Electric drive system and manufacturing method thereof

Abstract

An electric drive system and a method of manufacturing the same are provided. An electric drive system includes an axle housing, a power electronics unit, and a potting material. The axle housing accommodates the motor and the transmission. The power electronic unit is electrically connected with the motor. The potting material covers the power electronic unit and is bonded to the axle housing. In this way, the electric drive system can have the advantages of compact layout, high reliability, good NVH performance and low production cost.

Description

Technical Field

[0001] The present application relates to the field of electric vehicles, and more particularly to an electric drive system and a manufacturing method thereof. Background Art

[0002] Chinese Patent Application CN114070168A discloses a high-power motor controller and an integrated electric drive system for electric vehicles. The motor controller is mainly fixed on the motor and the reduction gearbox through four feet. Inside the box body of the motor controller, there are a bus bar plate, an integrated control device, and a three-phase output device. However, the box body itself, as well as the fasteners and seals required for the box body, etc., occupy a large space, resulting in a high production cost and being unfavorable for the layout of the electric drive system.

[0003] Chinese Patent Application CN114312265A discloses an integrated electric drive system and an electric vehicle. The controller is installed in the first housing space inside the integrated housing, and the motor and the reducer are respectively installed in the second housing space and the third housing space of the integrated housing. However, the cleanliness requirement of the controller is much higher than that of the motor and the reducer, making the electric drive system need to be assembled in an environment with a relatively high cleanliness. In addition, for the controllers purchased from other manufacturers, the integrated manufacturer has difficulties in the installation, debugging, and repair of the controllers. Summary of the Invention

[0004] In view of the state of the above-mentioned prior art, the present application is made. The purpose of the present application is to provide an electric drive system and a manufacturing method thereof, which can overcome or mitigate at least one of the disadvantages described in the above background art.

[0005] To achieve the above purpose, the present application adopts the following technical solutions.

[0006] The present application provides an electric drive system as follows, including: a bridge housing that houses a motor and a transmission; a power electronics unit that is electrically connected to the motor; and a potting material that coats the power electronics unit and is joined to the bridge housing.

[0007] In an alternative embodiment, the potting material is installed on the bridge housing through fasteners, and / or the potting material is adhered to the bridge housing.

[0008] In another alternative embodiment, the power electronics unit is installed on the bridge housing through fasteners.

[0009] In another alternative embodiment, the bridge housing is provided with a potting groove, and the potting material is configured to be cured in the potting groove.

[0010] In another alternative, the axle housing includes a first housing and a second housing, the first housing accommodating the motor, the second housing accommodating the transmission, and the potting material being joined to the first housing.

[0011] In another alternative, the potting material covers more than 85% of the surface area of the power electronics unit.

[0012] The present application also provides a manufacturing method of an electric drive system as follows, including: covering the power electronics unit with a potting material; and joining the potting material to the axle housing.

[0013] In an alternative, covering the power electronics unit with the potting material includes: positioning the power electronics unit in a mold; pouring the uncured potting material into the mold; curing the uncured potting material; and removing the power electronics unit and the cured potting material from the mold.

[0014] In another alternative, joining the potting material to the axle housing includes: mounting the cured potting material to the axle housing by fasteners.

[0015] In another alternative, covering the power electronics unit with the potting material includes: positioning the power electronics unit in the axle housing; and pouring the uncured potting material into the axle housing, and joining the potting material to the axle housing includes: curing the uncured potting material.

[0016] By adopting the above technical solutions, by providing the potting material, the potting material can replace some parts, so that the electric drive system can have fewer parts and smaller internal clearances. In addition, the power electronics unit can be sealed by the potting material, making the power electronics unit not easily damaged. Moreover, the power electronics unit and the potting material can form an integral body with better stiffness, so that there is no vibration source between the power electronics unit and the potting material. Further, the potting process can be pre-completed in an environment with higher cleanliness. The potted power electronics unit can be protected by the potting material, so that the power electronics unit will not be contaminated, and thus the electric drive system does not require an assembly environment with higher cleanliness. In this way, the electric drive system can have a compact layout, high reliability, good NVH performance, and low production cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Shows a schematic diagram of an electric drive system according to a first embodiment of the present application.

[0018] Figure 2 Shows Figure 1Schematic diagram of the first housing, power electronics unit, and potting material of the electric drive system in

[0019] Figure 3 Shows Figure 1 Exploded view of the first housing, power electronics unit, and potting material of the electric drive system in

[0020] Figure 4 Shows Figure 1 Schematic diagram of the power electronics unit and potting material of the electric drive system in

[0021] Figure 5 Shows Figure 1 Schematic diagram of the power electronics unit and potting material of the electric drive system in, where the potting material is shown in a translucent manner for easy understanding.

