Three-bearing electric drive assembly, assembling method and controller configuration method

Abstract

The invention discloses a three-bearing electric drive assembly, an assembling method and a controller configuration method. The system comprises a rotor assembly which is provided with an inner hole, and two ends of the rotor assembly are respectively provided with a first bearing and a second bearing for supporting; one end, far away from the rotor assembly, of the input shaft is provided with a third bearing for supporting, and the other end is provided with a shaft neck matched with an inner hole of the rotor assembly; an outer ring of the second bearing is fixed on the shell through a pressing plate, and an inner ring of the second bearing is fixed on the rotor assembly through a clamping spring; and a three-phase outgoing line of the stator assembly is arranged on the reduction gearbox side. Through the special structural design, the Y-direction size is reduced, space utilization is optimized, and the enveloping space of the electric drive assembly is small; and through the design of the split type controller, the requirements of different customers are met, the universal design of parts is ensured to the greatest extent, and the development and production costs are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile electric drive assemblies, and in particular to a three-bearing electric drive assembly, an assembly method, and a controller configuration method. Background Art

[0002] As competition in the new energy vehicle market becomes increasingly fierce, the iteration and upgrade of its power system become more and more frequent, resulting in high costs for the development of new energy vehicle electric drive assemblies. Currently, most models may only be switched after hundreds of thousands of units, and the high development and production costs of customized electric drive assemblies are amortized on each unit, resulting in high costs for electric drive assemblies, which further leads to lower cost performance of models and lower sales.

[0003] In order to minimize development and production costs, it is necessary to minimize customized parts, and at the same time, one electric drive assembly can be adapted to multiple models or models of multiple automobile manufacturers. However, different models have different requirements for the mounting space and controller of the electric drive assembly. Traditional electric drive assemblies have the following problems when adapting to the requirements of different models:

[0004] 1. Traditional electric drive assemblies usually adopt a four-bearing design for the input shaft, which takes up a large space and is difficult to adapt to the limited installation space of different models;

[0005] 2. The stator assembly of the traditional electric drive assembly usually has wires coming out from the rear end cover, which increases the Y-axis dimension and affects the overall envelope space;

[0006] 3. The controller of a traditional electric drive assembly is usually an integrated design, which makes it difficult to meet the differentiated needs of different customers for controller functions.

[0007] In other words, the electric drive assembly in the prior art usually adopts a four-bearing design for the input shaft, which has a large structural size and is difficult to adapt to the installation space of various vehicle models. At the same time, the outlet position of the motor stator assembly is not designed reasonably, and the internal space is not effectively utilized, resulting in an increase in the overall size. In addition, the controller design lacks flexibility and cannot meet the differentiated needs of different customers, which restricts the versatility of the electric drive assembly. Summary of the invention

[0008] The purpose of the present invention is to solve the defects of the prior art and provide a three-bearing electric drive assembly, assembly method, and controller configuration method. By optimizing the bearing configuration and component layout, the envelope size of the assembly can be effectively reduced and the space utilization rate can be improved; through the modular design of the controller, the flexible configuration of the three-in-one and multi-in-one electric drive assemblies can be achieved to meet the differentiated needs of different customers; it can ensure that the envelope space of the electric drive assembly is small, while meeting the compatibility requirements of the three-in-one electric drive assembly and the multi-in-one electric drive assembly of the whole vehicle.

[0009] In order to achieve the above objectives, in a first aspect, the present invention provides a three-bearing electric drive assembly, comprising:

[0010] A rotor assembly, with a first bearing and a second bearing respectively disposed at two ends thereof, and the rotor assembly has an inner hole;

[0011] An input shaft, one end of which is away from the rotor assembly is provided with a third bearing for support, and the other end of the input shaft is provided with a journal that matches the inner hole of the rotor assembly;

[0012] The outer ring of the second bearing is fixed tightly to the housing through a pressure plate, and the inner ring is axially limited and fixed to the rotor assembly through a retaining spring;

[0013] The journal end face of the input shaft close to the rotor assembly is in contact with the end face of the rotor assembly;

[0014] The stator assembly is arranged around the rotor assembly, and the three-phase output lines of the stator assembly are located on the reduction box side.

