Electric drive axle of new energy automobile

Abstract

An electric drive axle of a new energy automobile comprises a drive motor, a speed reducer, a controller and a differential mechanism, the drive motor, the speed reducer, the controller and the differential mechanism are installed in a shared shell, a drive motor installation cavity is formed in the middle of the shared shell, a speed reducer installation cavity is formed in one side of the drive motor, and a controller installation cavity is formed in the other side of the drive motor. A differential mounting cavity is formed in the front side of the speed reducer, axle tube connecting parts are arranged on the left side and the right side of the differential mounting cavity respectively, the two ends of a motor shaft of the driving motor are supported on the shared shell through bearings respectively, and one end of the motor shaft extends into the speed reducer mounting cavity to form a cantilever end; the cantilever end is provided with a driving bevel gear which is meshed with a driven bevel gear on the intermediate shaft of the speed reducer.

Description

Technical Field

[0001] The present invention relates to the field of electric drive bridges, and in particular to an electric drive bridge for new energy vehicles. Background Art

[0002] With the continuous development of new energy vehicles, miniaturization, high speed and light weight of electric drive systems have become the main research directions. The following problems still exist in the integration of electric drive axles in the prior art: 1. The housings of the motor, reducer and controller are separated from each other, which has high manufacturing costs; 2. The motor shaft of the motor and the input shaft of the reducer are connected by splines. For example, in the utility model patent with the authorization announcement number CN211335443U, the motor shaft of the drive motor and the input shaft of the reducer are used for power transmission through spline cooperation. This structure has particularly high requirements for spline precision, so the manufacturing cost of the spline shaft is high, and there are also problems such as spline wear and shaft frequency; 3. The motor rotor has oblique axial force, which will increase the load on the bearing, resulting in reduced bearing life and increased noise. Summary of the invention

[0003] In view of the above-mentioned problems, the present invention provides an electric drive axle for a new energy vehicle. The electric motor, controller and reducer are designed to share a common housing, and the reducer input shaft is designed to be coaxial with the motor shaft, thereby ensuring that the rear axle has a compact structure, small size and low cost, thereby realizing a highly integrated power layout for new energy vehicles.

[0004] The technical solution of the present invention is: an electric drive axle of a new energy vehicle, including a drive motor, a reducer, a controller, and a differential. The drive motor, reducer, controller, and differential are installed in a common shell. The middle part of the common shell is a drive motor installation cavity, one side of the drive motor is a reducer installation cavity, the other side of the drive motor is a controller installation cavity, and the front side of the reducer is a differential installation cavity. Bridge pipe connecting parts are respectively provided on the left and right sides of the differential installation cavity. Both ends of the motor shaft of the drive motor are respectively supported on the common shell through bearings, and one end of the motor shaft extends into the reducer installation cavity to form a cantilever end. A driving helical gear is provided on the cantilever end to mesh with a driven helical gear on the intermediate shaft of the reducer.

[0005] Preferably, the active helical gear is integrally formed at the cantilever end of the motor shaft.

[0006] Preferably, the helical angles of the driving helical gear and the driven helical gear range from 8° to 30°.

[0007] Preferably, the common shell includes a shell body, a controller end cover, a reducer end cover, and a differential cover. The inner cavity of the shell body is provided with a drive motor mounting cavity, a reducer mounting cavity, a controller mounting cavity, and a differential mounting cavity. The controller end cover is arranged on one side of the controller mounting cavity of the shell body, the reducer end cover is arranged on one side of the reducer mounting cavity of the shell body, and the differential cover is arranged on one side of the differential mounting cavity of the shell body.

[0008] Preferably, the controller end cover, reducer end cover and differential cover are all connected to the housing body by bolts.

[0009] The advantages of the present invention are: 1. The reducer input shaft of the present invention is integrally formed with the motor shaft of the motor, and an active helical gear is integrally formed on the motor shaft, thereby eliminating the spline connection between the reducer input shaft and the motor shaft of the motor, avoiding many problems caused by the spline connection, and at the same time reducing the two bearings required for the reducer input shaft, reducing one assembly process of the reducer and the motor, improving the sealing performance, and reducing the manufacturing cost.

[0010] 2. The motor, controller and reducer of the present invention are all arranged in a common housing, with compact structure, small size and low cost, thus realizing a highly integrated power layout of new energy vehicles.

