Integrated electric drive system

Abstract

The invention relates to the technical field of driving, and discloses an integrated electric driving system which comprises a cylindrical shell, a controller shell and a fan, a motor assembly is arranged in the cylindrical shell, a duct extending from the first end of the cylindrical shell to the second end of the cylindrical shell is formed in the outer surface of the cylindrical shell, a controller assembly is arranged in the controller shell, and the fan is arranged in the controller assembly. The controller shell and the cylindrical shell are arranged at an interval so as to form an air duct extending in the same direction as the duct, and the fan is arranged at the first end of the cylindrical shell and is configured to be capable of driving air to flow through the duct and the air duct; the cylindrical shell for accommodating the motor assembly and the controller shell for accommodating the controller assembly are integrated together, and the fan arranged at the first end of the cylindrical shell in a matched mode drives air to flow through the duct in the cylindrical shell and the air duct between the controller shell and the cylindrical shell. Independent assemblies are reduced, wiring is reduced, space is saved, and meanwhile effective heat dissipation of the motor assembly and the controller assembly is achieved.

Description

Technical Field

[0001] The present invention relates to the field of drive technology, and in particular to an integrated electric drive system. Background Art

[0002] With the rapid development of industrial automation, new energy vehicles, and intelligent manufacturing, performance requirements for electric drive systems are increasing. Traditional electric drive systems typically design and manufacture the motor, motor controller, and cooling system as independent modules, which are connected externally to achieve coordinated operation. However, this split-structure design has gradually exposed many drawbacks in practical applications:

[0003] 1) Low system integration, redundant volume and installation space

[0004] The separate layout of the motor, motor controller, and cooling system results in a bulky overall design, taking up excessive installation space. For example, cable connection space must be reserved between the motor controller and the motor, and the cooling system (such as a separate fan or liquid cooling pipes) requires additional configuration, making it difficult to meet the requirements of compact equipment or space-constrained scenarios.

[0005] 2) Energy loss and low operating efficiency

[0006] Long-distance cable connections between the motor controller and the motor body can lead to power transmission losses (such as resistive heat loss), reducing system efficiency (usually accounting for 3%-5% of the loss); in addition, the separate design between the motor controller and the motor body requires additional filtering and protection circuits, further increasing energy losses; in addition, traditional heat dissipation systems (such as independent air cooling) are difficult to accurately match the thermal load of the motor controller and the motor body, resulting in delayed heat dissipation or excessive cooling; when the motor controller is separated from the heat dissipation system, heat easily accumulates inside the motor controller (such as excessive temperature rise of the IGBT module), causing performance reduction or even device failure.

[0007] 3) Poor reliability and high maintenance costs

[0008] In a split system, the electrical connections between the motor body and the motor controller (such as connectors and terminals) are easily affected by vibration, moisture or dust, leading to poor contact or short circuit risks; the independent installation of cooling system pipes or fans may cause leakage or failure due to mechanical stress; in addition, multiple independent modules need to be debugged and maintained separately, increasing system downtime and labor costs.

[0009] 4) Insufficient intelligence and collaborative control capabilities

[0010] In a split system, data exchange between the motor controller, the motor body, and the cooling system relies on external communication (such as the CAN bus), which results in signal delays and makes it difficult to achieve real-time collaborative control (such as dynamically adjusting the cooling strategy to match load changes). In addition, traditional cooling systems are only designed for a single heat source (such as the motor body or motor controller) and are unable to coordinate the global heat load, resulting in energy waste (such as overcooling) or local overheating.

[0011] 5) Manufacturing costs

[0012] In a split system, independent modules need to be molded, assembled and tested separately, which increases production costs; the split structure requires repeated configuration of non-core components such as shells and brackets, resulting in higher material costs. Summary of the Invention

[0013] The present invention aims to solve one of the above-mentioned technical problems in the prior art at least to a certain extent.