[0015] In some optional embodiments of the present invention, the position of the journal on the input shaft rotor assembly side that matches the inner hole of the rotor assembly coincides with the position of the bearing on the motor side of the rotor assembly.

[0016] In some optional embodiments of the present invention, it also includes:

[0017] A main housing, used for accommodating and installing the rotor assembly, the stator assembly and the input shaft;

[0018] A rear end cover connected to the main housing and disposed at an end of the rotor assembly away from the input shaft;

[0019] A first controller, installed inside the main housing;

[0020] a second controller, the second controller being selectively mounted on the rear end cover;

[0021] Among them, when only the first controller is set, the electric drive assembly becomes a three-in-one electric drive assembly; when the first controller and the second controller are set at the same time, the electric drive assembly becomes an all-in-one electric drive assembly.

[0022] Preferably, the first controller and the second controller are connected above the rear end cover.

[0023] Preferably, a high-voltage power line is provided on the first controller, and the high-voltage power line is located above the motor near the rear end cover and leads out to the reducer end.

[0024] In some optional embodiments of the present invention, the inner hole of the rotor assembly includes a positioning hole, and the end surface of the rotor assembly includes a positioning shoulder; the journal of the input shaft includes a positioning journal, and the end surface of the input shaft includes a positioning shoulder;

[0025] The input shaft is radially positioned through the positioning journal and the inner hole of the rotor assembly; the positioning shoulder of the input shaft is fitted with the positioning shoulder of the rotor assembly to form axial positioning.

[0026] In a second aspect, the present invention provides an assembly method for the three-bearing electric drive assembly according to the first aspect, comprising the following steps:

[0027] A first bearing and a second bearing are respectively installed at both ends of the rotor assembly;

[0028] Assemble the rotor assembly and the stator assembly together;

[0029] The inner ring of the second bearing is fixed to the rotor assembly by means of a retaining ring;

[0030] The outer ring of the second bearing is fixed to the housing via a pressure plate;

[0031] Set the three-phase outgoing wires of the stator assembly on the reduction box side;

[0032] A third bearing is installed at the end of the input shaft away from the rotor assembly;

[0033] The journal of the input shaft is matched with the inner hole of the rotor assembly so that the end face of the input shaft fits with the end face of the rotor assembly.

[0034] In some optional embodiments of the present invention, the following steps are also included:

[0035] A first controller is installed inside the main housing, and a high-voltage power line is arranged above the motor near the rear end cover to lead out to the reducer end;

[0036] It is determined whether to install a second controller on the rear end cover to form a three-in-one or multi-in-one electric drive assembly according to needs.

[0037] Preferably, when installing the second controller, the first controller and the second controller are connected above the rear end cover.

[0038] In a third aspect, the present invention provides a controller configuration method applied to the three-bearing electric drive assembly described in the first aspect, comprising:

[0039] A first controller is arranged inside the main housing;

[0040] A second controller is selectively arranged on the rear end cover;

[0041] Among them, when only the first controller is set, the electric drive assembly becomes a three-in-one electric drive assembly; when the first controller and the second controller are set at the same time, the electric drive assembly becomes an all-in-one electric drive assembly.

[0042] Preferably, when installing the second controller, the first controller and the second controller are connected above the rear end cover.

[0043] Preferably, a high-voltage power line is provided on the first controller, and the high-voltage power line is located above the motor near the rear end cover and leads out to the reducer end.

[0044] In a fourth aspect, the present invention further provides a vehicle, comprising the three-bearing electric drive assembly as described in the first aspect.

