An oil cooling electric drive assembly cooling oil online self-cleaning system and a control method thereof

Abstract

This invention discloses an online self-cleaning system and control method for cooling oil in an oil-cooled electric drive assembly, relating to the field of cooling oil cleaning technology. The oil-cooled electric drive assembly housing has a cooling oil inlet and outlet, and includes: an oil tank; an oil supply pump, with the pump inlet connected to the oil tank; a proportional directional valve, with the pump outlet connected to the valve inlet via a pipeline; the valve outlet connected to the cooling oil inlet; the cooling oil outlet connected to the tank return port; a cooling oil contamination detection component connected to the pipeline to detect the cooling oil contamination level; a cooling oil cleaning component, with the proportional directional valve outlet connected to the cleaning component inlet; the cleaning component outlet connected to the tank return port; and a self-cleaning controller electrically connected to the pump, proportional directional valve, and cooling oil contamination detection component. This invention's online self-cleaning system can continuously maintain oil cleanliness during operation and shutdown.

Description

Technical Field

[0001] This invention relates to the field of cooling oil cleaning technology, and in particular to an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly and its control method. Background Technology

[0002] With the rapid development of new energy vehicles and electrified equipment, oil-cooled electric drive assemblies have been widely used due to their advantages such as efficient heat dissipation, compact structure, and high reliability. Existing systems generally employ non-homogeneous oil cooling structures, with components such as the motor and reducer cooled by independent or semi-independent oil circuits. This results in a large number of oil circuits, complex structures, high costs, and difficulty in uniformly controlling the temperature and flow of oil in multiple circuits, leading to limited overall heat dissipation capacity. Under high power density and highly integrated layout conditions, problems such as localized overheating, efficiency reduction, and maintenance difficulties are more likely to occur. Furthermore, traditional oil-cooled systems typically use fixed filter elements to capture contaminants, lacking real-time monitoring of key parameters such as oil contamination level, pressure, and flow rate. Filter blockage is difficult to detect in time, easily causing a decrease in system flow and a decline in heat dissipation performance. Under conditions of high temperature, high load, and frequent start-stop, the rate of oil contaminant generation accelerates significantly, and existing filtration structures cannot automatically adjust the cleaning intensity according to the degree of contamination, easily leading to over-filtration or under-filtration.

[0003] Existing oil-cooling systems often rely on manual cleaning or filter replacement after the vehicle has stopped when contamination is severe. This results in low maintenance efficiency and impacts vehicle operation. While some bypass filtration systems can slow down contamination accumulation to some extent, they still lack online contamination monitoring, intelligent flow path switching, and adaptive adjustment of cleaning intensity. They also lack online self-cleaning capabilities during both operation and parking, making it difficult to meet the requirements of modern electric drive assemblies for long-cycle operation, high reliability, and low maintenance. To adapt to the high integration and high power density demands of next-generation electric drive systems, adopting a homogeneous oil-cooling solution has become a necessary technological direction for achieving efficient heat dissipation and simplifying the oil circuit structure.

[0004] Therefore, how to provide an online self-cleaning system for oil-cooled electric drive assembly cooling oil and its control method, which can achieve unified cooling and lubrication of motor and reducer through a single oil circuit, reduce system complexity and manufacturing cost, and organically combine online monitoring of oil contamination, automatic flow path switching and adaptive cleaning strategy, so that the system can continuously maintain oil cleanliness in both running and stopped states, thereby improving overall heat dissipation performance, operational reliability and life of key components, is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, the present invention proposes an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly and a control method thereof, aiming to solve at least one of the above-mentioned technical problems.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This invention provides an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly. The housing of the oil-cooled electric drive assembly has a cooling oil inlet and a cooling oil outlet, comprising:

[0008] An oil tank and an oil supply pump, wherein the oil supply pump inlet is connected to the oil tank to draw in cooling oil;

[0009] The proportional directional valve is provided with the oil pump outlet connected to the proportional directional valve inlet via pipeline one for oil supply; the proportional directional valve outlet one is connected to the cooling oil inlet via pipeline two for distributing cooling oil; and the cooling oil outlet is connected to the oil tank return port via a return oil pipeline for returning cooling oil.

[0010] A cooling oil contamination detection component is connected to the pipeline to detect the contamination level of the cooling oil it delivers.

[0011] The cooling oil cleaning assembly has its outlet 2 of the proportional directional valve connected to the inlet of the cooling oil cleaning assembly via pipeline 3 to distribute the cooling oil to be purified; the outlet of the cooling oil cleaning assembly is connected to the return port of the oil tank to deliver the purified cooling oil.

[0012] The self-cleaning controller is electrically connected to the oil supply pump, the proportional directional valve, and the cooling oil contamination detection component to receive cooling oil contamination data fed back by the cooling oil contamination detection component, thereby controlling the working state of the oil supply pump and the proportional directional valve.

[0013] In use, the online self-cleaning system for the cooling oil of an oil-cooled electric drive assembly, as described in this invention, firstly uses a self-cleaning controller to start the oil supply pump to draw cooling oil from the oil tank. The cooling oil is then sequentially delivered through pipeline one, a proportional directional valve, and pipeline two to the housing of the oil-cooled electric drive assembly to cool and lubricate the motor and reducer. Under the control of the self-cleaning controller, the proportional directional valve distributes the oil delivered through pipeline one to pipelines two and three in a proportional manner, thereby achieving simultaneous cooling and cleaning of the cooling oil. The cooling oil diverted to the housing of the oil-cooled electric drive assembly flows back to the oil tank via the cooling oil outlet and return oil pipeline on the housing. The cooling oil diverted to the cooling oil cleaning component is purified and then returns to the oil tank. The self-cleaning controller can control the distribution ratio of the proportional reversing valve based on the contamination level of the cooling oil transported in pipeline 1 detected by the cooling oil contamination detection component. This allows for a reasonable distribution of the cooling oil and cleaning oil quantities in the oil-cooled electric drive assembly, thereby ensuring improved system oil cleanliness while achieving adaptive matching between cleaning intensity and contamination level. This improves cleaning efficiency, avoids excessive cleaning which increases energy consumption, and enhances the overall machine reliability.

[0014] As a further improvement to the above technical solution, a flow control valve is also included, which is installed on the second pipeline to control the supply flow of cooling oil.

[0015] The beneficial effects of the above technical solution are: the flow control valve can control the amount of cooling oil delivered to the oil-cooled electric drive assembly according to the signal transmitted by the self-cleaning controller, thus ensuring the cooling and lubrication effect.

[0016] As a further improvement to the above technical solution, it also includes pressure sensor one and pressure sensor two; pressure sensor one is installed on pipeline one to detect oil supply pressure; pressure sensor two is installed on pipeline two and corresponds to the proportional directional valve and the flow control valve to detect oil supply pressure; the self-cleaning controller is electrically connected to pressure sensor one and pressure sensor two.

[0017] The beneficial effects of the above technical solution are: the self-cleaning controller adjusts the oil supply pressure of the oil supply pump according to the oil pressure signal in pipeline one fed back by pressure sensor one and the oil pressure signal in pipeline two fed back by pressure sensor two, so as to ensure that the amount and oil pressure of cooling oil delivered to the oil-cooled electric drive assembly are stable.

[0018] As a further improvement to the above technical solution, an overflow valve is also included, wherein the oil inlet of the overflow valve is connected to the first pipeline, and the oil outlet of the overflow valve is connected to the return port of the oil tank.