[0014] In order to achieve the above objectives, the present invention provides an integrated electric drive system, comprising:

[0015] a cylindrical housing, wherein a motor assembly is disposed in the cylindrical housing, and a duct is formed on an outer surface of the cylindrical housing and extends from a first end to a second end thereof;

[0016] a controller housing, wherein a controller assembly is disposed in the controller housing, the controller housing being spaced apart from the cylindrical housing to form an air duct extending in the same direction as the duct; and

[0017] A fan is provided at the first end of the cylindrical housing and is configured to drive air to flow through the duct and the air duct respectively.

[0018] Preferably, the outer surface of the cylindrical shell is provided with a plurality of angular plates spaced apart along its circumference, and the angular plates are extended along the axial direction of the cylindrical shell and can be enclosed with the outer surface of the cylindrical shell to form the duct.

[0019] Preferably, a reinforcing rib plate extending along the axial direction of the cylindrical shell is provided in the duct, one side of the reinforcing rib plate is connected to the outer surface of the cylindrical shell, and the other side of the reinforcing rib plate is connected to the angled plate;

[0020] Preferably, a plurality of ridges are provided on at least one side surface of the reinforcing rib plate, and the plurality of ridges are respectively extended along the length direction of the duct.

[0021] Preferably, the angled plate comprises a first support plate and a second support plate perpendicular to each other, and opposite sides of the first support plate and the second support plate are respectively connected to the outer surface of the cylindrical shell;

[0022] Preferably, the first support plates of two adjacent angled plates are arranged in the same plane.

[0023] Preferably, a first fin group is provided on the cylindrical shell in the duct, and the first fin group includes a plurality of first plate-shaped fins extending along the axial direction of the cylindrical shell;

[0024] Preferably, a plurality of the first plate-shaped fins are arranged at the same height on the outer surface of the cylindrical shell;

[0025] Preferably, a second fin group is provided on the cylindrical shell between two adjacent angular plates, and the second fin group includes a plurality of second plate-shaped fins extending along the axial direction of the cylindrical shell;

[0026] Preferably, outer ends of the plurality of second plate-shaped fins are flush with each other and form a supporting surface together with one side surface of the two angled plates.

[0027] Preferably, four angular plates are provided, and the four angular plates are evenly spaced along the circumference of the cylindrical shell.

[0028] Preferably, a front end cover and a rear end cover are respectively provided at both ends of the cylindrical shell, and the end faces of both ends of the cylindrical shell respectively form stop fits with the front end cover and the rear end cover, and are respectively fixedly connected by bolts or screws.

[0029] Preferably, the front end cover and the rear end cover are respectively provided with an annular convex portion on one side close to the cylindrical shell, and the annular convex portion is used to be inserted into the cylindrical cavity of the cylindrical shell and form a stop fit with the inner wall of the cylindrical shell.

[0030] Preferably, the air duct is provided with a plurality of heat sinks extending along the length direction thereof;

[0031] Preferably, one side of the heat sink is connected to the controller housing and / or the cylindrical housing.

[0032] Preferably, the integrated electric drive system also includes a fan cover, which is used to install the fan to the first end of the cylindrical shell, and the fan cover is configured to guide the wind generated by the fan to the first end of the cylindrical shell and the air inlet end of the air duct.

[0033] Through the above technical solution, by integrating the cylindrical shell accommodating the motor assembly and the controller shell accommodating the controller assembly, and cooperating with the fan arranged at the first end of the cylindrical shell to drive the air to flow through the duct on the cylindrical shell and the air duct between the controller shell and the cylindrical shell, effective heat dissipation of the motor assembly and the controller assembly is achieved while reducing independent components, reducing wiring and saving space. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a structural schematic diagram of an integrated electric drive system provided by the present invention;

[0035] Figure 2 is a cross-sectional view along the axial direction of an integrated electric drive system provided by the present invention;

[0036] Figure 3 is a radial cross-sectional view of an integrated electric drive system provided by the present invention;

[0037] Figure 4 This is a structural diagram of a motor body provided by the present invention;

[0038] Figure 5 yes Figure 4 A magnified schematic diagram of position A in the middle;

[0039] Figure 6 This is a cross-sectional view of a motor body provided by the present invention;

[0040] Figure 7 This is an exploded view of a motor body provided by the present invention.