[0011] 3. In the present invention, the axial force generated when the driving helical gear and the driven helical gear are meshed offsets a portion of the axial force of the motor rotor helical stage, thereby increasing the bearing life, reducing noise, and improving NVH performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram of the internal structure of the present invention; Figure 2 It is a schematic diagram of the first external structure of the present invention; Figure 3 This is a second external structure schematic diagram of the present invention. DETAILED DESCRIPTION

[0013] See also Figures 1 to 3, an electric drive bridge of a new energy vehicle, including a drive motor 4, a reducer 3, a controller 2, and a differential 6. The drive motor 4, the reducer 3, the controller 2, and the differential 6 are installed in a common shell 1. The common shell 1 includes a shell body 11, a controller end cover 12, a reducer end cover 13, and a differential cover 14. The middle part of the common shell 1 is a drive motor installation cavity, the reducer installation cavity is located on one side of the drive motor 4, the controller installation cavity is located on the other side of the drive motor 4, and the differential installation cavity is located on the front side of the reducer 3. The controller end cover 12 is arranged on one side of the controller installation cavity, the reducer end cover 13 is arranged on one side of the reducer installation cavity, and the differential cover 14 is arranged on one side of the differential installation cavity of the shell body 11. Bridge pipe connecting parts 7 are respectively provided on the left and right sides of the differential installation cavity. The controller end cover 12, the reducer end cover 13, and the differential cover 14 are all connected to the shell body 11 by bolts. Through such an arrangement, the structure of the electric drive axle is compact and small in size, and the production cost is reduced. In addition, by setting the controller end cover 12, the reducer end cover 13, and the differential cover 14, it is convenient to assemble the controller 2, the reducer 3, and the differential 6 in the common housing 1. The two ends of the motor shaft 41 of the drive motor 4 are supported on the common housing 1 through bearings 5 ​​respectively. One end of the motor shaft 41 extends into the reducer installation cavity to form a cantilever end. The cantilever end is provided with a driving helical gear 411 that meshes with the driven helical gear 31 on the intermediate shaft of the reducer 3. The driving helical gear 411 is integrally formed at the cantilever end of the motor shaft 41. The helical angle of the driving helical gear 411 and the driven helical gear 31 ranges from 8° to 30°. Within this angle range, the axial force generated when the driving helical gear 411 meshes with the driven helical gear 31 can offset a part of the axial force of the motor rotor helical stage, thereby increasing the bearing life, reducing noise, and improving NVH performance.

[0014] The present invention is applied to electric vehicles, by integrating the controller 2, the motor 4 and the reducer 3 into a three-in-one electric drive assembly, integrating the motor shaft 41 with the reducer input shaft, and integrating the active bevel gear 411 onto the motor shaft 41 for integral processing, eliminating the spline connection, and realizing the design of a common housing for the motor 4, the controller 2 and the reducer 3, with a compact structure, small size and low cost. It also avoids the shaft side frequency problem caused by the spline connection between the motor 4 and the reducer input shaft, the spline wear problem, the spline knocking problem, etc., and at the same time reduces the two bearings required for the assembly of the reducer input shaft, reduces one assembly process of the reducer 3 and the motor 4, and improves the sealing performance.

[0015] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modification made to the present invention by those skilled in the art without departing from the spirit of the present invention shall fall within the protection scope of the present invention.

Claims

1. An electric drive axle for a new energy vehicle, comprising a drive motor (4), a reducer (3), a controller (2), and a differential (6), characterized in that: The drive motor (4), the reducer (3), the controller (2), and the differential (6) are installed in a common housing (1); the middle part of the common housing (1) is a drive motor installation cavity, the one side of the drive motor (4) is a reducer installation cavity, the other side of the drive motor (4) is a controller installation cavity, and the front side of the reducer (3) is a differential installation cavity; bridge tube connecting parts (7) are respectively provided on the left and right sides of the differential installation cavity; both ends of the motor shaft (41) of the drive motor (4) are supported on the common housing (1) through bearings (5); one end of the motor shaft (41) extends into the reducer installation cavity to form a cantilever end; a driving helical gear (411) is provided on the cantilever end to mesh with a driven helical gear (31) on the intermediate shaft of the reducer (3).

2. The electric drive axle of a new energy vehicle according to claim 1, characterized in that: The active bevel gear (411) is integrally formed at the cantilever end of the motor shaft (41).

3. The electric drive axle of a new energy vehicle according to claim 1, characterized in that: The helical angles of the driving helical gear (411) and the driven helical gear (31) range from 8° to 30°.

4. The electric drive axle of a new energy vehicle according to claim 1, characterized in that: The common housing (1) comprises a housing body (11), a controller end cover (12), a reducer end cover (13), and a differential cover (14); the housing body (11) has an inner cavity provided with a drive motor mounting cavity, a reducer mounting cavity, a controller mounting cavity, and a differential mounting cavity; the controller end cover (12) is arranged on one side of the controller mounting cavity of the housing body (11); the reducer end cover (13) is arranged on one side of the reducer mounting cavity of the housing body (11); and the differential cover (14) is arranged on one side of the differential mounting cavity of the housing body (11).

5. The electric drive axle of a new energy vehicle according to claim 4, characterized in that: The controller end cover (12), the reducer end cover (13), and the differential cover (14) are all connected to the housing body (11) via bolts.

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