Electric drive assembly with input shaft with limit axial size and assembling method of electric drive assembly

Abstract

The invention discloses an electric drive assembly with a limit axial size input shaft and an assembling method of the electric drive assembly. The electric drive assembly comprises a speed reducer assembly and a motor assembly. The speed reducer assembly comprises an input shaft assembly, a rotary transformer and a rotary transformer pressing plate. The motor assembly comprises a rotor assembly and a stator assembly; the input shaft assembly and the rotor assembly rotate synchronously; an inner hole is formed in one end of the rotor assembly in the axial direction of the rotor assembly, and one end of the input shaft assembly is coaxially inserted and connected into the inner hole. The other end of the input shaft assembly is coaxially connected with a first bearing, the connection section of the rotor assembly and the input shaft assembly is coaxially connected with a second bearing, and the other end of the input shaft assembly is coaxially connected with a third bearing; the connection section of the rotor assembly and the input shaft assembly is coaxially connected with a rotary transformer and a rotary transformer pressing plate; and a three-phase outgoing line of the stator assembly is positioned on one side of the speed reducer assembly. The axial size of the electric drive assembly is greatly reduced, and the universality and carrying performance of the electric drive assembly are effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive drive assemblies, and specifically refers to an electric drive assembly with an input shaft of an extreme axial dimension and an assembly method thereof. Background Art

[0002] In the field of research, development and manufacturing of modern passenger vehicles, the subframe, as an important part of the vehicle chassis system, plays a key role in improving the vehicle's handling performance, reducing noise and vibration, etc. However, the development process of the passenger vehicle subframe involves complex design, testing and manufacturing processes, and the cost is relatively high. In order to effectively control the cost, in actual production, a design strategy of matching one subframe with multiple vehicle models is usually adopted. Once the subframe is developed, the electric drive installation space in the left-right direction of the whole vehicle is determined. Due to the differences in design concepts and vehicle model positioning among different manufacturers, the electric drive installation space sizes of subframes of each manufacturer or different vehicle models in the left-right direction of the whole vehicle are different. This difference in installation space puts forward diverse requirements for the axial dimension of the input shaft of the electric drive assembly that matches it.

[0003] Currently, the existing electric drive assemblies have certain limitations in terms of the axial dimension of the input shaft. Some electric drive assemblies cannot be adapted to some vehicle models with a small electric drive installation space due to the large axial dimension of the input shaft, resulting in limited installation ranges. This not only affects the market application range of the electric drive assembly, but also restricts the choices of vehicle manufacturers in terms of vehicle model configuration and cost control to a certain extent.

[0004] In order to meet the diverse requirements of different vehicle models and manufacturers for the frame installation space, improve the versatility and installability of the electric drive assembly to adapt to the increasingly diverse market demands, and at the same time enhance the flexibility of vehicle manufacturers in vehicle model configuration and cost control ability, it is urgently necessary to develop an electric drive assembly with a small axial dimension of the input shaft to solve the above problems existing in the prior art. Summary of the Invention

[0005] The purpose of the present invention is to solve the deficiencies in the above background art, and provide an electric drive assembly with an input shaft of an extreme axial dimension and an assembly method thereof, which can effectively improve the versatility and installability, adapt to the increasingly diverse market demands, and at the same time enhance the flexibility of vehicle manufacturers in vehicle model configuration and cost control ability.

[0006] To achieve this purpose, the electric drive assembly with an input shaft having a limit axial dimension designed by the present invention includes a reducer assembly and a motor assembly; the reducer assembly includes an input shaft assembly, a resolver, and a resolver pressure plate; the motor assembly includes a rotor assembly and a stator assembly; the input shaft assembly and the rotor assembly rotate synchronously; one end of the rotor assembly is axially provided with an inner hole, and one end of the input shaft assembly is coaxially inserted and connected into the inner hole; the other end of the input shaft assembly is coaxially connected with a first bearing, and a second bearing is coaxially connected to the connection section between the rotor assembly and the input shaft assembly, and the other end of the input shaft assembly is coaxially connected with a third bearing; the resolver and the resolver pressure plate are coaxially connected to the connection section between the rotor assembly and the input shaft assembly; the three-phase leads of the stator assembly are located on one side of the reducer assembly.