[0045] The beneficial effects of the present invention are:

[0046] 1. The three-bearing design of the input shaft replaces the traditional four-bearing design of the input shaft, which effectively reduces the Y-direction size of the electric drive assembly and reduces the overall envelope space;

[0047] 2. The three-phase outgoing line of the stator assembly is set on the reduction box side, which fully utilizes the space between the rotor assembly and the input shaft gear, reduces the length requirement of the stator assembly on the rear end cover side, and further optimizes the Y-direction dimension;

[0048] 3. The split design of the first controller and the second controller can flexibly meet the controller requirements of different customers, while maintaining the consistency of core components such as reducers and motors, ensuring the universal design of parts to the greatest extent and effectively reducing development and production costs;

[0049] 4. Through modular design, a set of basic structures can be configured as a three-in-one or multi-in-one electric drive assembly as needed, which improves the flexibility and adaptability of the product and can adapt to the installation space and functional requirements of more vehicle models. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] In order to more clearly illustrate the technical solutions of the embodiments disclosed in the present invention, the drawings of the embodiments will be briefly introduced below. These drawings are only used for illustrative purposes and are not intended to limit the protection scope of the present invention.

[0051] Figure 1 It is a cross-sectional schematic diagram of a three-bearing electric drive assembly of the present invention;

[0052] Figure 2 It is a cross-sectional schematic diagram of a rotor assembly and an input shaft of a three-bearing electric drive assembly of the present invention;

[0053] Figure 3 This is a schematic diagram of the connection between the motor and the controller of a three-bearing electric drive assembly of the present invention;

[0054] Figure 4 Schematic diagram of the three-in-one and all-in-one electric drive assembly of the present invention. DETAILED DESCRIPTION

[0055] The technical solution of the present invention (including the preferred technical solution) is further described in detail below by means of the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0056] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0057] Example 1

[0058] like Figure 1 and Figure 2 As shown, this embodiment provides a three-bearing electric drive assembly, including a rotor assembly 1, a stator assembly 2, a main housing 3 and an input shaft 4. Different from the conventional electric drive assembly using four bearings, this embodiment uses only three bearings, including the first to third bearings, namely: a rotor distal end bearing 5, an intermediate bearing 6 and an input shaft distal end bearing 7.

[0059] The two ends of the rotor assembly 1 are supported by the rotor distal bearing 5 and the intermediate bearing 6, respectively. Specifically, the rotor distal bearing 5 supports the left end of the rotor assembly 1 (i.e., the end away from the input shaft 4), and the intermediate bearing 6 supports the right end of the rotor assembly 1 (i.e., the end close to the input shaft 4). The rotor assembly 1 is provided with an inner hole 1.2. The end face of the rotor assembly 1 is also provided with a rotor assembly positioning shoulder 1.3, which is used to cooperate with the end face of the input shaft 4 to form axial positioning.

[0060] One end of the input shaft 4 away from the rotor assembly 1 is supported by the input shaft distal bearing 7. The other end of the input shaft 4 is provided with an input shaft positioning journal 4.1, which is matched with the inner hole 1.2 of the rotor assembly 1. The end face of the input shaft 4 is provided with an input shaft positioning shoulder 4.2, which is in contact with the rotor assembly positioning shoulder 1.3 of the rotor assembly 1, forming an axial positioning between the input shaft 4 and the rotor assembly 1.

[0061] Installation structure of the intermediate bearing 6: The outer ring of the intermediate bearing 6 is fixed and tightly attached to the main housing 3 through the intermediate bearing pressure plate 8 and the connecting bolts 9, while the inner ring of the intermediate bearing 6 is axially positioned and fixed on the rotor assembly 1 through the circlip 14. This design ensures a stable connection between the rotor assembly 1 and the intermediate bearing 6, and is also convenient for assembly and maintenance.

[0062] The input shaft positioning shoulder 4.2 on the side of the input shaft 4 close to the rotor assembly 1 fits with the rotor assembly positioning shoulder 1.3 of the rotor assembly 1. This design enables a stable connection between the rotor assembly 1 and the input shaft 4 in the axial direction, reduces the axial clearance, and improves the running stability.