[0022] Figure 6 Shows a schematic diagram of the electric drive system according to the second embodiment of the present application.

[0023] Figure 7 Shows Figure 6 Schematic diagram of the electric drive system in, where the potting material is omitted.

[0024] Figure 8 Shows Figure 6 Schematic diagram of the first housing, power electronics unit, and potting material of the electric drive system in

[0025] Figure 9 Shows Figure 6 Schematic diagram of the first housing and power electronics unit of the electric drive system in

[0026] Figure 10 Shows Figure 6 Exploded view of the first housing, power electronics unit, and potting material of the electric drive system in

[0027] Figure 11 Shows Figure 6 Schematic diagram of the power electronics unit and potting material of the electric drive system in

[0028] Figure 12 Shows Figure 6 Schematic diagram of the power electronics unit and potting material of the electric drive system in, where the potting material is shown in a translucent manner for easy understanding.

[0029] Explanation of reference numerals

[0030] 1 Axle housing; 11 First housing; 12 Second housing; 1a Potting groove;

[0031] 2 Power electronics unit;

[0032] 3 Potting material;

[0033] 4 Bolts. Detailed implementation manners

[0034] The exemplary embodiments of the present application will be described below with reference to the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present application, rather than to exhaust all feasible ways of the present application, nor to limit the scope of the present application.

[0035] (First embodiment)

[0036] Figures 1 to 5 An electric drive system according to a first embodiment of the present application is shown, in particular an electric drive system suitable for an electric vehicle.

[0037] The electric drive system may include a axle housing 1, a power electronics unit 2 (PEU, power electric unit), a potting material 3, and a plurality of bolts 4 (an example of a fastener). The axle housing 1 may include a first housing 11 and a second housing 12, and the first housing 11 and the second housing 12 may be fixedly connected by a fastener. The first housing 11 may accommodate a motor, and the second housing 12 may accommodate a transmission. The power electronics unit 2 and the potting material 3 may be disposed outside the axle housing 1. The power electronics unit 2 may integrate an on-vehicle charger, a DC-DC converter, a power distribution unit (PDU, power distribution unit), and a motor control unit (MCU, motor control unit), and is electrically connected to the motor. The potting material 3 (in a cured state) may cover the power electronics unit 2 and is fixedly installed on the first housing 11 through the bolts 4, so that the potting material 3 is joined to the first housing 11.

[0038] The manufacturing method of the electric drive system may include:

[0039] Position the power electronics unit 2 in a mold (not shown in the figure);

[0040] Pour the uncured potting material 3 into the mold so that the power electronics unit 2 is immersed in the potting material 3. For example, the potting material 3 may include epoxy resin;

[0041] Cure the uncured potting material 3;

[0042] Remove the power electronics unit 2 and the cured potting material 3 from the mold; and

[0043] Install the cured potting material 3 on the first housing 11 through the fastener 4 so that the power electronics unit 2 and the potting material 3 are in the state as Figures 1 to 5Status shown.

[0044] The electric drive system of this embodiment has at least the following advantages.

[0045] (i) The electric drive system has a compact layout. By providing the potting material 3, the potting material 3 can replace some parts, so that the electric drive system can have a smaller number of parts and a smaller internal gap.

[0046] (ii) The electric drive system has high reliability. By providing the potting material 3, the power electronic unit 2 can be sealed by the potting material 3, so that the power electronic unit 2 is not easily damaged.

[0047] (iii) The electric drive system has good NVH (noise, vibration and harshness) performance. By providing the potting material 3, the power electronic unit 2 and the potting material 3 can form a whole with good rigidity, so that there is no vibration source between the power electronic unit 2 and the potting material 3.

[0048] (iv) The electric drive system has a lower production cost. By providing the potting material 3, the potting process can be completed in advance in an environment with a high degree of cleanliness. The potted power electronic unit 2 can be protected by the potting material so that the power electronic unit 2 will not be contaminated, so that the electric drive system does not require an assembly environment with a high degree of cleanliness.

[0049] (Second embodiment)

[0050] The second embodiment is a variation of the first embodiment. For features that are the same or similar to those of the first embodiment, the same reference numerals are used in this embodiment and detailed description of these features is omitted.