[0007] Further, the first bearing is axially positioned and installed inside the reducer assembly, and the second bearing and the third bearing are both axially positioned and installed inside the motor assembly.

[0008] Further, the resolver and the resolver pressure plate are axially positioned and installed inside the reducer assembly. One end of the rotor assembly is inserted into the reducer assembly, one end of the input shaft assembly is inserted into the inner hole and is located inside the motor assembly. A journal for installing the resolver and the resolver pressure plate is provided on the shaft section of the rotor assembly located inside the reducer assembly. The resolver and the resolver pressure plate are coaxially arranged on the journal of the rotor assembly located inside the reducer assembly. An installation surface for axially pressing and positioning in cooperation with the end face on the side of the resolver pressure plate away from the resolver is provided inside the reducer assembly, and the end face of the resolver pressure plate close to the resolver axially presses the resolver against the inner surface of the motor assembly.

[0009] Further, the inner hole includes a spline groove for cooperating with the input shaft assembly, and the input shaft assembly includes a spline for cooperating with the spline groove.

[0010] Further, the reducer assembly includes a reducer housing, and a first bearing installation groove for installing the first bearing is provided inside the reducer housing; the motor assembly includes a motor housing and a rear end cover. A second bearing installation groove for installing the second bearing is provided inside the motor housing, and a third bearing installation groove for installing the third bearing is provided on the rear end cover; the first bearing is axially positioned and installed in the first bearing installation groove through a first bearing axial limiting structure; the second bearing is axially positioned and installed in the second bearing installation groove through a second bearing axial limiting structure; the third bearing is axially positioned and installed in the third bearing installation groove through a third bearing axial limiting structure.

[0011] Furthermore, the first bearing axial position limiting structure includes a first bearing pressing plate fixed inside the reducer housing and used to limit the axial movement of the outer ring end face of the first bearing on the side close to the rotor assembly; the inner surface of the reducer housing used to limit the axial movement of the outer ring end face of the first bearing on the side away from the rotor assembly; and a bearing inner ring positioning bolt coaxially fixed inside the other end of the input shaft assembly and used to limit the axial movement of the inner ring end face of the first bearing on the side away from the rotor assembly.

[0012] Furthermore, the second bearing axial position limiting structure includes the inner surface of the motor housing and the rotor assembly shaft shoulder respectively used to limit the axial two-side end faces of the second bearing, and a wave washer coaxially installed on the rotor assembly is also arranged between the inner surface of the motor housing and the second bearing.

[0013] Furthermore, the third bearing axial position limiting structure includes the inner surface of the rear end cover fixed on the motor housing and used to limit the axial movement of the outer end face of the third bearing on the side away from the input shaft assembly, and a third bearing pressing plate fixed on the rear end cover and used to limit the axial movement of the outer end face of the third bearing on the side close to the input shaft assembly.

[0014] Furthermore, an assembly method of an electric drive assembly with an input shaft having a limit axial dimension includes: coaxially inserting one end of the input shaft assembly into the inner hole of the rotor assembly to make the input shaft assembly and the rotor assembly coaxially connected and rotatable synchronously; coaxially installing a first bearing at the other end of the input shaft assembly, coaxially installing a second bearing on the connection section between the rotor assembly and the input shaft assembly, and coaxially installing a third bearing at the other end of the input shaft assembly; coaxially installing a resolver and a resolver pressing plate on the connection section between the rotor assembly and the input shaft assembly; arranging the three-phase outgoing wires of the stator assembly on one side of the reducer assembly.

[0015] Still further, the assembly method of the electric drive assembly with an input shaft having a limit axial dimension further includes connecting the three-phase outgoing wires of the positioning assembly to the three-phase copper bars of the controller and installing the controller on the reducer assembly.