[0063] The input shaft positioning journal 4.1 on the side of the input shaft 4 close to the rotor assembly 1 that mates with the inner hole 1.2 of the rotor assembly coincides with the intermediate bearing installation position 1.1 on the motor side of the rotor assembly 1. This design further optimizes the bearing layout, reduces the number of additional bearing support points, and lowers the structural complexity and manufacturing cost.

[0064] The end face of the journal on the side of the input shaft 4 close to the rotor assembly 1 fits with the end face of the rotor assembly 1 to form axial positioning. At the same time, the fit between the input shaft positioning journal 4.1 and the rotor assembly positioning hole 1.2 forms radial positioning. This connection method not only ensures the stability of the connection but also simplifies the structural design and reduces the number of bearings used.

[0065] In some embodiments of the present invention, the journal position 4.1 on the side of the input shaft 4 close to the rotor assembly that mates with the inner hole of the rotor assembly coincides with the bearing position 1.1 on the motor side of the rotor assembly. This design makes full use of the space and further reduces the overall size of the system.

[0066] In some embodiments of the present invention, the input shaft 4 and the rotor assembly 1 are driven by splines.

[0067] In this embodiment, the stator assembly 2 is arranged around the rotor assembly 1 and is used to generate an electromagnetic field to drive the rotor assembly 1 to rotate. Through the reasonable layout of the stator assembly 2 and the rotor assembly 1, the electric drive assembly has good electromagnetic performance and thermal management characteristics.

[0068] Embodiment 2

[0069] As Figure 3 shown, in the three-bearing electric drive assembly of this embodiment, the three-phase output wires 2.1 of the stator assembly 2 are designed on the side of the reduction gearbox, rather than the conventional rear end cover side. This design effectively utilizes the space between the rotor assembly 1 and the gear of the input shaft 4, reduces the length of the stator assembly 2 on the side of the rear end cover 12, and thus further reduces the Y-direction dimension.

[0070] The three-phase outgoing line 2.1 of the stator assembly 2 is connected to the first controller 11 through the copper adapter plate 10. The copper adapter plate 10 plays a dual role of electrical connection and mechanical fixation, ensuring the reliability of the electrical connection and simplifying the assembly process.

[0071] The advantages of this output line structure design are: first, by setting the three-phase output line on the reduction box side, it is avoided to add extra space on the rear end cover side to accommodate the output line structure, thereby reducing the overall Y-direction size; second, this design method facilitates the installation and connection of the controller, thereby improving the system integration; finally, this structural design is also conducive to heat dissipation management, because the heat-generating components (such as the first controller 11) are arranged in a dispersed manner, which can reduce the problem of heat concentration.

[0072] Example 3

[0073] like Figure 4 As shown, this embodiment provides a three-in-one and multi-in-one electric drive assembly based on a three-bearing structure, which further optimizes the configuration of the controller on the basis of embodiments 1 and 2.

[0074] The first controller 11 is installed inside the main housing 3 and is responsible for basic motor control functions. The high-voltage power line is set on the first controller 11 and leads to the reducer end near the rear end cover 12 above the motor. When only the first controller 11 is provided, the electric drive assembly becomes a three-in-one electric drive assembly, that is, it integrates the motor, reducer and basic control functions.

[0075] The second controller 13 can be selectively installed on the rear end cover 12. When the first controller 11 and the second controller 13 are provided at the same time, the electric drive assembly becomes an all-in-one electric drive assembly with more complex and rich control functions. The first controller 11 and the second controller 13 are connected above the rear end cover 12 to form a control system with complementary functions.

[0076] This design enables efficient signal transmission and functional coordination between the two controllers, while facilitating heat dissipation and maintenance.

[0077] In this embodiment, the first controller 11 is mainly responsible for the basic control functions of the motor, such as motor speed control, torque control, etc.; the second controller 13 can be configured with other functions according to different customer needs, such as vehicle power management, energy recovery control, driving mode setting, etc. This modular design enables the electric drive assembly to flexibly adapt to the needs of different models and different customers while maintaining the consistency of core components.