[0019] The beneficial effect of the above technical solution is that the overflow valve can automatically open when the oil pressure in pipeline one or pipeline two exceeds the set threshold so that the excess high-pressure oil flows back to the oil tank, thereby preventing the oil supply pump and downstream oil circuit from overloading.

[0020] As a further improvement to the above technical solution, a flow divider valve is also included; one end of the second pipeline is connected to the oil outlet of the proportional directional valve, and the other end of the second pipeline is connected to the oil inlet of the flow divider valve; the oil outlet of the flow divider valve is connected to the oil inlet of the end cap oil passage of the motor of the oil-cooled electric drive assembly through a pipeline to supply cooling oil to the motor; the oil outlet of the second flow divider valve is connected to the oil inlet of the fuel injection passage of the reducer of the oil-cooled electric drive assembly through a pipeline to supply cooling oil to the reducer.

[0021] The cooling oil in the motor and the reducer can flow into the oil pan of the oil-cooled electric drive assembly, and the cooling oil outlet is located on the oil pan.

[0022] The beneficial effects of the above technical solution are: the flow divider valve can distribute the cooling oil in a specific direction, and deliver the cooling oil to the oil inlet of the motor end cover and the oil inlet of the reducer according to the set flow requirements, so that the stator, rotor and planetary gear mechanism of the motor can obtain a stable and matched cooling and lubrication oil supply, thereby ensuring the heat dissipation efficiency and transmission reliability of the oil-cooled electric drive under different working conditions.

[0023] As a further improvement to the above technical solution, the cooling oil cleaning assembly includes a cyclone separator, a magnetic particle collector, a precision filter, and a dirt collection and settling chamber.

[0024] The oil outlet of the proportional reversing valve is connected to the oil inlet of the cyclone separator via pipeline three to distribute the cooling oil to be purified; the oil outlet of the cyclone separator is connected to the oil inlet of the magnetic particle collector, the oil outlet of the magnetic particle collector is connected to the oil inlet of the precision filter, the oil outlet of the precision filter is connected to the oil inlet of the sludge settling chamber, and the oil outlet of the sludge settling chamber is connected to the return port of the oil tank to deliver the purified cooling oil.

[0025] The beneficial effects of the above technical solution are as follows: The cyclone separator is used for primary centrifugal pre-cleaning of the cooling oil to be cleaned, removing large particles with higher density, thereby reducing the load on the subsequent magnetic particle collector and precision filter. The magnetic particle collector is used to remove magnetic impurities in the cooling oil to achieve secondary cleaning, preventing ferromagnetic particles from entering the precision filter and causing excessive load or blockage of the filter element. The precision filter is used for tertiary fine filtration cleaning of the cooling oil, filtering out residual small particle impurities in the cooling oil. The sedimentation chamber is used for centralized sedimentation and collection of solid impurities, and can reduce the oil flow rate by expanding the flow cross-section, allowing the fine particles in the cooling oil to settle to the bottom of the chamber under gravity, thereby achieving the final separation of solid impurities from the oil.

[0026] As a further improvement to the above technical solution, the cooling oil cleaning assembly also includes a differential pressure sensor and a weight sensor; the differential pressure sensor is installed on the precision filter to detect the differential pressure value between the inlet and outlet of the precision filter; the weight sensor is installed on the dirt collection and settling chamber to detect its weight change; the self-cleaning controller is electrically connected to the differential pressure sensor and the weight sensor.

[0027] The beneficial effects of the above technical solution are as follows: The differential pressure sensor monitors the pressure change before and after the filter element in real time by detecting the oil pressure difference between the oil inlet and outlet sides of the precision filter, providing a basis for judging the degree of filter element blockage. The weight sensor detects the increase in weight of the dirt collection and settling chamber in real time, providing a basis for judging the state of impurity accumulation, thereby improving the stability and maintainability of the system.

[0028] Another aspect of the present invention provides a control method for an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly. Using the aforementioned online self-cleaning system for cooling oil in an oil-cooled electric drive assembly, the control method includes the following steps:

[0029] The self-cleaning controller controls the working status of the oil supply pump, thereby regulating the oil supply pressure; the cooling oil contamination detection component detects the contamination level of the cooling oil transported in pipeline one in real time and uploads the contamination level detection results to the self-cleaning controller; the self-cleaning controller determines the contamination level of the cooling oil based on the relative relationship between the detected contamination level and the preset contamination level benchmark value, and then adjusts the oil output ratio of the proportional reversing valve's outlet one and outlet two according to the cooling oil contamination level determination result.

[0030] As a further improvement to the above technical solution, the self-cleaning controller can execute different online self-cleaning modes for cooling oil based on the determination of the cooling oil contamination level; the working modes include normal circulation mode, low-intensity cleaning mode, high-intensity cleaning mode, and alarm and protection mode.

[0031] In normal circulation mode, the self-cleaning controller controls the opening of the first oil outlet of the proportional directional valve and the closing of the second oil outlet of the proportional directional valve, and monitors the contamination level of the cooling oil transported in pipeline 1 in real time.

[0032] In low-intensity cleaning mode and when the oil-cooled electric drive assembly is running, the self-cleaning controller controls the oil outlet of the proportional directional valve to be greater than the oil outlet of the proportional directional valve, and monitors the contamination level of the cooling oil transported in pipeline 1 in real time; in low-intensity cleaning mode and when the oil-cooled electric drive assembly is stopped, the self-cleaning controller controls the oil outlet of the proportional directional valve to be closed and controls the oil outlet of the proportional directional valve to be opened, and monitors the contamination level of the cooling oil transported in pipeline 1 in real time.

[0033] In high-intensity cleaning mode and when the oil-cooled electric drive assembly is running, the self-cleaning controller controls the oil outlet of the proportional directional valve to be less than the oil outlet of the proportional directional valve, and monitors the contamination level of the cooling oil transported in pipeline 1 in real time; in high-intensity cleaning mode and when the oil-cooled electric drive assembly is stopped, the self-cleaning controller controls the oil outlet of the proportional directional valve to be closed and controls the oil outlet of the proportional directional valve to be opened, and monitors the contamination level of the cooling oil transported in pipeline 1 in real time.

[0034] In alarm and protection mode, the self-cleaning controller opens the first oil outlet of the proportional directional valve and closes the second oil outlet of the proportional directional valve, and alarms to prompt the maintenance of the cooling oil cleaning component.

[0035] As a further improvement of the above technical solution, the cooling oil pollution level is divided into Pollution Level One, Pollution Level Two, Pollution Level Three, Pollution Level Four, and Pollution Level Five according to the ratio of the pollution degree of the cooling oil transported in Pipeline One to the preset pollution degree reference value a;

[0036] When the pollution degree ≥ a×90%, it is determined as Pollution Level Five and enters the alarm and protection mode; when a×70% ≤ pollution degree < a×90%, it is determined as Pollution Level Four and enters the high-intensity cleaning mode; when a×40% ≤ pollution degree < a×70%, it is determined as Pollution Level Three and enters the low-intensity cleaning mode; when a×20% ≤ pollution degree < a×40%, it is determined as Pollution Level Two, and when the pollution degree < a×20%, it is determined as Pollution Level One, and the normal circulation mode is maintained.