[0016] The beneficial effects of the present invention are:

[0017] 1. Axial dimension is extremely reduced: Through the unique connection structure between the input shaft assembly and the rotor assembly, combined with the support design of three bearings, the structure of the existing electric drive assembly where the rotor and the input shaft share four bearings for support is replaced, significantly reducing the axial dimension of the electric drive assembly. At the same time, the three-phase wires of the stator assembly exit on the side of the reduction gearbox, and the resolver and resolver pressure plate are installed on the side of the reduction gearbox, further reducing the axial thickness of the rear end cover and effectively utilizing the space between the rotor assembly and the input shaft gear. This enables the electric drive assembly to be adapted to more vehicle models with different subframe electric drive installation spaces, significantly improving its versatility and mountability to meet the increasingly diverse market demands.

[0018] 2. The axial positioning design of the bearings is reasonable and reliable: Each bearing adopts a reasonable axial limiting structure. For example, the first bearing is axially positioned through the first bearing pressure plate, the internal profile of the reducer housing, and the bearing inner ring positioning bolt; the second bearing is axially positioned through the internal profile of the motor housing, the shaft shoulder of the rotor assembly, and the wave washer; the third bearing is axially positioned through the rear end cover and the third bearing pressure plate. These designs ensure the stable and reliable operation of each bearing during work, improving the overall performance and reliability of the electric drive assembly.

[0019] 3. Component layout is optimized: Axially positioning and installing the resolver and resolver pressure plate inside the reducer assembly not only reduces the axial thickness of the rear end cover but also optimizes the internal space layout of the electric drive assembly, making the connection and collaborative work between components smoother.

[0020] 4. The assembly method is simple and efficient: The assembly method steps of the electric drive assembly with an input shaft having a limit axial dimension are clear: 1. Assemble the second bearing, the third bearing pressure plate, and the third bearing on the rotor assembly, and fix the third bearing pressure plate to the rear end cover through bolts, and the rear end cover and the rotor assembly form an integral structure; 2. Install the wave washer, and the rear end cover with the rotor assembly and the motor housing are assembled together (the stator-rotor assembled assembly); 3. Assemble the resolver, the slip ring, etc.; 4. Assemble components such as the first bearing pressure plate, the first bearing, and the bearing inner ring positioning bolt on the input shaft assembly, install the input shaft assembly into the reducer housing, and assemble other accessories (such as the three-phase adapter seat, the intermediate shaft assembly, the differential assembly, etc.); 5. Assemble the stator-rotor assembled assembly and the input shaft assembly together; 6. Assemble the controller and other accessories together. This simple and efficient assembly method is conducive to improving production efficiency, reducing assembly costs, and ensuring the stability of product quality.

[0021] 5. The vehicle model configuration flexibility is enhanced: The smaller axial dimension gives vehicle manufacturers greater freedom in vehicle model design and configuration, and they can more flexibly arrange the electric drive assembly according to the requirements of different vehicle models, optimizing the overall layout and space utilization of the vehicle.

[0022] 6. Cost-effective control: On the one hand, the electric drive assembly can be adapted to multiple vehicle models, reducing the cost investment in developing different electric drive assemblies for different vehicle models; on the other hand, the assembly method is simple and clear, which is conducive to improving production efficiency and reducing production costs, thus enhancing the vehicle manufacturer's ability in cost control. Brief Description of the Drawings

[0023] Figure 1 An exploded view of the electric drive assembly with an input shaft having a limit axial dimension designed by the present invention;

[0024] Figure 2 An axial sectional view of the electric drive assembly with an input shaft having a limit axial dimension designed by the present invention;

[0025] Figure 3 A top view of the three-phase line connection structure of the electric drive assembly with an input shaft having a limit axial dimension designed by the present invention;

[0026] Among them, 1 - reducer assembly, 2 - motor assembly, 3 - input shaft assembly, 4 - resolver, 5 - resolver pressure plate, 6 - rotor assembly, 7 - stator assembly, 8 - inner hole, 9 - first bearing, 10 - second bearing, 11 - third bearing, 12 - reducer housing, 13 - motor housing, 14 - first bearing mounting groove, 15 - second bearing mounting groove, 16 - third bearing mounting groove, 17 - first bearing pressure plate, 18 - bearing inner ring positioning bolt, 19 - wave washer, 20 - rear end cover, 21 - third bearing pressure plate, 22 - pressure plate bolt, 23 - stator three-phase line, 24 - three-phase adapter, 25 - controller three-phase copper busbar, 26 - junction box cover plate. Detailed Embodiments

[0027] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments.