[0078] The advantages of this split controller design are:

[0079] 1. Flexibility: It can be flexibly configured as a three-in-one or multi-in-one electric drive assembly according to different customers' requirements for control functions;

[0080] 2. Versatility: Keep the core components such as motors and reducers consistent, and only meet different needs through controller configuration, which ensures the versatility of parts to the greatest extent;

[0081] 3. Cost-effectiveness: reduces the need for dedicated development and reduces development and production costs;

[0082] 4. Convenient upgrade: When function upgrade is needed, only the controller part can be upgraded without replacing the entire electric drive assembly.

[0083] Example 4

[0084] This embodiment provides an assembly method of a three-bearing electric drive assembly, which mainly includes the following steps:

[0085] Step 1: Prepare the rotor assembly 1, stator assembly 2, main housing 3, input shaft 4, rotor distal bearing 5, intermediate bearing 6, input shaft distal bearing 7, intermediate bearing pressure plate 8, connecting bolts 9, retaining spring 14 and other components.

[0086] Step 2: Fix the stator assembly 2 in the main housing 3, and ensure that the three-phase outgoing wires 2.1 of the stator assembly 2 face the reduction box side.

[0087] Step 3: Install the rotor distal bearing 5 at the left end of the rotor assembly 1 and the intermediate bearing 6 at the right end. Specifically, press the inner ring of the rotor distal bearing 5 into the left end bearing seat of the rotor assembly 1, and press the inner ring of the intermediate bearing 6 into the right end bearing seat of the rotor assembly 1 (i.e., the intermediate bearing installation position 1.1).

[0088] Step 4: Assemble the rotor assembly 1 and the stator assembly 2 together to form a motor assembly.

[0089] Step 5: Install the rear end cover 2 on the main housing 3 so that the outer ring of the rotor distal end bearing 5 is fixed at the corresponding position of the rear end cover 2 .

[0090] Step 6: Fix the inner ring of the intermediate bearing 6 to the rotor assembly 1 through the retaining spring 14 , and fix the outer ring of the intermediate bearing 6 tightly to the main housing 3 through the intermediate bearing pressure plate 8 and the connecting bolts 9 .

[0091] Step 7: Install the copper adapter plate 10 and connect the three-phase output line 2.1 of the stator assembly 2 to the copper adapter plate 10.

[0092] Step 8: Install the input shaft distal end bearing 7 at the end of the input shaft 4 away from the rotor assembly. Specifically, press the inner ring of the input shaft distal end bearing 7 into the bearing seat of the input shaft 4.

[0093] Step 9: Connect the input shaft positioning journal 4.1 of the input shaft 4 with the inner hole 1.2 of the rotor assembly 1, so that the input shaft positioning shoulder 4.2 fits with the rotor assembly positioning shoulder 1.3. In this way, the input shaft 4 and the rotor assembly 1 form a stable connection, with both radial positioning and axial positioning. The rotor assembly 1 and the input shaft 4 are driven by splines.

[0094] Step 10: Choose to install the first controller 11 or install the first controller 11 and the second controller 13 at the same time as needed. When only basic control functions are required, only the first controller 11 is installed to form a three-in-one electric drive assembly; when more complex control functions are required, the first controller 11 and the second controller 13 are installed at the same time to form an all-in-one electric drive assembly.

[0095] Step 11: Install other components, such as the intermediate shaft, differential, etc., close the main housing, fix the outer ring of the input shaft distal bearing 7 at the corresponding position of the main housing 3, and complete the assembly of the entire electric drive system.

[0096] This assembly method simplifies the assembly process, reduces assembly difficulty, and improves production efficiency. In particular, the reduction in the number of bearings and the optimized design of the bearing positions make the structure of the electric drive assembly more compact and the envelope size smaller.