[0037] From the above technical solution, it can be seen that compared with the prior art, the present invention discloses an oil-cooled electric drive assembly cooling oil on-line self-cleaning system and its control method, which has the following advantages and beneficial effects.

[0038] 1. By setting Pressure Sensor One, Pressure Sensor Two, a cooling oil pollution detection component, a differential pressure sensor, and a weight sensor in the main oil circuit and the cleaning system, the present invention constructs a multi-dimensional monitoring system covering oil pressure, impurity concentration, filter element clogging degree, and dirt collection amount, and can obtain the pollution state of the cooling oil of the oil-cooled electric drive assembly in real time under vehicle running and parking conditions, so as to realize on-line detection of the oil pollution degree that cannot be achieved by the traditional system, and improve the reliability and timeliness of oil state judgment.

[0039] 2. By dynamically controlling the proportional reversing valve through the self-cleaning controller, the present invention can automatically switch between the normal circulation mode, the low-intensity cleaning mode, the high-intensity cleaning mode, or the alarm and protection mode according to the oil pollution level monitored in real time, and automatically adjust the diversion ratio entering the cleaning branch in different modes, so as to achieve an adaptive match between the cleaning intensity and the pollution degree, improve the cleaning efficiency, and avoid the increase in energy consumption caused by over-cleaning.

[0040] 3. When the vehicle is in operation, the present invention can maintain the safe flow of the main oil circuit by adjusting the speed of the oil supply pump and simultaneously perform on-line cleaning; when the vehicle is parked, the system can close the main oil circuit and make the oil fluid circulate independently in the cleaning branch through the low-speed drive of the oil supply pump to achieve deep cleaning, expanding the limitation that the prior art cannot perform cleaning under parking conditions, and further improving the working continuity and cleaning effect of the system.

[0041] 4. This invention utilizes a multi-stage impurity removal mechanism, consisting of a cyclone separator, magnetic particle collector, precision filter, and sedimentation chamber in the cleaning branch. This effectively removes various types of contaminants, allowing most impurities to be automatically processed within the system. Manual maintenance is only prompted when the filter element pressure difference exceeds a set threshold or the sedimentation chamber is full, significantly reducing maintenance frequency and extending the service life of the cooling oil and key components of the electric drive assembly. Improved system oil cleanliness further enhances the cooling and lubrication performance of the motor and reducer, improving the overall reliability of the machine. Attached Figure Description

[0042] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0043] Figure 1 This invention provides a schematic diagram of an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly.

[0044] Figure 2 This invention provides a schematic diagram of the heat dissipation oil circuit connection structure of an online self-cleaning system for oil-cooled electric drive assembly.

[0045] Figure 3 This invention provides a schematic diagram of the self-cleaning oil circuit connection structure of an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly.

[0046] Figure 4 This invention provides a schematic diagram showing the interconnected structure of the heat dissipation oil circuit and the self-cleaning oil circuit in an online self-cleaning system for an oil-cooled electric drive assembly.

[0047] Figure 5 This invention provides a flowchart for determining the contamination level of an impurity monitoring sensor in an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly.

[0048] Figure 6 The present invention provides a flowchart of a low-intensity cleaning mode for an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly.

[0049] Figure 7 The present invention provides a flowchart of a high-intensity cleaning mode for an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly.

[0050] Figure 8 The present invention provides a flowchart of the alarm and protection modes of an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly.

[0051] In the diagram: 1. Oil tank; 101. Return oil line; 2. Oil supply pump; 21. Line 1; 211. Bypass oil line; 22. Oil pump controller; 3. Proportional directional valve; 31. Line 2; 32. Line 3; 4. Cooling oil contamination detection assembly; 5. Cooling oil cleaning assembly; 51. Swirl distributor; 52. Magnetic particle trap; 53. Precision filter; 54. Dirt settling chamber; 55. Differential pressure sensor; 56. Weight sensor; 6. Self-cleaning controller; 7. Flow control valve; 8. Pressure sensor 1; 9. Pressure sensor 2; 10. Overflow valve; 11. Diverter valve; 12. Oil pan; 13. Cooler; 14. Motor; 141. Stator; 142. Rotor; 15. Reducer; 151. Planetary gear mechanism; 16. CAN bus; 17. Housing. Detailed Implementation

[0052] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0053] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0054] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0055] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0056] According to embodiments of the present invention, such as Figures 1 to 8 As shown, an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly is provided. The housing 17 of the oil-cooled electric drive assembly has a cooling oil inlet and a cooling oil outlet, and includes: an oil tank 1, an oil supply pump 2, a proportional reversing valve 3, a cooling oil contamination detection component 4, and a cooling oil cleaning component 5.

[0057] The oil inlet of oil pump 2 is connected to oil tank 1 to draw in cooling oil.

[0058] The oil pump 2 outlet is connected to the proportional directional valve 3 inlet via pipeline 21 to supply oil; the proportional directional valve 3 outlet is connected to the cooling oil inlet via pipeline 31 to distribute cooling oil; the cooling oil outlet is connected to the oil tank 1 return port via return oil pipeline 101 to return cooling oil.

[0059] The cooling oil contamination detection component 4 is connected to pipe 21 to detect the contamination level of the cooling oil it delivers.

[0060] The oil outlet of the proportional directional valve 3 is connected to the oil inlet of the cooling oil cleaning component 5 through the pipeline 32 to distribute the cooling oil to be purified; the oil outlet of the cooling oil cleaning component 5 is connected to the return port of the oil tank 1 to deliver the purified cooling oil.

[0061] The self-cleaning controller 6 is electrically connected to the oil supply pump 2, the proportional directional valve 3, and the cooling oil contamination detection component 4 to receive the cooling oil contamination data fed back by the cooling oil contamination detection component 4, thereby controlling the working status of the oil supply pump 2 and the proportional directional valve 3.

[0062] In this embodiment, the online self-cleaning system for the cooling oil of an oil-cooled electric drive assembly first activates the oil supply pump 2, controlled by the self-cleaning controller 6, to draw cooling oil from the oil tank 1. The cooling oil is then sequentially delivered through pipeline 21, the proportional directional valve 3, and pipeline 31 to the housing 17 of the oil-cooled electric drive assembly for cooling and lubrication of the motor and reducer. Under the control of the self-cleaning controller 6, the proportional directional valve 3 distributes the oil delivered through pipeline 21 proportionally to pipelines 31 and 32, thereby achieving simultaneous cooling and cleaning of the cooling oil. The cooling oil diverted to the housing 17 of the oil-cooled electric drive assembly flows back to the oil tank 1 via the cooling oil outlet and return oil pipeline 101 on the housing 17. The cooling oil diverted to the cooling oil cleaning component 5 is purified and then returns to the oil tank 1. The self-cleaning controller 6 can control the distribution ratio of the proportional reversing valve 3 according to the contamination level of the cooling oil transported in pipeline 21 detected by the cooling oil contamination detection component 4. This allows for a reasonable distribution of the cooling oil and cleaning oil quantities in the oil-cooled electric drive assembly, thereby ensuring improved system oil cleanliness while achieving adaptive matching between cleaning intensity and contamination level. This improves cleaning efficiency, avoids excessive cleaning which increases energy consumption, and enhances the overall machine reliability.