[0028] As Figure 1 -3 shows, in some embodiments, the electric drive assembly with an input shaft having a limit axial dimension designed by the present invention includes a reducer assembly 1 and a motor assembly 2. The reducer assembly 1 includes a reducer housing 12 and an input shaft assembly 3 disposed within the reducer housing 12. The motor assembly 2 includes a motor housing 13, a rear end cover 21, a rotor assembly 6 and a stator assembly 7 disposed within the motor housing 13. Among them, the stator assembly 7 and the motor housing 13 can be designed as an integral structure. The input shaft assembly 3 and the rotor assembly 6 rotate synchronously.

[0029] To achieve the design of the limit axial dimension of the electric drive assembly, the present invention provides the following specific embodiments based on the structure of the electric drive assembly in the above-mentioned certain embodiments:

[0030] Example 1

[0031] One end of the rotor assembly 6 is axially provided with an inner hole 8 along its axis, and one end of the input shaft assembly 3 is coaxially inserted and connected into the inner hole 8; the other end of the input shaft assembly 3 is coaxially connected with a first bearing 9, and a second bearing 10 is coaxially connected on the connecting section of the rotor assembly 6 and the input shaft assembly 3, and the other end of the input shaft assembly 3 is coaxially connected with a third bearing 11; the first bearing 9 is axially positioned and installed inside the reducer assembly 1, and the second bearing 10 and the third bearing 11 are both axially positioned and installed inside the motor assembly 2. Through the innovative design of three-bearing support + inner-hole coaxial connection + stator housing integration, on the premise of maintaining high reliability, the ultimate reduction of the axial dimension of the electric drive assembly is achieved, providing key technical support for the platform development of new energy vehicles.

[0032] Example 2

[0033] On the basis of the above embodiment, a connection structure between the inner hole and the input shaft assembly 3 is provided: the inner hole 8 includes a spline groove and an inner hole journal, and the input shaft assembly 3 includes a spline and an input shaft journal. The inner hole 8 and the input shaft assembly 3 are connected through the spline and the spline groove to achieve synchronous rotation, and the axial installation and positioning are achieved through the journal. This connection structure effectively utilizes the internal space of the rotor assembly 6 and the input shaft assembly 3, avoiding the use of additional connection components (such as couplings, etc.), thereby further reducing the axial dimension of the electric drive assembly, meeting the requirements of realizing the design of the ultimate axial dimension. Due to the improvement of the strength and stability of the connection structure, the energy loss during the transmission process is reduced, thereby improving the transmission efficiency of the electric drive assembly. At the same time, the precise axial positioning and the reduced axial movement also help to reduce vibration and noise, improving the performance and comfort of the entire system.

[0034] Example 3

[0035] Based on the above-mentioned First Embodiment or Second Embodiment, a specific embodiment of the three-bearing support structure of the electric drive assembly is provided: A first bearing mounting groove 14 for mounting the first bearing 9 is provided inside the reducer housing 12; a second bearing mounting groove 15 for mounting the second bearing 10 is provided inside the motor housing 13, and a third bearing mounting groove 16 for mounting the third bearing 11 is provided on the rear end cover 21; the first bearing 9 is axially positioned and mounted in the first bearing mounting groove 14 through the first bearing axial limiting structure; the second bearing 10 is axially positioned and mounted in the second bearing mounting groove 15 through the first bearing axial limiting structure; the third bearing 11 is axially positioned and mounted in the third bearing mounting groove 16 through the third bearing axial limiting structure. The first bearing mounting groove 14 is located inside the reducer housing 12, precisely manufactured according to the specifications of the first bearing 9, with high-precision inner wall to ensure stable installation and rotational accuracy. The second bearing mounting groove 15 is inside the motor housing 13, adapted to the second bearing 10, taking into account the spatial layout with other components to achieve a compact design. The third bearing mounting groove 16 is provided inside the rear end cover 21, specifically designed for the third bearing 11 to meet the installation accuracy requirements.

