All-in-one electric driving system and maneuvering equipment

Abstract

The invention provides an all-in-one electric driving system which comprises a motor assembly, the motor assembly comprises a shell assembly and an electric control power board, a containing cavity is formed in one side of the shell assembly, and the containing cavity is configured to be used for containing the electric control power board; the PTC heating assembly comprises a PTC heater and a connector assembly, the PTC heater is connected to one side of the shell assembly, and the connector assembly is connected with the PTC heater and the electric control power board. The PTC heater and the electric control power board are both arranged in the shell assembly, the PTC heater is connected with the electric control power board through the connector assembly, wire harnesses and wire harness connecting pieces are saved, structural arrangement can be optimized, the outer envelope of the electric drive system can be effectively compressed, and meanwhile the number and cost of two pieces are reduced.

Description

Technical Field

[0001] The present application relates to the technical field of electric drive devices, and more particularly, to an integrated electric drive system and a motorized device. Background Art

[0002] With the increasing depletion of fossil energy and the increasing environmental pollution, electric vehicles are becoming more and more popular among users.

[0003] The electric drive system is the core component of an electric vehicle. The electric drive system is an integrated whole formed by combining multiple components, which includes a drive motor, a control assembly, a transmission, an air compressor, a water pump, a high-voltage distribution box, a vehicle controller, an on-board charger, and a DC converter, etc.

[0004] Currently, there are various integration methods, with a large number of parts and a relatively large volume, which require a high layout space. Therefore, how to optimize the structural layout is particularly important. Summary of the Invention

[0005] The purpose of the present application is to provide an integrated electric drive system and a motorized device, which can effectively compress the outer envelope of the electric drive system, reduce the number of parts and costs by optimizing the structural layout.

[0006] In a first aspect, an embodiment of the present application provides an integrated electric drive system, including: a motor assembly, including a housing assembly and an electronic control power board, a receiving cavity is configured on one side of the housing assembly, and the receiving cavity is configured to receive the electronic control power board; a PTC heating assembly, including a PTC heater and a connector, the PTC heater is connected to one side of the housing assembly, and the connector is respectively connected to the PTC heater and the electronic control power board.

[0007] In the above implementation process, both the PTC heater and the electronic control power board are arranged on the housing assembly, and the PTC heater is connected to the electronic control power board through a connector, saving the wiring harness and wiring harness connectors, optimizing the structural layout, effectively compressing the outer envelope of the electric drive system, and reducing the number of parts and costs at the same time.

[0008] In some embodiments, the motor assembly further includes an electronic control cover plate, and the electronic control cover plate is connected to the housing assembly for covering the electronic control power board.

[0009] In the above implementation process, the electronic control power board is arranged on the housing assembly and covered by the electronic control cover plate, which can not only ensure the safety of the electronic control power board, but also protect it, improving the service life.

[0010] In some embodiments, the electric control cover is provided with an inspection window and an inspection plate, the inspection window is used to reveal the connection position between the connector and the electric control power board, and the inspection plate is connected to the inspection window.

[0011] In the above implementation process, the connection position between the connector and the electric control power board is set at the maintenance window, and the maintenance window is changed from a maintenance plate to a cover, which can be used for rapid disassembly and maintenance of the PTC heater, thereby improving efficiency.

[0012] In some embodiments, the motor assembly further includes a half-axle bracket, a half-axle hole is configured on one side of the housing assembly, and the half-axle bracket is connected to the half-axle hole.

[0013] In the above implementation process, a half-axle bracket is connected to one side of the housing assembly, which can improve the coaxiality and reduce the eccentricity of the half-axle assembly. At the same time, it can also improve the stiffness of the motor assembly, effectively suppress deformation, optimize the assembly NVH effect, and improve the motor assembly mode.

[0014] In some embodiments, an output hole and a first positioning hole are disposed on one side of the housing component, and the output hole and the first positioning hole are located on the same central axis, which can simplify the assembly process and improve the assembly accuracy of parts.

[0015] In some embodiments, the housing assembly is further provided with an input hole, and the input hole and the output hole are located on the same central axis, which can simplify the assembly process and improve the assembly accuracy of parts.