[0051] Reference Figures 6 to 12 The electric drive system may include a bridge housing 1, a power electronic unit 2 (PEU), a potting material 3, and a plurality of bolts 4 (an example of a fastener) that are particularly optional. The first housing 11 may be provided with a potting groove 1a. The power electronic unit 2 may be disposed in the potting groove 1a and fixedly mounted to the first housing 11 by bolts 4, so that the power electronic unit 2 is joined to the first housing 11. The potting material 3 (in a cured state) may cover the power electronic unit 2 and bond to the wall of the potting groove 1a, so that the potting material 3 is joined to the first housing 11.

[0052] The method of manufacturing an electric drive system may include:

[0053] The power electronic unit 2 is fixedly mounted on the first housing 11 by means of bolts 4, so that the power electronic unit 2 is positioned in the potting groove 1a;

[0054] Pour the potting material 3 in an uncured state into the potting groove 1a; and

[0055] Cure the potting material 3 in an uncured state so that the potting material 3 adheres to the wall portion of the potting groove 1a and the power electronic unit 2 while curing.

[0056] It should be understood that the above embodiments are merely exemplary and are not used to limit the present application. Those skilled in the art can make various modifications and changes to the above embodiments under the teaching of the present application without departing from the scope of the present application.

[0057] (i) The potting material 3 is not limited to being joined to the first housing 11. For example, it can be joined to the second housing 12.

[0058] (ii) The potting groove 1a is not limited to being provided in the first housing 11. For example, it can be jointly defined by the first housing 11 and the second housing 12, or can be defined solely by the second housing 12.

[0059] (iii) The power electronic unit 2 is not limited to being positioned in the potting groove 1a by the bolt 4. For example, a positioning structure can be provided in the potting groove 1a, and the power electronic unit 2 can be sleeved or clamped to the positioning structure, for example. The power electronic unit 2 can also be positioned in the potting groove 1a by abutting against the side wall of the potting groove 1a.

[0060] (iv) The transmission in the present application includes a transmission with adjustable gear positions and a speed reducer with a single gear ratio.

[0061] (v) The potting material 3 covering the power electronic unit 2 in the present application includes, but does not necessarily mean that the potting material 3 completely and 100% covers the power electronic unit 2. The potting material 3 can partially cover the power electronic unit 2. In particular, the potting material 3 can cover at least one side surface of the power electronic unit 2, or cover more than 50% of the surface area of the power electronic unit 2. In one example, the potting material 3 covers most of the surface of the power electronic unit 2, for example, more than 85% of the surface.

Claims

1. An electric drive system, characterized in that, Comprising: A bridge housing (1) that houses an electric motor and a transmission; A power electronics unit (2) that is electrically connected to the electric motor; And A potting material (3) that coats the power electronics unit (2) and is joined to the bridge housing (1).

2. The electric drive system according to claim 1, wherein, The potting material (3) is mounted on the bridge housing (1) by fasteners, and / or the potting material (3) is adhesively bonded to the bridge housing (1).

3. The electric drive system according to claim 1 or 2, characterized in that The power electronics unit (2) is mounted on the bridge housing (1) by fasteners.

4. The electric drive system according to claim 1 or 2, characterized in that, The bridge housing (1) is provided with a potting groove (1a), and the potting material (3) is configured to be cured within the potting groove (1a).

5. The electric drive system according to claim 1 or 2, characterized in that, The bridge housing (1) includes a first housing (11) and a second housing (12). The first housing (11) houses the electric motor, and the second housing (12) houses the transmission. The potting material (3) is joined to the first housing (11).

6. The electric drive system according to claim 1 or 2, characterized in that, The potting material (3) coats more than 85% of the surface area of the power electronics unit (2).

7. A manufacturing method of an electric drive system, characterized in that, Comprising: Coating the power electronics unit (2) with the potting material (3); And Joining the potting material (3) to the bridge housing (1).

8. The manufacturing method according to claim 7, characterized in that, Coating the power electronics unit (2) with the potting material (3) includes: Positioning the power electronics unit (2) within a mold; Pouring the uncured potting material (3) into the mold; Curing the uncured potting material (3); and Removing the power electronics unit (2) and the cured potting material (3) from the mold.

9. The manufacturing method according to claim 8, characterized in that, Joining the potting material (3) to the bridge housing (1) includes: Mounting the cured potting material (3) on the bridge housing (1) by fasteners.

10. The manufacturing method according to claim 7, characterized in that, Coating the power electronics unit (2) with the potting material (3) includes: Positioning the power electronics unit (2) within the bridge housing (1); and Pouring the uncured potting material (3) into the bridge housing (1), Joining the potting material (3) to the bridge housing (1) includes: Curing the uncured potting material (3).

Images