[0063] Specifically, the oil supply pump 2 is an electronic oil pump. The self-cleaning controller 6 is electrically connected to the oil pump controller 22, which is electrically connected to the oil supply pump 2. The oil pump controller 22 is used to receive the target pressure, flow rate and working mode commands issued by the self-cleaning controller 6, and output speed regulation signals to the oil supply pump 2 to adjust its speed and oil supply in real time, so as to ensure that the main oil circuit maintains a safe and stable oil supply in each mode.

[0064] In some embodiments, a flow control valve 7 is also included, which is installed on the pipeline 31 to control the flow rate of cooling oil supply.

[0065] The flow control valve 7 can control the amount of cooling oil delivered to the oil-cooled electric drive assembly according to the signal transmitted by the self-cleaning controller 6, so as to ensure the cooling and lubrication effect.

[0066] In some embodiments, pressure sensor 8 and pressure sensor 9 are also included; pressure sensor 8 is installed on pipeline 21 to detect oil supply pressure; pressure sensor 9 is installed on pipeline 31 and is located between proportional directional valve 3 and flow control valve 7 to detect oil supply pressure; self-cleaning controller 6 is electrically connected to pressure sensor 8 and pressure sensor 9.

[0067] Specifically, the pressure measuring port of pressure sensor 8 is mechanically connected and communicates with the pressure measuring through hole on the outer peripheral wall of pipe 21; the pressure measuring port of pressure sensor 9 is mechanically connected and communicates with the pressure measuring through hole on the outer peripheral wall of pipe 31; and the detection port of impurity monitoring sensor is mechanically connected and communicates with the sampling through hole on the outer peripheral wall of pipe 21.

[0068] The self-cleaning controller 6 adjusts the oil supply pressure of the oil supply pump 2 based on the oil pressure signal in pipeline 21 fed back by pressure sensor 8 and the oil pressure signal in pipeline 31 fed back by pressure sensor 9, so as to ensure that the amount and pressure of cooling oil delivered to the oil-cooled electric drive assembly are stable.

[0069] Specifically, pressure sensor 8 is used to detect the oil pressure at the outlet of oil pump 2 in real time and upload the pressure data to the self-cleaning controller 6. The self-cleaning controller 6 then adjusts the speed of oil pump 2 according to pressure changes, thereby ensuring that the main oil circuit maintains a stable and safe working pressure in all operating modes. Pressure sensor 9 is used to detect the oil pressure at the outlet of proportional directional valve 3 in real time and upload the pressure data to the self-cleaning controller 6. The self-cleaning controller 6 then adjusts the speed of oil pump 2 according to pressure changes, thereby ensuring that the main oil circuit maintains a stable and safe working pressure in all operating modes.

[0070] In some embodiments, the system also includes an overflow valve 10, with the inlet of the overflow valve 10 connected to a pipeline 21 and the outlet of the overflow valve 10 connected to the return port of the oil tank 1.

[0071] The overflow valve 10 can automatically open when the oil pressure in pipeline 21 or pipeline 31 exceeds the set threshold, so that the excess high-pressure oil flows back to the oil tank to prevent the oil supply pump 2 and downstream oil circuit from being overloaded.

[0072] Specifically, a bypass oil pipe 211 is connected to pipeline 21; one end of the bypass oil pipe 211 is connected to and communicates with pipeline 21, and the other end is connected to and communicates with the return port of oil tank 1; an overflow valve 10 is installed on the bypass oil pipe 211, which is used to automatically open when the system oil pressure exceeds the set threshold, so that the excess high-pressure oil flows back to oil tank 1 through the bypass oil pipe 211, thereby limiting the maximum pressure of the oil circuit and preventing the oil supply pump 2 and the downstream oil circuit from overloading; after the oil pressure returns to the normal range, the overflow valve 10 automatically closes, so that the oil re-enters the normal circulation, thereby ensuring that the entire cooling and lubrication system maintains a safe and stable pressure level under various operating conditions.

[0073] In some embodiments, the system further includes a flow divider valve 11; one end of a second pipeline 31 is connected to and communicates with the oil outlet of the proportional directional valve 3, and the other end of the second pipeline 31 is connected to and communicates with the oil inlet of the flow divider valve 11; the oil outlet of the flow divider valve 11 is connected to and communicates with the oil inlet of the end cap oil passage of the motor of the oil-cooled electric drive assembly through a pipeline to supply cooling oil to the motor; the oil outlet of the flow divider valve 11 is connected to and communicates with the oil inlet of the fuel injection passage of the reducer of the oil-cooled electric drive assembly through a pipeline to supply cooling oil to the reducer.

[0074] The cooling oil in the motor and reducer can flow into the oil pan 12 of the oil-cooled electric drive assembly, and the cooling oil outlet is located on the oil pan 12.

[0075] Specifically, the housing 17 of the oil-cooled electric drive assembly is equipped with a circulating oil passage, an end cover oil passage, an oil injection passage, and an oil pan 12. The circulating oil passage and the end cover oil passage are connected, and the oil outlets of both the circulating oil passage and the oil injection passage are connected to the oil pan 12. After entering the end cover oil passage, the cooling oil is divided into two paths. One path enters the circulating oil passage and is sprayed through the oil injection holes to cool the outer surface of the end windings and to cool the stator along the oil passage. The remaining oil flows back to the oil pan 12 from the outlet of the circulating oil passage. The other path enters the end cover oil passage to internally cool the shaft and rotor, and is sprayed through the oil slinger holes to cool the inner surface of the end windings. After entering the oil injection passage, the cooling oil is sprayed through multiple oil injection channels and oil injection holes to the sun gear, planet gears, ring gear, and output shaft bearings, achieving comprehensive lubrication and cooling of the planetary gear set. The sprayed and slinged oil eventually flows into the oil pan 12, is cooled again, and returns to the oil tank, completing the cooling and lubrication cycle.

[0076] The flow divider valve 11 can distribute the cooling oil in a specific direction, delivering the cooling oil to the oil inlet of the motor end cover and the oil inlet of the reducer according to the set flow requirements. This ensures that the stator, rotor, and planetary gear mechanism of the reducer all receive a stable and matched supply of cooling and lubrication oil, thereby guaranteeing the heat dissipation efficiency and transmission reliability of the oil-cooled electric drive under different operating conditions.

[0077] Specifically, the flow control valve 7 is used to precisely regulate the flow rate of the oil entering the diversion valve 11 in the main oil circuit. By adjusting the valve core opening of the flow control valve 7, the flow rate of the main oil circuit is stabilized within the set range, thereby ensuring that the cooling oil passage of the motor and the oil injection passage of the reducer obtain a constant and reliable oil supply under different operating conditions. This avoids insufficient cooling and lubrication caused by load changes, diversion ratio adjustments, or oil pump speed changes, and provides stable upstream flow conditions for subsequent diversion control.

[0078] Specifically, the diverter valve 11 is used to directionally distribute the cooling oil in the main oil circuit downstream of the flow control valve 7. According to the set flow requirements, the oil is delivered to the oil inlet of the motor end cover oil passage and the oil inlet of the reducer injection passage, so that the stator 141 and rotor 142 of the motor 14 and the planetary gear mechanism 151 of the reducer 15 all obtain a stable and matched cooling and lubrication oil supply, thereby ensuring the heat dissipation efficiency and transmission reliability of the electric drive assembly under different operating conditions.