[0016] In some embodiments, the housing assembly is further provided with a second positioning hole, and the second positioning hole is spaced apart from the first positioning hole. The assembly of the reducer housing can be achieved through the cooperation of the first positioning hole and the second positioning hole.

[0017] In some embodiments, the motor assembly further includes a reducer housing, and the reducer housing is respectively connected to the first positioning hole and the second positioning hole.

[0018] In some embodiments, the motor assembly further includes a motor end cover, which is connected to a side of the housing assembly close to the half-axle bracket.

[0019] In a second aspect, the present application also provides a motorized device comprising an all-in-one electric drive system as described in any one of the above items.

[0020] Since the motorized equipment provided in the second aspect includes an all-in-one electric drive system, the motorized equipment has all the technical effects of the all-in-one electric drive system, which will not be elaborated here.

[0021] Other features and advantages of the present application will be described in the following specification, or some features and advantages can be inferred from the specification or determined without doubt, or can be learned by implementing the above technologies of the present application.

[0022] To make the above objects, features and advantages of the present application more obvious and understandable, the following specific preferred embodiments are given, and in conjunction with the accompanying drawings, the detailed description is as follows. Description of the Drawings

[0023] To more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings required to be used in the embodiments of the present application. It should be understood that the following drawings only show some embodiments of the present application, and thus should not be regarded as limiting the scope. For those of ordinary skill in the art, without creative efforts, other relevant drawings can also be obtained based on these drawings.

[0024] Figure 1 Structural schematic diagram of the multi-in-one electric drive system provided by the embodiment of the present application;

[0025] Figure 2 Top view of the multi-in-one electric drive system provided by the embodiment of the present application;

[0026] Figure 3 Structural schematic diagram of the half shaft bracket of the multi-in-one electric drive system provided by the embodiment of the present application;

[0027] Figure 4 Structural schematic diagram of the housing assembly of the multi-in-one electric drive system provided by the embodiment of the present application.

[0028] Reference Signs

[0029] 10, motor assembly; 101, electric control housing; 102, motor housing; 1021, output hole; 1022, input hole; 1023, first positioning hole; 1024, second positioning hole; 103, motor end cover; 104, electric control cover plate; 105, inspection plate; 106, electric control power board; 107, half shaft bracket; 108, reducer housing; 20, PTC heating assembly; 201, PTC heater; 202, connector; 30, oil cooler. Detailed Embodiments

[0030] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Usually, the components of the embodiments of the present application described and shown in the accompanying drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application to be protected, but only represents the selected embodiments of the present application. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without creative efforts belong to the scope of protection of the present application.

[0031] In the present application, the orientation or positional relationship indicated by terms such as "upper", "lower", "left", "right", "front", "rear", "top", "bottom", "inner", "outer", "middle", "vertical", "horizontal", "lateral", "longitudinal", etc. is based on the orientation or positional relationship shown in the accompanying drawings. These terms are mainly used to better describe the present application and its embodiments, and are not used to limit that the indicated device, element or component must have a specific orientation, or be constructed and operated in a specific orientation.

[0032] Moreover, in addition to being used to represent the orientation or positional relationship, some of the above terms may also be used to represent other meanings. For example, the term "upper" may also be used to represent a certain attachment relationship or connection relationship in some cases. For those of ordinary skill in the art, the specific meanings of these terms in the present application can be understood according to specific circumstances.

[0033] In addition, the terms "mounted", "arranged", "provided with", "connected", "linked" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection, or a point connection; it can be directly connected, or indirectly connected through an intermediate medium, or there is an internal connection between two devices, elements or components. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0034] In addition, the terms "first", "second", etc. are mainly used to distinguish different devices, elements or components (the specific types and structures may be the same or different), and are not used to indicate or imply the relative importance and quantity of the indicated devices, elements or components. Unless otherwise specified, the meaning of "a plurality" is two or more.

[0035] Embodiment

[0036] The composition of the oil-cooled multi-in-one electric drive assembly for new energy vehicles generally includes a drive motor, a reducer, a motor controller, a PTC (heater), a PDU (high-voltage system distribution unit, responsible for power distribution and management in the high-voltage system of new energy vehicles), a DCDC (DC converter, mainly responsible for converting the DC power of the battery pack into the DC power required by each system of the vehicle, such as the drive motor, power steering system, and air conditioning equipment), and an OBC (on-board charger, a power electronic device for charging the automotive power battery, which can dynamically adjust the charging current and voltage parameters according to the data provided by the vehicle battery management system BMS, execute corresponding charging instructions, and complete the charging process). There are two ways of physical integration and mechanical integration. It has a large number of parts, a relatively large volume, and high requirements for the layout space.