[0041] Description of Reference Numerals

[0042] 100. Cylindrical shell; 101. First end; 102. Second end; 110. First fin group; 111. First plate-shaped fin; 120. Second fin group; 121. Second plate-shaped fin; 130. Front end cover; 140. Rear end cover; 150. Screw; 160. Annular protrusion; 200. Angular plate; 201. First support plate; 202. Second support plate; 210. Duct; 220. Reinforcing rib plate; 221. Rib; 300. Fan; 400. Controller shell; 410. Air duct; 411. Air inlet end; 412. Air outlet end; 420. Heat sink; 500. Fan cover; 510. Air vent; 600. H-shaped bracket. DETAILED DESCRIPTION

[0043] The following describes the specific embodiments of the present invention in detail with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present invention and are not intended to limit the present invention.

[0044] As mentioned above, combined with Figure 1 、 Figure 2 and Figure 3 As shown, the present invention provides an integrated electric drive system, including a cylindrical shell 100, a controller shell 400 and a fan 300, wherein a motor assembly is arranged in the cylindrical shell 100, and a duct 210 extending from a first end 101 to a second end 102 is formed on the outer surface of the cylindrical shell 100, and a controller assembly is arranged in the controller shell 400, and the controller shell 400 is spaced apart from the cylindrical shell 100 to form an air duct 410 extending in the same direction as the duct 210, and the fan 300 is arranged at the first end 101 of the cylindrical shell 100 and is configured to drive air to flow through the duct 210 and the air duct 410 respectively.

[0045] In the present invention, the cylindrical shell 100 is an important component of the motor body, which is used to accommodate and protect the motor assembly. The motor assembly specifically includes a stator and a rotor. The stator is mounted on the inner wall of the cylindrical shell 100 and consists of an iron core and a winding. When energized, it can generate a rotating magnetic field to drive the rotor to rotate. The rotor is mounted on the rotating shaft inside the cylindrical shell 100. It interacts with the stator through the rotating magnetic field to convert electrical energy into mechanical energy. The heat generated in this process will be directly transferred to the cylindrical shell 100. Therefore, the key to the heat dissipation of the motor is the heat dissipation of the cylindrical shell 100. In addition, the controller assembly of the motor will also generate heat during operation. If heat accumulates inside the motor controller, such as if the temperature rise of the IGBT module is too high, it will cause performance reduction or even device failure. Therefore, it is necessary to dissipate heat and cool the controller assembly of the motor.

[0046] In the technical solution provided by the present invention, the cylindrical shell 100 accommodating the motor assembly and the controller shell 400 accommodating the controller assembly are integrated together, and the fan 300 arranged at the first end 101 of the cylindrical shell 100 drives the air to flow through the duct 210 on the cylindrical shell 100 and the air duct 410 between the controller shell 400 and the cylindrical shell 100, thereby reducing independent components, reducing wiring and saving space, while achieving effective heat dissipation of the motor assembly and the controller assembly.

[0047] With the structural layout provided by the present invention, the fan 300 can achieve effective heat dissipation in a relatively concentrated position without the need for additional heat dissipation devices or complex heat dissipation pipelines, which not only improves the heat dissipation efficiency but also reduces the accumulation of heat in the system; in addition, the integrated electric drive system provided by the present invention has high operating efficiency, and the reasonable layout of the heat dissipation system and the motor controller can ensure that the temperature of the electric drive system is maintained within an appropriate range, avoiding damage caused by overheating, and improving the long-term operation reliability of the electric drive system. Compared with the traditional decentralized heat dissipation design, the integrated electric drive system provided by the present invention can better control the transfer and dissipation of heat, thereby extending the service life.

[0048] In the present invention, the controller housing 400 can be spaced apart from the cylindrical housing 100 in any appropriate form. In some embodiments, an H-shaped bracket 600 is provided on the outer surface of the cylindrical housing 100, and the lower end opening of the H-shaped bracket 600 is clamped on the outer surface of the cylindrical housing 100, and the controller housing 400 is fixed in the upper end opening of the H-shaped bracket 600 by a support foot.