[0036] Fourth Embodiment

[0037] Based on the above-mentioned Third Embodiment, a specific embodiment of the first bearing axial limiting structure is provided: The first bearing axial limiting structure includes a first bearing pressure plate 17 fixed inside the reducer housing 1 and used to limit the axial movement of the outer ring end face of the first bearing 9 on the side close to the rotor assembly 6; the inner surface of the reducer housing used to limit the axial movement of the outer ring end face of the first bearing 9 on the side away from the rotor assembly 6; and a bearing inner ring positioning bolt 18 coaxially fixed inside the other end of the input shaft assembly 3 and used to limit the axial movement of the inner ring end face of the first bearing 9 on the side away from the rotor assembly 6.

[0038] Fifth Embodiment

[0039] Based on the above-mentioned Third Embodiment, a specific embodiment of the second bearing axial limiting structure is provided: The second bearing axial limiting structure includes the inner surface of the motor housing and the rotor assembly shoulder respectively used to limit the axial two side end faces of the second bearing 10, and a wave washer 19 coaxially mounted on the rotor assembly 6 is further provided between the inner surface of the motor housing and the second bearing 10. In addition to the inner surface of the motor housing 13 and the shoulder of the rotor assembly 6 respectively limiting the two side end faces of the second bearing 10, a bearing pressure plate can also be provided to limit the axial position of the second bearing 10, and through the structure of the wave washer 19, the axial clearance is compensated.

[0040] Sixth Embodiment

[0041] Based on the above-mentioned Embodiment 3, a specific embodiment of the axial limiting structure of the third bearing is provided: The axial limiting structure of the third bearing 11 includes an inner surface of the rear end cover fixed to the motor housing 13 for restricting the axial movement of the outer end surface of the third bearing 11 on the side away from the input shaft assembly 3, and a third bearing pressure plate 21 fixed to the rear end cover 20 for restricting the axial movement of the outer end surface of the third bearing 11 on the side close to the input shaft assembly 3.

[0042] The support structure of the above three bearings ensures the coaxiality of the input shaft assembly 3 and the rotor assembly 6, reduces energy loss, and ensures stable and accurate power transmission. It improves the versatility and mountability of the electric drive assembly.

[0043] Embodiment 7

[0044] Based on the above-mentioned Embodiment 1 or Embodiment 2 or Embodiment 3 or Embodiment 4 or Embodiment 5 or Embodiment 6, a layout structure of the resolver 4 and the resolver pressure plate 5 is provided: A resolver 4 and a resolver pressure plate 5 are coaxially connected to the connection section between the rotor assembly 6 and the input shaft assembly 3, and the resolver 4 and the resolver pressure plate 5 are axially positioned and installed inside the reducer housing 12. The resolver 4 and the resolver pressure plate 5 are located between the second bearing 10 and the gear of the input shaft assembly 3. Specifically, one end of the rotor assembly 6 is inserted into the reducer housing 12, one end of the input shaft assembly 3 is inserted into the inner hole 8 and is located inside the motor housing 13. A shaft neck for installing the resolver 4 and the resolver pressure plate 5 is provided on the shaft section of the rotor assembly 6 located inside the reducer housing 12. The resolver 4 and the resolver pressure plate 5 are coaxially arranged on the shaft neck of the rotor assembly 6 located inside the reducer housing 12. An installation surface (the resolver pressure plate 5 and the inner surface of the reducer housing 12 can be fixedly connected by bolts) for axially pressing and cooperating with the end surface of the resolver pressure plate 5 on the side away from the resolver 4 is provided inside the reducer housing 12. The end surface of the resolver pressure plate 5 close to the resolver 4 axially presses the resolver 4 against the inner surface of the motor assembly 2. The resolver 4 and the resolver pressure plate 5 are accurately axially positioned and installed inside the reducer housing 12, are stable and reliable during operation, and reduce measurement errors and signal interference caused by displacement. Cleverly utilize the space between the second bearing 10 and the gear of the input shaft assembly 3, without occupying additional axial dimensions, which conforms to the design concept of the ultimate axial dimension of the electric drive assembly and improves the overall compactness. This position is close to the connection between the input shaft assembly 3 and the rotor assembly 6, which is beneficial for the resolver 4 to accurately measure the rotation angle of the rotor assembly 6, and the resolver pressure plate 5 to efficiently transmit signals, ensuring accurate motor control and improving the performance of the electric drive assembly. It optimizes the internal layout of the electric drive assembly, improves the overall performance, and lays a foundation for improving the versatility and mountability.