[0079] Specifically, the oil pan 12 is used to collect the high-temperature cooling oil returning from the internal circulation oil passage of the motor 14 and the internal injection oil passage of the reducer 15, and serves as a temporary oil storage chamber for the system. This allows the returned oil to form a stable oil reservoir at the bottom of the oil tank by gravity settling, ensuring that the oil tank 1 has a continuous and stable source of oil. At the same time, the oil pan 12 can naturally settle some large particulate impurities in the returned oil, reducing the risk of impurities entering the upstream oil supply pump 2 and oil circuit, thereby improving the reliability of the entire cooling and lubrication system.

[0080] In some embodiments, a cooler 13 is installed on the return oil line 101.

[0081] The cooler 13 is used to exchange heat and cool down the high-temperature cooling oil discharged from the cooling oil outlet on the oil pan 12. By exchanging heat with the external cooling medium, the oil temperature is restored to a suitable working range, thereby ensuring that the cooling oil has sufficient cooling capacity before entering the internal circulation oil passage of the motor 14 and the internal spray oil passage of the reducer 15. This avoids the decrease in efficiency of the electric drive assembly, the degradation of insulation performance and lubrication failure caused by excessive oil temperature, and improves the thermal stability and reliability of the system under different operating conditions.

[0082] In some embodiments, the cooling oil cleaning assembly 5 includes a cyclone separator 51, a magnetic particle collector 52, a precision filter 53, and a dirt collection and settling chamber 54.

[0083] The oil outlet of the proportional directional valve 3 is connected to the oil inlet of the cyclone separator 51 via the pipeline 32 to distribute the cooling oil to be purified; the oil outlet of the cyclone separator 51 is connected to the oil inlet of the magnetic particle collector 52, the oil outlet of the magnetic particle collector 52 is connected to the oil inlet of the precision filter 53, the oil outlet of the precision filter 53 is connected to the oil inlet of the sludge settling chamber 54, and the oil outlet of the sludge settling chamber 54 is connected to the return port of the oil tank 1 to deliver the purified cooling oil.

[0084] The cyclone separator 51 is used for primary centrifugal pre-cleaning of the cooling oil to be cleaned, removing large particles with higher density, thereby reducing the load on the subsequent magnetic particle collector 52 and precision filter 53. The magnetic particle collector 52 removes magnetic impurities from the cooling oil for secondary cleaning, preventing ferromagnetic particles from entering the precision filter 53 and causing excessive load or clogging of the filter element. The precision filter 53 performs tertiary fine filtration cleaning of the cooling oil, removing residual small particulate impurities. The sedimentation chamber 54 is used for centralized sedimentation and collection of solid impurities, and can reduce the oil flow rate by expanding the flow cross-section, allowing fine particles in the cooling oil to settle to the bottom of the chamber under gravity, thus achieving the final separation of solid impurities from the oil.

[0085] Specifically, the cyclone separator 51 is used to perform primary centrifugal separation on the cooling oil entering the clean branch. By forming a high-speed cyclone in the separation chamber, the oil generates radial centrifugal force, separating large particles of impurities with higher density from the oil and throwing them to the outer wall of the separation chamber. They then settle down along the wall to the lower collection area, thereby achieving rapid and low-resistance removal of large particulate pollutants. This provides a more stable and lower-load pre-treated oil for the subsequent deep filtration of the magnetic particle trap 52 and the precision filter 53.

[0086] Specifically, the magnetic particle collector 52 is used for secondary removal of magnetic impurities from the oil after cyclone separation. By generating a stable magnetic field through permanent magnets or electromagnets arranged in the flow channel, the ferromagnetic particles in the oil that were not removed by the primary centrifugal separation are adsorbed and fixed in the area of ​​the magnetic field. This prevents ferromagnetic particles from entering the precision filter element and causing excessive load or blockage of the filter element, thereby improving the stability and reliability of the subsequent filtration process and further enhancing the overall cleanliness of the cooling oil.

[0087] Specifically, the precision filter 53 is used to perform three-stage fine filtration on the oil after cyclone separation and magnetic capture. It uses high-precision porous filter material to trap residual tiny particulate impurities in the oil, ensuring that the oil reaches a high level of cleanliness before entering the subsequent flow path. This prevents fine particles from entering the motor and reducer and causing wear or blockage, improves the lubrication reliability and overall service life of the system, and achieves graded filtration and centralized treatment.

[0088] Specifically, the sludge settling chamber 54 is used to centrally settle and collect the tiny particulate impurities remaining in the oil after filtration by the precision filter 53, as well as the solid impurities in the system. By expanding the flow cross-section and reducing the oil flow rate, the fine particles in the oil and the residue generated during system operation settle to the bottom of the chamber under the action of gravity, thereby achieving the final separation of solid impurities from the oil. At the same time, the sludge settling chamber 54 can reduce the risk of impurities re-entering the oil circuit and facilitate the centralized cleaning of deposits during the maintenance phase, improving the maintainability and reliability of the cleaning system.

[0089] In some embodiments, the cooling oil cleaning assembly 5 further includes a differential pressure sensor 55 and a weight sensor 56; the differential pressure sensor 55 is mounted on the precision filter 53 to detect the differential pressure between the inlet and outlet of the precision filter 53; the weight sensor 56 is mounted on the sludge settling chamber 54 to detect the amount of weight change; and the self-cleaning controller 6 is electrically connected to the differential pressure sensor 55 and the weight sensor 56.

[0090] Specifically, the pressure measuring port of the differential pressure sensor 55 is mechanically connected and communicates with the pressure measuring through-hole on the inlet and outlet oil pipes of the precision filter 53. The weight sensor 56 is mechanically connected to the bottom of the sludge settling chamber 54.

[0091] The differential pressure sensor 55 monitors the pressure change before and after the filter element in real time by detecting the oil pressure difference between the oil inlet and outlet sides of the precision filter 53, providing a basis for judging the degree of filter element blockage. The weight sensor 56 detects the increase in weight of the dirt collection and settling chamber 54 in real time, providing a basis for judging the state of impurity accumulation, thereby improving the stability and maintainability of the system.

[0092] Specifically, the differential pressure sensor 55 is used to detect the oil pressure difference between the oil inlet side and the oil outlet side of the precision filter 53. By monitoring the pressure change before and after the filter element of the precision filter 53 in real time, the degree of filter element blockage is determined, and the differential pressure signal is uploaded to the self-cleaning controller 6. The self-cleaning controller 6 determines whether the filter element needs manual maintenance based on whether the differential pressure exceeds the set threshold, thereby ensuring that the cleaning system maintains effective filtration capacity and avoiding a decrease in main oil flow or insufficient cooling due to filter element blockage.

[0093] Specifically, the weight sensor 56 detects the increase in weight of impurities deposited at the bottom of the sedimentation chamber 54 in real time. By measuring the weight change of the sediment at the bottom of the chamber, the sensor determines the accumulation state of impurities in the sedimentation chamber 54 and uploads the detection signal to the self-cleaning controller 6. The self-cleaning controller 6 determines whether the sedimentation chamber 54 is fully loaded or close to fully loaded based on whether the weight change reaches the set cleaning threshold. This enables the monitoring and maintenance prompts of the impurity deposition state, thereby providing accurate prompts for maintenance and preventing excessive accumulation of impurities in the sedimentation chamber 54 from affecting cleaning efficiency or causing secondary pollution, thus improving the stability and maintainability of the system.