[0097] Example 5

[0098] In this embodiment, a controller configuration method for a three-bearing electric drive assembly is provided, which is applied to the electric drive assembly with a three-bearing structure in the above embodiment. The method includes the following steps:

[0099] Step S1: a first controller 11 is arranged inside the main housing 3;

[0100] Step S2: Evaluate customer needs and determine whether a second controller 13 needs to be configured;

[0101] Step S3: If the customer needs more control functions, a second controller 13 is provided on the rear end cover 12 to form an all-in-one electric drive assembly; if the customer only needs basic control functions, only the first controller 11 is configured to form a three-in-one electric drive assembly;

[0102] Step S4: configure the high-voltage power line 11.1 of the first controller 11 so that it is located above the motor and close to the rear end cover 12 and leads out to the reducer end;

[0103] Step S5: When the second controller 13 is configured, the first controller 11 and the second controller 13 are connected above the rear end cover 12 to establish a signal transmission channel between the two controllers.

[0104] This method achieves a balance between customization and standardization of the electric drive assembly by evaluating customer needs and flexibly configuring the controller module. For customers with different control requirements, only the controller configuration needs to be adjusted, while the core components such as the motor and reducer remain unchanged, greatly reducing development and production costs.

[0105] Example 6

[0106] This embodiment describes the application scenarios and specific configuration methods of the three-bearing electric drive assembly in different vehicle models.

[0107] For small pure electric passenger vehicles, due to strict space restrictions, the input shaft three-bearing electric drive system of the present invention can be used and configured as a three-in-one electric drive assembly (i.e., only the first controller 11 is installed) to meet basic power requirements and control functions. Since the Y-dimension of the system is small, it is particularly suitable for small vehicles with limited installation space.

[0108] For medium and large pure electric passenger cars or luxury models, more complex control functions are often required, such as more sophisticated torque control, richer driving modes, etc. In this case, the input shaft three-bearing electric drive system of the present invention can be adopted and configured as an all-in-one electric drive assembly (i.e., the first controller 11 and the second controller 13 are installed at the same time). The first controller 11 is responsible for basic motor control functions, and the second controller 13 provides more advanced control functions. The two work together to meet the needs of high-end models.

[0109] For commercial vehicles, such as pure electric light trucks or buses, they can be flexibly configured according to specific needs. For cost-conscious commercial vehicles, a three-in-one configuration can be used; for commercial vehicles that require higher reliability or special functions (such as off-road adaptability), an all-in-one configuration can be used.

[0110] It is worth noting that no matter which configuration is adopted, the core components of the electric drive system (such as motors, reducers, etc.) remain consistent, and only the controller configuration is used to meet different needs. This design concept ensures the versatility of parts to the greatest extent and reduces development and production costs.

[0111] This flexible adaptation method allows the same electric drive assembly architecture to be applied to a variety of models, greatly reducing development and production costs. For automakers, this means faster time to market and higher cost-effectiveness. For consumers, this means more competitive product prices and more reliable product quality.

[0112] Example 7

[0113] This embodiment provides a vehicle based on a three-bearing electric drive assembly, which includes a vehicle body, a chassis, a power system, and an electric drive assembly with a three-bearing structure as described in the above embodiments.

[0114] In this vehicle, the electric drive assembly is installed at the front or rear of the vehicle and connected to the wheels through half shafts to provide driving force for the vehicle. Since the electric drive assembly adopts a three-bearing structure and an optimized internal layout, its envelope size is small, which makes the vehicle design more flexible, optimizes the interior space layout, and improves ride comfort.

[0115] At the same time, according to the different positioning of the vehicle model, you can choose a three-in-one electric drive assembly or a multi-in-one electric drive assembly configuration. For entry-level models, you can choose a three-in-one configuration to reduce costs; for high-end models, you can choose a multi-in-one configuration to provide richer driving functions and a better driving experience.

[0116] This vehicle design based on a modular electric drive assembly not only reduces vehicle development costs and shortens development cycles, but also improves product reliability and maintenance convenience, providing consumers with more cost-effective and reliable product options.

[0117] The advantages of the present invention are described below from different perspectives.