[0045] Embodiment 8

[0046] Based on the above-mentioned Embodiment 1, Embodiment 2, Embodiment 3, Embodiment 4, Embodiment 5, Embodiment 6, or Embodiment 7, a layout structure of the stator three-phase lines 23 is provided: The stator three-phase lines 23 are located on one side of the reducer housing 12. The positioning three-phase lines 23 are connected to the controller three-phase copper bars 25 through the three-phase adapter seat 24. The controller, the three-phase adapter seat 24, and the controller three-phase copper bars 25 are all installed on the reducer housing 12. After being connected to the controller three-phase copper bars 25, the stator three-phase lines 23 are hidden by the junction box cover plate 26. Concentrating the installation of relevant electrical connection components on the reducer housing 12 makes rational use of space, reduces the overall occupied space of the electric drive assembly, meets the requirements of compact design, and is conducive to adapting to various vehicle models. The centralized installation facilitates the inspection, maintenance, and replacement of the line connections and the controller, improves the maintenance efficiency, and reduces the maintenance cost. The junction box cover plate 26 hides the connection part, playing a protective role to prevent the intrusion of dust, water vapor, etc., which may affect the electrical performance; at the same time, it makes the appearance of the electric drive assembly more regular. The three-phase adapter seat 24 ensures the stable connection between the stator three-phase lines 23 and the controller three-phase copper bars 25, reduces signal transmission loss, ensures efficient power transmission, and improves the performance of the electric drive assembly. It improves the functions of the electric drive assembly, enhances its versatility and reliability, and provides a more advantageous electric drive system solution for vehicle manufacturers.

[0047] Embodiment 9

[0048] Based on the above-mentioned Embodiment 1, Embodiment 2, Embodiment 3, Embodiment 4, Embodiment 5, Embodiment 6, Embodiment 7, or Embodiment 8, an assembly method for an electric drive assembly is provided, including the following steps:

[0049] Step 1: Component preparation: Prepare components such as the reducer housing 12, the input shaft assembly 3, the resolver 4, the resolver pressure plate 5, the motor housing 13, the rotor assembly 6, the stator assembly 7 (if the stator assembly 7 and the motor housing 13 are of an integrated structure, there is no need to prepare separately), the first bearing 9, the second bearing 10, the third bearing 11, the first bearing pressure plate 17, the bearing inner ring positioning bolt 18, the wave washer 19, the rear end cover 20, the third bearing pressure plate 21, the pressure plate bolt 22, and the three-phase adapter seat 24.

[0050] Step 2: Stator assembly installation: Stably install the stator assembly 7 inside the motor housing 13, and pay special attention to ensuring that the stator three-phase lines 23 face the side of the reducer housing 12 to prepare for subsequent line connections.

[0051] Step 3: Motor assembly: At the left end of the rotor assembly 6 (taking Figure 2Install the second bearing 10 (taking the left - right direction shown as the standard), install the third bearing pressing plate 21 and the third bearing 11 in sequence at the right end of the rotor assembly 6, then install the rear end cover 20, and use the pressing plate bolts 22 to firmly tighten the third bearing pressing plate 21 on the rear end cover 20. Subsequently, install the overall structure of the rotor assembly 6 and the rear end cover 21 into the motor housing 13. Thus, the assembly of the rotor assembly 6 and the stator assembly 7 is completed, forming the motor assembly 2.

[0052] Step 4: Installation of the resolver and related components: Install the resolver 4 and the resolver pressing plate 5 at the left end of the rotor assembly 6 to ensure accurate installation positions and guarantee its normal operation.