[0094] Specifically, the cooling oil contamination detection component 4 is an impurity monitoring sensor used to detect the concentration level of particulate contaminants in the cooling oil in real time and upload the detection results to the self-cleaning controller 6. This allows the self-cleaning controller 6 to determine the current contamination level based on changes in oil contamination and trigger the corresponding cleaning mode, thereby achieving automatic adjustment of the cooling oil cleaning intensity and dynamic control of the oil circuit operation status. The self-cleaning controller 6 is used to collect the status parameters and signals of pressure sensor 1 8, pressure sensor 2 9, cooling oil contamination detection component 4, differential pressure sensor 55, and weight sensor 56, and outputs control commands to the oil supply pump 2, proportional directional valve 3, flow control valve 7, and oil pump controller 22 according to the built-in control strategy, so as to realize the pressure regulation of the cooling oil circuit, the diversion control of the cleaning branch, and the automatic switching of the cleaning mode.

[0095] Specifically, the proportional directional valve 3 is used to proportionally distribute the oil output by the oil supply pump 2 under the control of the self-cleaning controller 6. By adjusting the valve core opening of the proportional directional valve 3, the oil is diverted between the main oil circuit and the cleaning branch circuit according to a set ratio, thereby realizing the dynamic switching and flow regulation of the heat dissipation oil circuit and the self-cleaning oil circuit. Thus, different working modes such as normal circulation, low-intensity cleaning, high-intensity cleaning or alarm protection are automatically selected according to the oil contamination level.

[0096] According to another embodiment of the present invention, a control method for an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly is provided. The control method includes the following steps:

[0097] The self-cleaning controller 6 controls the working state of the oil supply pump 2 and thus regulates the oil supply pressure; the cooling oil contamination detection component 4 detects the contamination degree of the cooling oil transported in pipeline 21 in real time and uploads the contamination degree detection result to the self-cleaning controller 6; the self-cleaning controller 6 determines the contamination level of the cooling oil based on the relative relationship between the detected contamination degree and the preset contamination degree benchmark value, and then adjusts the oil output ratio of the proportional reversing valve 3's outlet 1 and outlet 2 according to the determination result of the cooling oil contamination level.

[0098] In some embodiments, the self-cleaning controller 6 can execute different online self-cleaning working modes of the cooling oil according to the determination result of the cooling oil pollution level; the working modes include a normal circulation mode, a low-intensity cleaning mode, a high-intensity cleaning mode, and an alarm and protection mode.

[0099] In the normal circulation mode, the self-cleaning controller 6 controls the opening of the first oil outlet of the proportional reversing valve 3, controls the closing of the second oil outlet of the proportional reversing valve 3, and continuously monitors the pollution degree of the cooling oil conveyed in the first pipeline 21 through the impurity monitoring sensor; the pressure stability is maintained through the first pressure sensor 8 and the second pressure sensor 9.

[0100] In the low-intensity cleaning mode and when the oil-cooled electric drive assembly is in the operating state, the self-cleaning controller 6 controls the oil output of the first oil outlet of the proportional reversing valve 3 to be greater than the oil output of the second oil outlet of the proportional reversing valve 3, and continuously monitors the pollution degree of the cooling oil conveyed in the first pipeline 21; in the low-intensity cleaning mode and when the oil-cooled electric drive assembly is in the shutdown state, the self-cleaning controller 6 controls the closing of the first oil outlet of the proportional reversing valve 3, controls the opening of the second oil outlet of the proportional reversing valve 3, and continuously monitors the pollution degree of the cooling oil conveyed in the first pipeline 21.

[0101] In the high-intensity cleaning mode and when the oil-cooled electric drive assembly is in the operating state, the self-cleaning controller 6 controls the oil output of the first oil outlet of the proportional reversing valve 3 to be less than the oil output of the second oil outlet of the proportional reversing valve 3, and continuously monitors the pollution degree of the cooling oil conveyed in the first pipeline 21; in the high-intensity cleaning mode and when the oil-cooled electric drive assembly is in the shutdown state, the self-cleaning controller 6 controls the closing of the first oil outlet of the proportional reversing valve 3, controls the opening of the second oil outlet of the proportional reversing valve 3, and continuously monitors the pollution degree of the cooling oil conveyed in the first pipeline 21.

[0102] In the alarm and protection mode, the self-cleaning controller 6 controls the opening of the first oil outlet of the proportional reversing valve 3, controls the closing of the second oil outlet of the proportional reversing valve 3, and gives an alarm to prompt the maintenance of the cooling oil cleaning component 5.

[0103] In some embodiments, the cooling oil pollution level is divided into pollution level one, pollution level two, pollution level three, pollution level four, and pollution level five according to the ratio of the pollution degree of the cooling oil conveyed in the first pipeline 21 to the preset pollution degree reference value a.

[0104] When the pollution degree ≥ a×90%, it is determined as pollution level five and enters the alarm and protection mode; when a×70% ≤ pollution degree < a×90%, it is determined as pollution level four and enters the high-intensity cleaning mode; when a×40% ≤ pollution degree < a×70%, it is determined as pollution level three and enters the low-intensity cleaning mode; when a×20% ≤ pollution degree < a×40%, it is determined as pollution level two, and when the pollution degree < a×20%, it is determined as pollution level one, and the normal circulation mode is maintained.

[0105] In some embodiments, the self-cleaning controller 6 is electrically connected via CAN bus 16 to the oil pump controller 22, the cooling oil contamination detection component 4, the flow control valve 7, the pressure sensor 1 8, the pressure sensor 2 9, the differential pressure sensor 55, and the weight sensor 56 to enable signal transmission between the control units.

[0106] Specifically, the electronic oil pump is electrically connected to the oil pump controller 22; the oil pump controller 22, the impurity monitoring sensor, the flow control valve 7, the pressure sensor 1 8, the pressure sensor 2 9, the differential pressure sensor 55, and the weight sensor 56 are connected in parallel on the CAN bus 16, and the CAN bus 16 is electrically connected to the self-cleaning controller 6.

[0107] In some embodiments, the online self-cleaning system for the oil-cooled electric drive assembly cooling oil of the present invention can, in practical applications, coordinate and control the proportional directional valve 3, the oil supply pump 2, and related monitoring components through the self-cleaning controller 6 according to the oil contamination state and vehicle operating conditions, to achieve four working modes: normal circulation, low-intensity cleaning, high-intensity cleaning, and alarm and protection. The specific control flow for each mode is further explained below in conjunction with the working states.

[0108] Specifically, such as Figure 2 As shown, in normal circulation mode, the system operates with the cooling oil circuit fully open. The self-cleaning controller 6 determines that the oil contamination level is not higher than contamination level two based on the contamination level collected by the impurity monitoring sensor, and controls the proportional directional valve 3 to keep the main oil circuit fully open (i.e., pipeline 21, pipeline 31, and return oil pipeline 101 are in a conductive state) and the cleaning branch closed (i.e., pipeline 32 is closed). The oil supply pump 2 continuously supplies oil according to the target speed adjusted by the oil pump controller 22. The cooling oil sequentially enters the end cover oil passage and circulation oil passage of the motor 14 and the injection passage of the reducer 15 through the flow control valve 7 and the diverter valve 11, and performs routine cooling and lubrication on the stator, rotor, and planetary gear set. The system uses pressure sensor 8 and pressure sensor 9 to monitor the main oil circuit pressure in real time to maintain a stable oil supply.