[0118] 1. Traditional electric drive assemblies usually adopt a four-bearing design for the input shaft, that is, there is a bearing at each end of the rotor assembly and a bearing at each end of the input shaft. This design results in a larger Y-axis dimension of the electric drive assembly, which is not conducive to compact design.

[0119] The three-bearing structure of the input shaft adopted by the present invention eliminates the independent bearing on the input shaft near the rotor assembly side, and realizes the support function through the precise matching of the input shaft positioning journal and the inner hole of the rotor assembly. At the same time, the input shaft positioning journal coincides with the bearing position on the motor side of the rotor assembly, further optimizing the structural layout. This design has the following technical advantages:

[0120] 1. Reduce the number of bearings: from the traditional four bearings to three bearings, reducing material costs and assembly complexity;

[0121] 2. Reduce the Y-direction size: The independent bearing on the input shaft close to the rotor assembly is eliminated, which reduces the axial length and makes the Y-direction size of the electric drive assembly smaller;

[0122] 3. Improve structural rigidity: The precise matching of the input shaft positioning journal and the inner hole of the rotor assembly, combined with the fitting design of the input shaft positioning shoulder and the rotor assembly positioning shoulder, improves the rigidity and stability of the overall structure;

[0123] 4. Reduce vibration and noise: Reducing the number of bearings and improving structural rigidity can help reduce the vibration and noise levels of the system.

[0124] Through these technical optimizations, the electric drive assembly of the present invention achieves a smaller envelope size and higher space utilization while ensuring performance and reliability, providing greater flexibility for the design of new energy vehicles.

[0125] Second, in traditional electric drive assemblies, the three-phase output lines of the stator assembly are usually arranged on the rear end cover side. This design results in low space utilization on the rear end cover side, limiting the compact design of the electric drive assembly.

[0126] The present invention sets the three-phase outgoing line 2.1 of the stator assembly 2 on the reduction box side and connects it to the first controller 11 through the adapter copper plate 10. This design has the following technical advantages:

[0127] 1. Make full use of internal space: effectively utilize the space between the rotor assembly and the input shaft gear, which is often wasted in traditional designs;

[0128] 2. Reduce the length of the rear end cover side: Reduce the length requirement of the stator assembly on the rear end cover side, and further reduce the Y-direction size of the electric drive assembly;

[0129] 3. Optimize the wiring path: The wiring path from the three-phase outgoing line to the first controller is shorter, which reduces power loss and improves system efficiency;

[0130] 4. Improve heat dissipation conditions: By adjusting the electrical connection position, the internal heat flow distribution is optimized and the heat dissipation conditions of the system are improved.

[0131] This optimized design of the cable outlet position, combined with the three-bearing structure, further reduces the overall size of the electric drive assembly, improves space utilization, and provides greater possibilities for the flexible application of the electric drive assembly in various vehicle models.

[0132] 3. In traditional electric drive assemblies, the controller usually adopts an integrated design, which is difficult to adapt to the differentiated needs of different customers and limits the versatility of the electric drive assembly.

[0133] The present invention adopts a split design of the first controller 11 and the second controller 13, which can be configured as a three-in-one electric drive assembly or a multi-in-one electric drive assembly as needed. This design has the following technical advantages:

[0134] 1. Meet differentiated needs: Different customers have different requirements for control functions, and the split design can flexibly adapt to these differentiated needs;

[0135] 2. Improve the versatility of parts: The core components such as motors and reducers remain consistent, and only the controller configuration needs to be adjusted as needed, which greatly improves the versatility of parts;

[0136] 3. Reduce development costs: One set of infrastructure can adapt to multiple configuration requirements, reducing the cost of developing electric drive assemblies for different models;

[0137] 4. Shorten the development cycle: The modular design allows the development and upgrade of new functions to be concentrated on the controller module, without the need to redesign the entire system, greatly shortening the development cycle.

[0138] This modular design of the controller, combined with the three-bearing structure and optimized cable outlet position, forms a highly flexible and cost-effective electric drive assembly solution, providing more options for new energy vehicle manufacturers.