[0053] Step 5: Installation of the input shaft assembly into the reducer housing: Install the first bearing 9 at the left end of the input shaft assembly 3 and fix the bearing inner ring positioning bolt 18. Install the input shaft assembly 3 with the installed bearing into the reducer housing 12, then install the first bearing pressing plate 17 and tighten it with the pressing plate bolts 22 to complete the installation of the input shaft assembly 3 in the reducer housing 12.

[0054] Step 6: Connection between the input shaft and the rotor shaft: Insert the right end of the input shaft assembly 3 into the inner hole 8 of the rotor assembly 6 to realize the connection between the input shaft assembly 3 and the rotor assembly 6, enabling them to rotate synchronously. The two are driven through splines to ensure effective power transmission.

[0055] Step 7: Circuit connection: Connect the stator three - phase wires 23 to the three - phase adapter 24 to complete the connection of the key circuits inside the electric drive assembly and ensure a smooth power transmission path.

[0056] The above assembly method ensures the precise positioning of each component through an orderly component preparation and installation process, guaranteeing the overall structure of the electric drive assembly is compact and stable. Each bearing and related components are assembled step by step to improve the shafting stability, ensure the synchronous rotation of the input shaft and the rotor shaft, and effective power transmission; the circuit connection steps are clear, ensuring a smooth power transmission path and improving the assembly quality and performance of the electric drive assembly.

[0057] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is 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 construed as a limitation to the present invention. When using the terms "comprising", "having" and "including" described in this specification, there may also be another part or other parts, and the terms used may generally be singular but may also represent plural forms. It should be noted that although the terms "first", "second", "top", "bottom", "one side", "the other side", "one end", "the other end", etc. may appear and be used in this specification to describe various different components, these components and parts should not be limited by these terms. These terms are only used to distinguish one component and part from another component and part. For example, without departing from the scope of this specification, the first component may be referred to as the second component, and similarly, the second component may be referred to as the first component. In certain cases, the components at the top and bottom may also be swapped or converted with each other; the components at one end and the other end may have the same or different performances from each other.

[0058] Finally, it should be noted that the above embodiments are only relatively representative examples of the present invention. Obviously, the present invention is not limited to the above embodiments and there can be many variations. Any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention should be considered to fall within the protection scope of the present invention.

Claims

1. An electric drive assembly with an input shaft of a maximum axial size, comprising a reducer assembly (1) and a motor assembly (2); the reducer assembly (1) comprises an input shaft assembly (3), a rotary transformer (4) and a rotary transformer pressure plate (5); the motor assembly (2) comprises a rotor assembly (6) and a stator assembly (7); the input shaft assembly (3) and the rotor assembly (6) rotate synchronously; characterized in that: One end of the rotor assembly (6) is provided with an inner hole (8) along its axial direction, and one end of the input shaft assembly (3) is coaxially inserted into and connected to the inner hole (8); The other end of the input shaft assembly (3) is coaxially connected to a first bearing (9), the connecting section between the rotor assembly (6) and the input shaft assembly (3) is coaxially connected to a second bearing (10), and the other end of the input shaft assembly (3) is coaxially connected to a third bearing (11); The rotary transformer (4) and the rotary transformer pressure plate (5) are coaxially connected to the connection section between the rotor assembly (6) and the input shaft assembly (3); The three-phase outgoing wires of the stator assembly (7) are located on one side of the reducer assembly (1).

2. The electric drive assembly with a maximum axial dimension input shaft according to claim 1, characterized in that: The first bearing (9) is axially positioned and installed inside the reducer assembly (1), and the second bearing (10) and the third bearing (11) are both axially positioned and installed inside the motor assembly (2).

3. The electric drive assembly with a maximum axial dimension input shaft according to claim 1, characterized in that: The rotary transformer (4) and the rotary transformer pressure plate (5) are axially positioned and installed inside the reducer assembly (1); one end of the rotor assembly (6) is inserted into the reducer assembly (1); one end of the input shaft assembly (3) is inserted into the inner hole (8) and is located in the motor assembly (2); a shaft section of the rotor assembly (6) located in the reducer assembly (1) is provided with a journal for installing the rotary transformer (4) and the rotary transformer pressure plate (5); the rotary transformer (4) and the rotary transformer pressure plate (5) are coaxially arranged on the journal of the rotor assembly (6) located in the reducer assembly (1); a mounting profile is provided in the reducer assembly (1) for axially pressing and fitting with the end face of the rotary transformer pressure plate (5) away from the rotary transformer (4); the end face of the rotary transformer pressure plate (5) close to the rotary transformer (4) axially presses the rotary transformer (4) against the internal profile of the motor assembly (2).