[0109] Specifically, the main oil circuit refers to the oil circuit containing pipe 21 (line 1) and pipe 31 (line 2); the cleaning branch circuit refers to the oil circuit containing pipe 32 (line 3). For example... Figure 4 and Figure 6As shown, in low-intensity cleaning mode, the self-cleaning controller 6 determines that online cleaning is required based on the pollution level being pollution level three. When the vehicle is running, the system is in a state where the cooling oil circuit and the self-cleaning oil circuit are partially connected. The self-cleaning controller 6 adjusts the proportional reversing valve 3 to allow 30%~40% of the oil to enter the cleaning branch. Pressure sensor 29 detects and transmits the pressure of the main oil circuit after diversion. The self-cleaning controller 6 sends a speed adjustment command to the oil pump controller 22 based on the pressure change to maintain a safe flow rate in the main circuit. The oil in the cleaning branch passes sequentially through the vortex diverter 51, the magnetic particle collector 52, the precision filter 53, and the dirt collection and settling chamber 54, completing multi-stage filtration before returning to the oil tank 1. When the pollution level drops to no higher than pollution level two, the system returns to the normal circulation mode; if the pollution level does not drop to pollution level two, the system upgrades to high-intensity cleaning mode. When the vehicle is in a running and parked state, if... Figure 3 As shown, the system is in a fully connected cleaning oil circuit operation state. The self-cleaning controller 6 controls the proportional directional valve 3 to close the main oil circuit and fully open the cleaning branch circuit. The oil pump controller 22 controls the oil supply pump 2 to run at a low speed, so that all oil is circulated and processed within the cleaning branch circuit. The system monitors the cleaning effect based on the data from the impurity monitoring sensor. If the contamination level is not higher than contamination level two, the cleaning ends and the system enters standby mode; if the contamination level is higher than contamination level two, a manual inspection prompt is triggered.

[0110] Specifically, the cooling oil circuit consists of pipe 21 (forming the loop), pipe 31 (forming the loop), the oil passage and circulation passage of the motor 14 end cap, the oil injection passage of the reducer 15, the oil pan 12, the return oil pipe 101, and the oil tank 1, connected in sequence; the self-cleaning oil circuit consists of pipe 32 (forming the loop), the vortex distributor 51, the magnetic particle collector 52, the precision filter 53, the dirt collection and settling chamber 54, and the oil tank 1, connected in sequence. For example... Figure 4 and Figure 7 As shown, in high-intensity cleaning mode, the self-cleaning controller 6 determines that the oil contamination is severe based on a contamination level of four, requiring rapid cleaning with a large flow rate. When the vehicle is running, the system operates with the cooling oil circuit and self-cleaning oil circuit partially connected. The proportional directional valve 3 controls 70%~100% of the main oil circuit flow to be diverted to the cleaning branch. Pressure sensor 2 9 transmits the main oil circuit pressure back in real time, and the self-cleaning controller 6 adjusts the electronic oil pump speed to ensure that the main oil circuit supply is not lower than the minimum safe flow rate. The self-cleaning oil circuit performs high-efficiency filtration throughout the entire process. Changes in oil cleanliness are monitored in real time by the impurity monitoring sensor, and contamination level three is used as the boundary to determine whether high-intensity cleaning can effectively purify the oil. As the oil gradually purifies, when the contamination level drops from level four to level three, it indicates that the oil has been effectively cleaned, and the system downgrades to low-intensity cleaning mode (see the workflow of low-intensity cleaning mode for details). Figure 6If the pollution level remains higher than pollution level three, the system switches to alarm and protection mode. When the vehicle is parked, if... Figure 3 As shown, the system is in a fully connected self-cleaning oil circuit operating state. The self-cleaning controller 6 controls the proportional directional valve 3 to close the main oil circuit and fully open the cleaning branch. At the same time, the oil supply pump 2 drives all the oil to circulate in the self-cleaning oil circuit at low speed, achieving deep cleaning during shutdown. Cleaning ends and the system enters standby mode when the contamination level is not higher than contamination level two; if it is still higher than contamination level two, manual maintenance is prompted.

[0111] Specifically, such as Figure 2 and Figure 8 As shown, in alarm and protection mode, when the impurity monitoring sensor detects a contamination level of five, the self-cleaning controller 6 immediately triggers an alarm and prompts the driver to stop for maintenance. Simultaneously, it controls the proportional directional valve 3 to close the cleaning branch and sends a command to the oil pump controller 22 to operate the oil supply pump 2 at low speed, maintaining a minimum oil supply in the main oil circuit to protect the electric drive assembly's basic cooling needs for a short period. After the vehicle enters maintenance mode, the filter element of the precision filter 53 is removed and replaced, and the sediment inside the collection and settling chamber 54 is cleaned or sludge is removed. After maintenance, the self-cleaning controller 6 drives the oil to circulate in the self-cleaning oil circuit while the vehicle remains stationary, using the impurity monitoring sensor to determine if the oil contamination level has returned to no higher than contamination level two. When the oil contamination level reaches the required level, it automatically exits the alarm mode; if the contamination level is still high, it prompts that the coolant needs to be replaced. It should be noted that: Figures 5 to 8 In this context, all Y values ​​represent "yes" and all N values ​​represent "no".

[0112] The pressure sensor 8, pressure sensor 9, impurity monitoring sensor, differential pressure sensor 55, and weight sensor 56 of this invention all communicate with the self-cleaning controller 6 via the CAN bus 16, forming a real-time dynamic closed-loop oil condition monitoring system. Pressure sensor 8 monitors the oil pressure at the outlet of the oil supply pump 2; pressure sensor 9 monitors the oil pressure at the outlet of the proportional directional valve 3; the impurity monitoring sensor identifies the oil contamination level; differential pressure sensor 55 determines the filter element blockage status; and weight sensor 56 determines whether the sedimentation chamber is fully loaded. The self-cleaning controller 6 integrates data from all sensors to intelligently adjust the opening of the proportional directional valve 3, the speed of the oil supply pump 2, and the cleaning mode, achieving automated management of the oil circulation status and filtration intensity.

[0113] This invention achieves automated oil cleaning under various operating conditions, including vehicle operation, parking, light load, and heavy load, by dynamically switching between the main oil circuit and the cleaning branch circuit. This avoids problems such as decreased cooling performance, accelerated mechanical wear, or oil circuit blockage caused by the accumulation of contaminants. Because the cleaning branch circuit uses a tiered filtration structure, it effectively extends the service life of the filter element and reduces the frequency of manual maintenance. Simultaneously, it improves the cooling capacity of the motor stator, rotor, and planetary gear set, ensuring the long-term reliability of the electric drive assembly.