[0049] In the technical solution provided by the present invention, by spacing the controller housing 400 for accommodating the controller assembly from the cylindrical housing 100 for accommodating the motor assembly, an air duct 410 extending in the same direction as the duct 210 is formed. During actual use, a set of air cooling systems can simultaneously form flowing air in the duct 210 and the air duct 410, thereby simultaneously removing the heat generated by the controller assembly during operation and transferred to the controller housing 400, as well as the heat generated by the motor assembly during operation and transferred to the cylindrical housing 100. In addition, the motor provided by the present invention can also achieve a compact design, avoiding a series of disadvantages brought about by the traditional design and manufacture of the motor body, motor controller and heat dissipation system as independent modules.

[0050] It should be noted that in the present invention, the air duct 410 is part of the motor, and the controller assembly can be not only disposed in the controller housing 400, but can also be partially disposed in the air duct 410. For example, a module with a large heat generation can be directly disposed in the air duct 410. This not only makes the motor more compact, but also further achieves heat control and improves the heat dissipation effect.

[0051] In the technical solution provided by the present invention, a duct 210 is formed by enclosing an angular plate 200 extending along the axial direction of the cylindrical shell 100 and the outer surface of the cylindrical shell 100. The duct 210 can serve as an air flow channel, so that the flowing air can reliably contact the outer surface of the cylindrical shell 100 while flowing from the first end 101 to the second end 102 of the cylindrical shell 100, thereby ensuring the heat exchange effect, so that the flowing air can be fully utilized to effectively take away the heat generated by the motor component during operation and transferred to the cylindrical shell 100; the inventors of the present application found that compared with the traditional motor housing with only cooling fins, the motor housing structure based on the cylindrical shell 100 provided by the present invention can effectively improve the heat dissipation efficiency of the motor.

[0052] In some embodiments, the outer surface of the cylindrical shell 100 is provided with a plurality of angular plates 200 spaced apart along its circumference. The angular plates 200 extend along the axial direction of the cylindrical shell 100 and can be enclosed with the outer surface of the cylindrical shell 100 to form the duct 210.

[0053] In some embodiments, combined Figure 4 and Figure 5 As shown, a reinforcing rib plate 220 extending along the axial direction of the cylindrical shell 100 is provided in the duct 210, one side of the reinforcing rib plate 220 is connected to the outer surface of the cylindrical shell 100, and the other side of the reinforcing rib plate 220 is connected to the angular plate 200; through the above arrangement, on the one hand, the structural strength of the duct 210 formed by the angular plate 200 and the outer surface of the cylindrical shell 100 can be ensured, and on the other hand, the reinforcing rib plate 220 can be used as a heat dissipation structure to improve the heat dissipation efficiency by expanding the heat dissipation area.

[0054] In some embodiments, at least one side of the reinforcing rib plate 220 is provided with a plurality of ridges 221, each extending along the length of the duct 210. This arrangement not only guides airflow and ensures structural strength, but also increases the heat dissipation area of the reinforcing rib plate 220, thereby further improving heat dissipation efficiency.

[0055] In the present invention, the angled plate 200 may be of any appropriate structural form, as long as it can cooperate with the outer surface of the cylindrical shell 100 to enclose and form a duct 210 extending from the first end 101 to the second end 102 of the cylindrical shell 100. In some embodiments of the present invention, the angled plate 200 includes a first support plate 201 and a second support plate 202 that are perpendicular to each other, and the first support plate 201 and the second support plate 202 are respectively connected to the outer surface of the cylindrical shell 100 on opposite sides.

[0056] In some embodiments, the first support plates 201 of two adjacent angular plates 200 are arranged in the same plane. With the above-mentioned structural arrangement, the two angular plates 200 can serve as a support structure for the cylindrical shell 100, enabling it to be placed stably.

[0057] In some embodiments, combined Figure 6 and Figure 7 As shown, in order to further improve the heat dissipation effect of the cylindrical shell 100, a first fin group 110 is provided on the cylindrical shell 100 in the duct 210, and the first fin group 110 includes a plurality of first plate-shaped fins 111 extending along the axial direction of the cylindrical shell 100; it can be understood that by providing the first plate-shaped fins 111 on the cylindrical shell 100, the heat dissipation area can be effectively increased, so as to facilitate the timely removal of the heat generated by the motor component during operation and transferred to the cylindrical shell 100; in addition, the plurality of first plate-shaped fins 111 extending along the axial direction of the cylindrical shell 100 located in the duct 210 can also cooperate with each other to form a gas flow channel, so that the air can effectively contact the cylindrical shell 100 and the first plate-shaped fins 111, thereby ensuring the heat dissipation effect.