[0037] During the design process, the inventor found that the PTC is generally externally mounted on the housing by bolts and connected to the domain controller through an external corrugated wire harness. Generally, two sets of connectors, wire harness fixing clips, and housing threaded holes are required.

[0038] In view of this, as Figure 1 - Figure 2 shown, in a first aspect, an embodiment of the present application provides a multi-in-one electric drive system, including: a motor assembly 10, including a housing assembly and an electronic control power board 106. One side of the housing assembly is configured with a receiving cavity, and the receiving cavity is configured to receive the electronic control power board 106; a PTC heating assembly 20, including a PTC heater 201 and a connector 202. The PTC heater 201 is connected to one side of the housing assembly, and the connector 202 is respectively connected to the PTC heater 201 and the electronic control power board 106.

[0039] Exemplarily, when the temperature of the PTC heater 201 is lower than its Curie temperature, its resistance value increases with the increase of temperature; when the temperature is higher than the Curie temperature, its resistance value decreases with the increase of temperature. The main applications of the PTC heater 201 in new energy vehicles include battery heating, air conditioning system heating, defrosting, and cooling.

[0040] Among them, the housing assembly includes a motor housing 102 and an electronic control housing 101. The electronic control housing 101 is disposed above the motor housing 102. The electronic control housing 101 is configured with a receiving cavity for receiving the electronic control power board 106. The PTC heater 201 is arranged on the electronic control housing 101 and fixed to the electronic control housing 101 by four bolts. The PTC power and the DCU power part are integrated in one board design. The positive and negative electrodes of the PTC heater 201 are sealed with the electronic control housing 101 through a set of connectors 202 and fixed to the electronic control power board 106 by two bolts;

[0041] It should be noted that the PTC heater 201 can be set at the upper left side of the shell assembly, or it can be set at other positions of the shell assembly according to actual conditions, for example, the PTC heater 201 and the oil cooler 30 are located on the same side of the shell assembly, which is not specifically limited here.

[0042] In the above implementation process, the PTC heater 201 and the electric control power board 106 are both arranged in the shell assembly, and the PTC heater 201 is connected to the electric control power board 106 through the connector 202, which saves the wiring harness and wiring harness connectors, can optimize the structural layout, effectively compress the outer envelope of the electric drive system, and reduce the number and cost of the two parts.

[0043] like Figure 1 and Figure 2 As shown, the motor assembly 10 further includes an electric control cover plate 104 , which is connected to the housing assembly and is used to cover the electric control power board 106 .

[0044] Exemplarily, the electric control cover plate 104 is connected to the electric control housing 101 and is located on a side of the electric control housing 101 away from the motor housing 102 . The electric control cover plate 104 and the electric control housing 101 can be fastened with screws to cover the accommodating cavity.

[0045] In the above implementation process, the electric control power board 106 is arranged in the housing assembly and covered by the electric control cover plate 104, which not only ensures the safety of the electric control power board 106, but also protects it and increases its service life.

[0046] In some embodiments, the electric control cover 104 is provided with an inspection window and an inspection plate 105 , wherein the inspection window is used to reveal the connection position between the connector 202 and the electric control power board 106 , and the inspection plate 105 is connected to the inspection window.

[0047] In the above implementation process, the connection position between the connector 202 and the electric control power board 106 is set at the maintenance window, and the maintenance window is covered by the maintenance plate 105, which can be used for rapid disassembly and maintenance of the PTC heater 201, thereby improving efficiency.

[0048] During the design process, the inventor discovered that for an electric drive with a three-section half-axle arrangement, the motor-end half-axle bracket 107 is generally located on the motor end cover 103, while the differential bearing hole is located on the motor housing 102, resulting in relatively poor coaxiality between the bearing hole of the half-axle bracket 107 and the differential bearing. The motor end cover 103 is connected to the domain control cavity by bolts, and the domain control cavity is integrated with the motor housing 102 in a cantilever state, has relatively poor stiffness, is easily deformed during casting, and has a low modal state, which affects the NVH performance of the entire machine.