4. The electric drive assembly with a maximum axial dimension input shaft according to claim 1, characterized in that: The inner hole (8) comprises a spline groove matched with the input shaft assembly (3), and the input shaft assembly (3) comprises a spline matched with the spline groove.

5. The electric drive assembly with a maximum axial dimension input shaft according to claim 2, characterized in that: The reducer assembly (1) comprises a reducer housing (12), wherein a first bearing mounting groove (14) for mounting the first bearing (9) is provided inside the reducer housing (12); the motor assembly (2) comprises a motor housing (13) and a rear end cover (20), wherein a second bearing mounting groove (15) for mounting the second bearing (10) is provided inside the motor housing (13), and a third bearing mounting groove (16) for mounting the third bearing (11) is provided on the rear end cover (20); The first bearing (9) is axially positioned and installed in the first bearing installation groove (14) through a first bearing axial limiting structure; The second bearing (10) is axially positioned and installed in the second bearing installation groove (15) through a second bearing axial limiting structure; The third bearing (11) is axially positioned and installed in the third bearing installation groove (16) through a third bearing axial limiting structure.

6. The electric drive assembly with a maximum axial dimension input shaft according to claim 5, characterized in that: The first bearing axial limiting structure comprises a first bearing pressure plate (17) fixed inside the reducer housing (1) and used to limit the axial movement of the outer ring end face of the first bearing (9) close to the rotor assembly (6); an internal profile of the reducer housing and used to limit the axial movement of the outer ring end face of the first bearing (9) away from the rotor assembly (6); and a bearing inner ring positioning bolt (18) coaxially fixed inside the other end of the input shaft assembly (3) and used to limit the axial movement of the inner ring end face of the first bearing (9) away from the rotor assembly (6).

7. The electric drive assembly with a maximum axial dimension input shaft according to claim 5, characterized in that: The second bearing axial limiting structure comprises an internal profile of the motor housing and a rotor assembly shoulder for limiting the axial end surfaces of the second bearing (10) respectively, and a corrugated spring washer (19) coaxially mounted on the rotor assembly (6) is also provided between the internal profile of the motor housing and the second bearing (10).

8. The electric drive assembly with a maximum axial dimension input shaft according to claim 5, characterized in that: The axial limiting structure of the third bearing (11) comprises an inner profile of a rear end cover for limiting the axial movement of the outer end face of the third bearing (11) away from the input shaft assembly (3) and a third bearing pressure plate (21) fixed to the rear end cover (20) for limiting the axial movement of the outer end face of the third bearing (11) close to the input shaft assembly (3).

9. A method for assembling an electric drive assembly having an input shaft with a limited axial dimension according to any one of claims 1 to 8, characterized in that: It includes: Insert one end of the input shaft assembly (3) coaxially into the inner hole (8) of the rotor assembly (6), so that the input shaft assembly (3) and the rotor assembly (6) are coaxially connected and can rotate synchronously; A first bearing (9) is coaxially mounted on the other end of the input shaft assembly (3), a second bearing (10) is coaxially mounted on the connecting section between the rotor assembly (6) and the input shaft assembly (3), and a third bearing (11) is coaxially mounted on the other end of the input shaft assembly (3); A rotary transformer (4) and a rotary transformer pressure plate (5) are coaxially mounted on a connection section between a rotor assembly (6) and an input shaft assembly (3); The three-phase outgoing wires of the stator assembly (7) are arranged on one side of the reducer assembly (1).

10. The method for assembling an electric drive assembly having an input shaft with a limit axial dimension according to claim 9, characterized in that: It also includes connecting the three-phase output lines of the positioning assembly (7) with the three-phase copper busbars of the controller, and installing the controller on the reducer assembly (1).

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