[0058] In some embodiments, a plurality of the first plate-shaped fins 111 are arranged at the same height on the outer surface of the cylindrical shell 100 ; it is understandable that the above arrangement can avoid occupying too much cross-sectional area of the duct 210 while taking into account the air flow in the duct 210 .

[0059] In some embodiments, in order to further improve the heat dissipation efficiency of the cylindrical shell 100 , a second fin group 120 is provided on the cylindrical shell 100 between two adjacent angular plates 200 , and the second fin group 120 includes a plurality of second plate-shaped fins 121 extending along the axial direction of the cylindrical shell 100 .

[0060] In some embodiments, outer ends of the plurality of second plate-shaped fins 121 are flush with each other and form a supporting surface together with one side surface of the two angled plates 200 .

[0061] In some embodiments, four angular plates 200 are provided, and the four angular plates 200 are evenly spaced along the circumference of the cylindrical shell 100 .

[0062] In some embodiments, the two ends of the cylindrical shell 100 are respectively provided with a front end cover 130 and a rear end cover 140, and the end faces of the two ends of the cylindrical shell 100 respectively form a stop fit with the front end cover 130 and the rear end cover 140, and are respectively fixedly connected by bolts or screws 150. The cylindrical shell 100 and the front end cover 130 and the rear end cover 140 provided at both ends can achieve effective protection of the motor assembly. The above-mentioned arrangement not only makes the motor housing structure simple, but also has the advantage of easy assembly. Compared with the prior art, the above-mentioned structure provided by the present invention can avoid the inconvenience of using long bolts to pass through along the length direction of the motor to connect the front end cover 130 or the rear end cover 140 to the cylindrical shell 100.

[0063] In some embodiments, an annular protrusion 160 is provided on one side of the front end cover 130 and the rear end cover 140 near the cylindrical housing 100. The annular protrusion 160 is configured to be inserted into the cylindrical cavity of the cylindrical housing 100 and to form a stop with the inner wall of the cylindrical housing 100. During installation, the annular protrusion 160 facilitates the positioning and installation of the front end cover 130 and the rear end cover 140 at both ends of the cylindrical housing 100.

[0064] In the present invention, a plurality of heat sinks 420 extending along the length direction of the air duct 410 are provided in the air duct 410; by providing the heat sinks 420, on the one hand, the heat dissipation efficiency can be improved by increasing the surface area, and on the other hand, the flowing air can be constrained by two adjacent heat sinks 420, so that the air is constrained to flow from the air inlet end 411 of the air duct 410 to the air outlet end 412 while fully contacting the heat sinks 420, thereby effectively taking away the heat.

[0065] In the present invention, the heat sink 420 can be made of high thermal conductivity material, such as aluminum alloy or copper, which can transfer the heat on the controller housing 400 or the cylindrical housing 100 to the air duct 410, so that the heat is promptly carried away by the air flowing through the air duct 410.

[0066] In some embodiments, one side of the heat sink 420 is connected to the controller housing 400 and / or the cylindrical housing 100. It is understood that the heat sink 420 can be connected to the controller housing 400, or to the cylindrical housing 100, or to both.

[0067] In some embodiments, the integrated electric drive system further includes a fan cover 500, which is used to mount the fan 300 to the first end 101 of the cylindrical housing 100. The fan cover 500 is configured to guide the wind generated by the fan 300 to the first end 101 of the cylindrical housing 100 and the air inlet end 411 of the air duct 410. It is understood that the fan cover 500 is also provided with air holes 510 to allow air to freely enter the fan 300.

[0068] While the preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, the present invention is not limited thereto. Within the technical scope of the present invention, various simple variations of the technical solution of the present invention may be made. To avoid unnecessary repetition, the present invention will not further describe various possible combinations. However, these simple variations and combinations should also be considered as disclosed herein and fall within the scope of protection of the present invention.

