branch, and the cover plate includes a third cover plate, the third cover plate at least partially covers the notch of the third groove.

12. The electric assembly according to claim 11, characterized in that: The plate surface of the third cover plate facing away from the third groove is provided with a mounting groove, an IGBT assembly is provided in the housing assembly, the IGBT assembly is installed at the groove opening of the mounting groove to close the mounting groove and define the second branch, and the groove bottom of the mounting groove is provided with a first channel and a second channel, the first channel connects the third groove and the second branch, and the second channel connects the second branch and the first flow channel.

13. The electric assembly according to claim 8, characterized in that: The second flow channel also includes an outflow branch; The groove includes a fourth groove, the fourth groove is connected to the first flow channel and the outflow branch, and the cover plate includes a fourth cover plate, and the fourth cover plate covers a part of the notch of the fourth groove.

14. The electric assembly according to claim 1, characterized in that: The first flow channel includes a plurality of motor flow channel segments extending along the axial direction of the motor, and the plurality of motor flow channel segments are interconnected.

15. The electric assembly according to claim 2, characterized in that: The second flow channel also includes an inlet branch and an outflow branch, the inlet branch is connected to the first branch, and the outflow branch is connected to the first flow channel. The heat dissipation flow channel has a liquid inlet and a liquid outlet, the liquid inlet is connected to the inlet branch, and the liquid outlet is connected to the outflow branch. The liquid inlet and the liquid outlet are arranged on the same side of the shell assembly.

16. The electric assembly according to claim 1, characterized in that: The electric assembly also includes a DC charging terminal, a capacitor assembly, a DC bus, and a first shellless contactor and a second shellless contactor; The capacitor assembly comprises a capacitor and a housing, wherein the housing is provided with a first mounting cavity and a second mounting cavity, the first housing-less contactor is mounted in the first mounting cavity, and the second housing-less contactor is mounted in the second mounting cavity.

17. The electric assembly according to claim 1, characterized in that: The electric assembly also includes a three-phase magnetic ring assembly, and the three-phase magnetic ring assembly includes: a magnetic core having a central hole; and, A three-phase conductive bar is passed through the central hole, one end of the three-phase conductive bar is used to be connected to the IGBT component, and the other end of the three-phase conductive bar is used to be connected to the three-phase coil of the motor; Among them, three conductive bars in the three-phase conductive bar are arranged in sequence along the first direction.

18. A vehicle, characterized in that: Comprising an electric assembly as described in any one of claims 1 to 17.

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