[0139] Those skilled in the art will readily appreciate that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, replacements, improvements, etc. made within the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A three-bearing electric drive assembly, characterized in that: include: A rotor assembly, with a first bearing and a second bearing respectively disposed at two ends thereof, and the rotor assembly has an inner hole; An input shaft, one end of which is away from the rotor assembly is provided with a third bearing for support, and the other end of the input shaft is provided with a journal that matches the inner hole of the rotor assembly; The outer ring of the second bearing is fixed tightly to the housing through a pressure plate, and the inner ring is axially limited and fixed to the rotor assembly through a retaining spring; The journal end face of the input shaft close to the rotor assembly is in contact with the end face of the rotor assembly; The stator assembly is arranged around the rotor assembly, and the three-phase output lines of the stator assembly are located on the reduction box side.

2. The three-bearing electric drive assembly according to claim 1, characterized in that: The position of the journal on the input shaft rotor assembly side that matches the inner hole of the rotor assembly coincides with the position of the bearing on the motor side of the rotor assembly.

3. The three-bearing electric drive assembly according to claim 1 or 2, characterized in that: Also includes: A main housing, used for accommodating and installing the rotor assembly, the stator assembly and the input shaft; A rear end cover connected to the main housing and disposed at an end of the rotor assembly away from the input shaft; A first controller, installed inside the main housing; a second controller, the second controller being selectively mounted on the rear end cover; Among them, when only the first controller is set, the electric drive assembly becomes a three-in-one electric drive assembly; when the first controller and the second controller are set at the same time, the electric drive assembly becomes an all-in-one electric drive assembly.

4. The three-bearing electric drive assembly according to claim 3 is characterized in that: The first controller and the second controller are connected above the rear end cover; a high-voltage power line is provided on the first controller, and the high-voltage power line is located above the motor near the rear end cover and leads out to the reducer end.

5. The three-bearing electric drive assembly according to claim 1, characterized in that: The inner hole of the rotor assembly includes a positioning hole, and the end surface of the rotor assembly includes a positioning shoulder; the journal of the input shaft includes a positioning journal, and the end surface of the input shaft includes a positioning shoulder; The input shaft is radially positioned through the positioning journal and the inner hole of the rotor assembly; the positioning shoulder of the input shaft is fitted with the positioning shoulder of the rotor assembly to form axial positioning.

6. An assembly method for the three-bearing electric drive assembly according to any one of claims 1 to 5, characterized in that: The following steps are involved: A first bearing and a second bearing are respectively installed at both ends of the rotor assembly; Assemble the rotor assembly and the stator assembly together; The inner ring of the second bearing is fixed to the rotor assembly by means of a retaining ring; The outer ring of the second bearing is fixed to the housing via a pressure plate; Set the three-phase outgoing line of the stator assembly on the reduction box side; Install a third bearing at the end of the input shaft away from the rotor assembly; The journal of the input shaft is matched with the inner hole of the rotor assembly so that the end face of the input shaft fits with the end face of the rotor assembly.

7. The assembly method according to claim 6, characterized in that: The following steps are also included: A first controller is installed inside the main housing, and a high-voltage power line is arranged above the motor near the rear end cover to lead out to the reducer end; It is determined whether to install a second controller on the rear end cover to form a three-in-one or multi-in-one electric drive assembly according to needs.

8. The assembly method according to claim 7, characterized in that: When installing the second controller, the first controller and the second controller are connected above the rear end cover.

9. A controller configuration method applied to the three-bearing electric drive assembly according to any one of claims 1 to 5, characterized in that: include: A first controller is arranged inside the main housing; A second controller is selectively arranged on the rear end cover; Among them, when only the first controller is set, the electric drive assembly becomes a three-in-one electric drive assembly; when the first controller and the second controller are set at the same time, the electric drive assembly becomes an all-in-one electric drive assembly.

10. The controller configuration method according to claim 9, characterized in that: When installing the second controller, the first controller and the second controller are connected above the rear end cover.

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