[0049] At the same time, in general, the half - shaft bracket 107 is fixed on the motor end - cover 103, and the coaxiality of the hole of the half - shaft bracket 107 and the differential bearing hole is ensured by two positioning pins of the motor housing 102 and the motor end - cover 103. Since it is a cross - housing positioning, the accuracy is relatively poor. When machining the motor housing 102, the hole of the half - shaft bracket 107 and the differential bearing hole can be machined in one pass by a forming tool, or machined by different tools in the same clamping process, which can improve the coaxiality of the two and reduce the eccentricity of the half - shaft assembly.

[0050] In view of this, as Figure 3 shown, the motor assembly 10 further includes a half - shaft bracket 107. One side of the housing assembly is provided with a half - shaft hole, and the half - shaft bracket 107 is connected to the half - shaft hole.

[0051] Exemplarily, the half - shaft bracket 107 is used for the penetration of a three - section half - shaft. The half - shaft bracket 107 is arranged on the motor housing 102, at the included angle between the bottom of the electric - control cavity and the stop of the motor cavity. Wherein, the hole of the half - shaft bracket 107 of the motor housing 102 and the differential bearing hole (i.e., the output hole 1021) are integrally cast and machined. When the motor housing 102 is cast, the half - shaft bracket 107 can effectively inhibit the deformation of the electric - control cavity (i.e., the accommodation cavity). If this part of the support is missing, the overall deformation of the area of the electric - control cavity far from the motor housing 102 is relatively large.

[0052] In the above implementation process, one side of the housing assembly is connected with a half - shaft bracket 107, which can improve the coaxiality, reduce the eccentricity of the half - shaft assembly, and at the same time can also improve the stiffness of the motor assembly 10, effectively inhibit deformation, optimize the NVH effect of the assembly, and improve the mode of the motor assembly 10.

[0053] The inventor found during the design process that, generally, the horizontal and vertical coordinate axes of the drawings of the assembly or parts are the X - axis and Y - axis respectively, the center O of the coordinate system is the axis center of the input shaft, the X - axis corresponds to the horizontal attitude of the electric drive, the axis centers of the differential output shaft and the positioning pins are (x1, y1) and (x2, y2) respectively, and the corresponding actual coordinate deviations are (△x1, △y1) and (△x2, △y2), and the actual position degrees are sqrt(△x1^2 + △y1^2) and sqrt(△x2^2 + △y2^2). The layout characteristics of this electric drive assembly are as follows: the axis center of the differential output shaft and the center of the mating - box positioning pin B are both on the X - axis. Under this layout,

[0054] The coordinates of the center of the subtraction output shaft and the positioning pin are (x1, 0) and (x2, 0) respectively, and the corresponding actual coordinate deviations are (△x1, △0) and (△x2, 0), and the actual position degrees are ∣△x1∣ and ∣△x2∣. Obviously, ∣△x1∣ ≤ sqrt(△x1^2 + △y1^2); ∣△x2∣ ≤ sqrt(△x2^2 + △y2^2). The new layout structure can improve the position degree of the bearing hole.

[0055] As Figure 4 shown, one side of the housing assembly is configured with an output hole 1021 and a first positioning hole 1023. The output hole 1021 and the first positioning hole 1023 are located on the same central axis. It can simplify the assembly process and improve the assembly accuracy of parts at the same time.

[0056] Exemplarily, the centers of the output hole 1021 and the first positioning hole 1023 are on the same central axis, for example, both are on the same X-axis abscissa or the same Y-axis ordinate. The first positioning hole 1023 is used to assemble the housing positioning pin. The whole design optimizes the housing positioning pin and can improve the assembly accuracy of the reducer.

[0057] Please refer to Figure 4 again. The housing assembly is further configured with an input hole 1022. The input hole 1022 and the output hole 1021 are on the same central axis, that is, the input hole 1022, the output hole 1021, and the first positioning hole 1023 are all on the same X-axis abscissa. It can simplify the assembly process and improve the assembly accuracy of parts at the same time.