[0114] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0115] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. An online self-cleaning system for cooling oil of an oil-cooled electric drive assembly, the oil-cooled electric drive assembly having a cooling oil inlet and a cooling oil outlet on a housing of the oil-cooled electric drive assembly, the online self-cleaning system comprising: include: An oil tank (1) and an oil supply pump (2), wherein the oil supply pump (2) is connected to the oil tank (1) for drawing cooling oil; The proportional directional valve (3) is connected to the oil inlet of the proportional directional valve (3) via a pipeline (21) to supply oil. The oil outlet of the proportional directional valve (3) is connected to the cooling oil inlet via a pipeline (31) to distribute cooling oil. The cooling oil outlet is connected to the return port of the oil tank (1) via a return oil pipeline (101) to return cooling oil. Cooling oil contamination detection component (4), which is connected to the pipeline (21) to detect the contamination level of the cooling oil it transports; The cooling oil cleaning assembly (5) has its outlet 2 of the proportional reversing valve (3) connected to the inlet of the cooling oil cleaning assembly (5) via pipeline 3 (32) to distribute the cooling oil to be purified; the outlet of the cooling oil cleaning assembly (5) is connected to the return port of the oil tank (1) to deliver the purified cooling oil. The self-cleaning controller (6) is electrically connected to the oil supply pump (2), the proportional reversing valve (3) and the cooling oil contamination detection component (4) to receive the cooling oil contamination data fed back by the cooling oil contamination detection component (4) and thereby control the working state of the oil supply pump (2) and the proportional reversing valve (3). A flow control valve (7) is installed on the second pipeline (31) to control the flow rate of cooling oil supply; Pressure sensor one (8) and pressure sensor two (9); pressure sensor one (8) is installed on the pipeline one (21) to detect the oil supply pressure; pressure sensor two (9) is installed on the pipeline two (31) and between the proportional directional valve (3) and the flow control valve (7) to detect the oil supply pressure; the self-cleaning controller (6) is electrically connected to pressure sensor one (8) and pressure sensor two (9); The cooling oil cleaning assembly (5) includes a differential pressure sensor (55) and a weight sensor (56); the differential pressure sensor (55) is installed on the precision filter (53) to detect the differential pressure value between the inlet and outlet of the precision filter (53); the weight sensor (56) is installed on the sludge settling chamber (54) to detect its weight change; the self-cleaning controller (6) is electrically connected to the differential pressure sensor (55) and the weight sensor (56).

2. The online self-cleaning system for cooling oil in an oil-cooled electric drive assembly according to claim 1, characterized in that, It also includes an overflow valve (10), the oil inlet of which is connected to the pipeline (21), and the oil outlet of which is connected to the return port of the oil tank (1).

3. The online self-cleaning system for cooling oil in an oil-cooled electric drive assembly according to claim 1, characterized in that, It also includes a flow divider valve (11); one end of the second pipeline (31) is connected to the oil outlet of the proportional directional valve (3), and the other end of the second pipeline (31) is connected to the oil inlet of the flow divider valve (11); the oil outlet of the flow divider valve (11) is connected to the oil inlet of the end cap oil passage of the motor of the oil-cooled electric drive assembly through a pipeline to supply cooling oil to the motor; the oil outlet of the second flow divider valve (11) is connected to the oil inlet of the fuel injection passage of the reducer of the oil-cooled electric drive assembly through a pipeline to supply cooling oil to the reducer. The cooling oil in the motor and the reducer can flow into the oil pan (12) of the oil-cooled electric drive assembly, and the cooling oil outlet is located on the oil pan (12).

4. The online self-cleaning system for cooling oil in an oil-cooled electric drive assembly according to claim 1, characterized in that, The cooling oil cleaning assembly (5) also includes a cyclone separator (51), a magnetic particle collector (52), a precision filter (53), and a dirt collection and settling chamber (54). The oil outlet of the proportional directional valve (3) is connected to the oil inlet of the cyclone separator (51) via the pipeline (32) to distribute the cooling oil to be purified; the oil outlet of the cyclone separator (51) is connected to the oil inlet of the magnetic particle collector (52), the oil outlet of the magnetic particle collector (52) is connected to the oil inlet of the precision filter (53), the oil outlet of the precision filter (53) is connected to the oil inlet of the sludge settling chamber (54), and the oil outlet of the sludge settling chamber (54) is connected to the oil return port of the oil tank (1) to deliver the purified cooling oil.

5. A control method for an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly, characterized in that, Using the online self-cleaning system for cooling oil of an oil-cooled electric drive assembly as described in any one of claims 1-4, the control method includes the following steps: The self-cleaning controller (6) controls the working state of the oil supply pump (2) and thus regulates the oil supply pressure; the cooling oil contamination detection component (4) detects the contamination degree of the cooling oil transported in pipeline 1 (21) in real time and uploads the contamination degree detection result to the self-cleaning controller (6); the self-cleaning controller (6) determines the contamination level of the cooling oil according to the relative relationship between the detected contamination degree and the preset contamination degree benchmark value, and then adjusts the oil output ratio of the oil outlet 1 and the oil outlet 2 of the proportional reversing valve (3) according to the determination result of the cooling oil contamination level.

6. The control method for an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly according to claim 5, characterized in that, The self-cleaning controller (6) can execute different online self-cleaning modes of cooling oil according to the results of the cooling oil contamination level determination; the working modes include normal circulation mode, low intensity cleaning mode, high intensity cleaning mode, and alarm and protection mode; In normal circulation mode, the self-cleaning controller (6) controls the opening of the first oil outlet of the proportional directional valve (3), controls the closing of the second oil outlet of the proportional directional valve (3), and monitors the contamination level of the cooling oil transported in pipeline (21) in real time. When the oil-cooled electric drive assembly is in the operating state under the low-intensity cleaning mode, the self-cleaning controller (6) controls the oil output of the first oil outlet of the proportional reversing valve (3) to be greater than the oil output of the second oil outlet of the proportional reversing valve (3), and monitors the pollution degree of the cooling oil conveyed in the first pipeline (21) in real time; when the oil-cooled electric drive assembly is in the shutdown state under the low-intensity cleaning mode, the self-cleaning controller (6) controls the first oil outlet of the proportional reversing valve (3) to be closed, controls the second oil outlet of the proportional reversing valve (3) to be opened, and monitors the pollution degree of the cooling oil conveyed in the first pipeline (21) in real time; When the oil-cooled electric drive assembly is in the operating state under the high-intensity cleaning mode, the self-cleaning controller (6) controls the oil output of the first oil outlet of the proportional reversing valve (3) to be less than the oil output of the second oil outlet of the proportional reversing valve (3), and monitors the pollution degree of the cooling oil conveyed in the first pipeline (21) in real time; when the oil-cooled electric drive assembly is in the shutdown state under the high-intensity cleaning mode, the self-cleaning controller (6) controls the first oil outlet of the proportional reversing valve (3) to be closed, controls the second oil outlet of the proportional reversing valve (3) to be opened, and monitors the pollution degree of the cooling oil conveyed in the first pipeline (21) in real time; In the alarm and protection mode, the self-cleaning controller (6) controls the first oil outlet of the proportional reversing valve (3) to be opened, controls the second oil outlet of the proportional reversing valve (3) to be closed, and gives an alarm prompt to repair the cooling oil cleaning component (5).

7. The control method for an online self-cleaning system for cooling oil in an oil-cooled electric drive assembly according to claim 6, characterized in that, The cooling oil pollution levels are divided into pollution level one, pollution level two, pollution level three, pollution level four and pollution level five according to the ratio of the pollution degree of the cooling oil conveyed in the first pipeline (21) to the preset pollution degree reference value a; When the pollution degree ≥ a×90%, it is determined as pollution level five and enters the alarm and protection mode; when a×70% ≤ pollution degree < a×90%, it is determined as pollution level four and enters the high-intensity cleaning mode; when a×40% ≤ pollution degree < a×70%, it is determined as pollution level three and enters the low-intensity cleaning mode; when a×20% ≤ pollution degree < a×40%, it is determined as pollution level two, and when the pollution degree < a×20%, it is determined as pollution level one, and the normal circulation mode is maintained.

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