Claims

1. An integrated electric drive system, characterized in that: include: A cylindrical housing (100), wherein a motor assembly is disposed in the cylindrical housing (100), and a duct (210) extending from a first end (101) to a second end (102) of the cylindrical housing (100) is formed on an outer surface of the cylindrical housing (100); a controller housing (400), wherein a controller assembly is disposed in the controller housing (400), and the controller housing (400) is spaced apart from the cylindrical housing (100) to form an air duct (410) extending in the same direction as the duct (210); and A fan (300) is provided at the first end (101) of the cylindrical housing (100) and is configured to drive air to flow through the duct (210) and the air duct (410).

2. The integrated electric drive system according to claim 1, characterized in that: The outer surface of the cylindrical shell (100) is provided with a plurality of angular plates (200) spaced apart along its circumference. The angular plates (200) are extended along the axial direction of the cylindrical shell (100) and can be enclosed with the outer surface of the cylindrical shell (100) to form the duct (210).

3. The integrated electric drive system according to claim 2, characterized in that: A reinforcing rib plate (220) extending along the axial direction of the cylindrical shell (100) is provided in the duct (210), one side of the reinforcing rib plate (220) is connected to the outer surface of the cylindrical shell (100), and the other side of the reinforcing rib plate (220) is connected to the angled plate (200); Preferably, a plurality of ridges (221) are provided on at least one side surface of the reinforcing rib plate (220), and the plurality of ridges (221) are respectively extended along the length direction of the duct (210).

4. The integrated electric drive system according to claim 2, characterized in that: The angled plate (200) comprises a first support plate (201) and a second support plate (202) perpendicular to each other, and opposite sides of the first support plate (201) and the second support plate (202) are respectively connected to the outer surface of the cylindrical shell (100); Preferably, the first support plates (201) of two adjacent angular plates (200) are arranged in a coplanar manner.

5. The integrated electric drive system according to claim 2, characterized in that: A first fin group (110) is provided on the cylindrical shell (100) in the duct (210), and the first fin group (110) includes a plurality of first plate-shaped fins (111) extending along the axial direction of the cylindrical shell (100); Preferably, a plurality of the first plate-shaped fins (111) are arranged at the same height on the outer surface of the cylindrical shell (100); Preferably, a second fin group (120) is provided on the cylindrical shell (100) between two adjacent angular plates (200), and the second fin group (120) includes a plurality of second plate-shaped fins (121) extending along the axial direction of the cylindrical shell (100); Preferably, the outer ends of the plurality of second plate-shaped fins (121) are flush with each other and form a supporting surface together with one side surface of the two angled plates (200).

6. The integrated electric drive system according to claim 2, characterized in that: Four angular plates (200) are provided, and the four angular plates (200) are evenly spaced along the circumference of the cylindrical shell (100).

7. The integrated electric drive system according to claim 1, characterized in that: The two ends of the cylindrical shell (100) are respectively provided with a front end cover (130) and a rear end cover (140). The end surfaces of the two ends of the cylindrical shell (100) respectively form stoppers with the front end cover (130) and the rear end cover (140), and are respectively fixedly connected by bolts or screws (150).

8. The integrated electric drive system according to claim 7, characterized in that: The front end cover (130) and the rear end cover (140) are respectively provided with an annular protrusion (160) on one side close to the cylindrical shell (100), and the annular protrusion (160) is used to be inserted into the cylindrical cavity of the cylindrical shell (100) and form a stop fit with the inner wall of the cylindrical shell (100).

9. The integrated electric drive system according to claim 1, characterized in that: The air duct (410) is provided with a plurality of heat sinks (420) extending along the length direction thereof; Preferably, one side of the heat sink (420) is connected to the controller housing (400) and / or the cylindrical housing (100).

10. The integrated electric drive system according to claim 1, characterized in that: The integrated electric drive system further comprises a fan cover (500), wherein the fan cover (500) is used to mount the fan (300) to the first end (101) of the cylindrical housing (100), and the fan cover (500) is configured to guide the wind generated by the fan (300) to the first end (101) of the cylindrical housing (100) and the air inlet end (411) of the air duct (410).

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