[0058] In some embodiments, the housing assembly is further configured with a second positioning hole 1024. The second positioning hole 1024 and the first positioning hole 1023 are spaced apart. The second positioning hole 1024 is used to assemble the housing positioning pin. Through the cooperation of the first positioning hole 1023 and the second positioning hole 1024, the assembly of the reducer housing 108 can be realized.

[0059] In some embodiments, the motor assembly 10 further includes a reducer housing 108. The reducer housing 108 is respectively connected to the first positioning hole 1023 and the second positioning hole 1024.

[0060] In some embodiments, the motor assembly 10 further includes a motor end cover 103. The motor end cover 103 is connected to one side of the housing assembly close to the half shaft bracket 107.

[0061] In a second aspect, the present application further provides a mobile device, including the multi-in-one electric drive system as described above.

[0062] Exemplarily, the mobile device includes a vehicle, which may be a new energy vehicle, including but not limited to pure electric vehicles, hybrid electric vehicles, hydrogen energy vehicles, etc. The embodiments of the present application do not make specific limitations thereto.

[0063] Since the mobile device provided in the second aspect includes an integrated electric drive system, the mobile device has all the technical effects of the integrated electric drive system, which will not be elaborated herein.

[0064] In all embodiments of the present application, "large" and "small" are relative, "many" and "few" are relative, and "upper" and "lower" are relative. For the expression methods of such relative terms, the embodiments of the present application will not elaborate further.

[0065] It should be understood that the phrases "in this embodiment", "in the embodiments of the present application", or "as an optional implementation manner" mentioned throughout the specification mean that specific features, structures, or characteristics related to the embodiments are included in at least one embodiment of the present application. Therefore, the phrases "in this embodiment", "in the embodiments of the present application", or "as an optional implementation manner" that appear throughout the specification do not necessarily refer to the same embodiment. In addition, these specific features, structures, or characteristics can be combined in one or more embodiments in any suitable manner. Those skilled in the art should also know that the embodiments described in the specification are all optional embodiments, and the actions and modules involved are not necessarily essential to the present application.

[0066] In various embodiments of the present application, it should be understood that the magnitudes of the sequence numbers of the above processes do not necessarily mean the order of execution. The order of execution of each process should be determined by its function and internal logic, and should not constitute any limitation to the implementation process of the embodiments of the present application.

[0067] The above is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present application, and all of them should be covered by the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. An all-in-one electric drive system, characterized in that, Comprising: A motor assembly, including a housing assembly and an electronic control power board. One side of the housing assembly is configured with a receiving cavity, and the receiving cavity is configured to receive the electronic control power board. A PTC heating assembly, including a PTC heater and a connector. The PTC heater is connected to one side of the housing assembly, and the connector is respectively connected to the PTC heater and the electronic control power board.

2. The all-in-one electric drive system according to claim 1, wherein The motor assembly further includes an electronic control cover plate, and the electronic control cover plate is connected to the housing assembly for covering the electronic control power board.

3. The multi-in-one electric drive system according to claim 2, wherein, The electronic control cover plate is configured with a maintenance window and a maintenance board. The maintenance window is used to expose the connection position between the connector and the electronic control power board, and the maintenance board is connected to the maintenance window.

4. The multi-in-one electric drive system according to claim 1, wherein, The motor assembly further includes a half shaft bracket. One side of the housing assembly is configured with a half shaft hole, and the half shaft bracket is connected to the half shaft hole.

5. The multi-in-one electric drive system according to claim 1 or 4, characterized in that One side of the housing assembly is configured with an output hole and a first positioning hole, and the output hole and the first positioning hole are located on the same central axis.

6. The multi-in-one electric drive system according to claim 5, characterized in that, The housing assembly is further configured with an input hole, and the input hole and the output hole are located on the same central axis.

7. The multi-in-one electric drive system according to claim 5, wherein The housing assembly is further configured with a second positioning hole, and the second positioning hole and the first positioning hole are spaced apart.

8. The multi-in-one electric drive system according to claim 7, wherein, The motor assembly further includes a reducer housing, and the reducer housing is respectively connected to the first positioning hole and the second positioning hole.

9. The multi-in-one electric drive system according to claim 4, wherein The motor assembly further includes a motor end cover, and the motor end cover is connected to one side of the housing assembly close to the half shaft bracket.

10. A mobile device, characterized in that, Including the multi-in-one electric drive system according to any one of claims 1-9.

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