Drive system

Abstract

A driving system disclosed by the present invention comprises a controller assembly, a driving motor, a generator and a main shell, the controller assembly comprises a PDM shell, a PDM module and a controller module, the PDM module is installed inside the PDM shell, the controller module is installed below the PDM shell, the PDM shell is installed above the main shell, the driving motor is installed on the main shell, and the power generator is installed on the main shell. The controller module is inserted into the main shell; the cooling circuit comprises a PDM cooling water channel arranged in the PDM module, a controller cooling water channel arranged in the controller module, a switching water channel arranged in the PDM shell and a main shell cooling water channel arranged in the main shell. And the PDM cooling water channel, the controller cooling water channel, the switching water channel and the main shell cooling water channel are communicated in sequence. The device has the advantages of being lower in design cost, convenient to install and compact in structure.

Description

Technical Field

[0001] This invention relates to the technical field of vehicles, and more particularly to a drive system. Background Technology

[0002] An existing drive system includes a main housing and a controller assembly, with the controller assembly installed inside the main housing. Because the controller assembly has a certain height and includes multiple connectors and connecting busbars, after the controller assembly is inserted into the main housing from top to bottom, the connectors need to pass laterally through the main housing to complete the assembly, and the connecting busbars need to extend downwards to connect with the motor inside the main housing.

[0003] Furthermore, since there is only the outer shell structure of the main shell, the main shell also needs to be equipped with a piping structure that connects to the cooling water channel, making the design of the main shell more complex, more difficult, and more difficult to assemble.

[0004] Therefore, it is necessary to design a drive system that has lower design costs, is easier to install, and has a more compact structure. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a drive system with lower design cost, convenient installation and compact structure.

[0006] The present invention provides a drive system including a controller assembly, a drive motor, a generator, and a main housing. The controller assembly includes a PDM housing, a PDM module, and a controller module. The PDM module is installed inside the PDM housing, the controller module is installed below the PDM housing, the PDM housing is installed above the main housing, and the controller module is inserted into the interior of the main housing. It also includes a cooling circuit, which includes a PDM cooling water channel in the PDM module, a controller cooling water channel in the controller module, a transfer water channel in the PDM housing, and a main housing cooling water channel in the main housing. The PDM cooling water channel, the controller cooling water channel, the transfer water channel, and the main housing cooling water channel are connected in sequence.

[0007] Furthermore, the PDM housing is provided with a water inlet, which is directly connected to the PDM cooling water channel.

[0008] Furthermore, the PDM housing is provided with a return water inlet and a water outlet. The return water inlet is connected to one end of the transfer water channel, and the water outlet is connected to the other end of the transfer water channel. The return water inlet is directly connected to the controller cooling water channel, and the water outlet is directly connected to the main housing cooling water channel.

[0009] Furthermore, one side of the PDM housing is provided with a high-voltage connector for inserting a high-voltage connector. At the corner of the adjacent side of the side where the high-voltage connector is located, there is an outwardly protruding boss. The interior of the boss forms an installation cavity, and the wiring harness of the high-voltage connector runs through the installation cavity.

[0010] Furthermore, an installation platform is provided on the side where the boss is located, and the water inlet, the water return outlet and the water outlet are all located on the installation platform.

[0011] Furthermore, the main housing includes a controller housing, a drive motor housing, a generator housing, and a gearbox housing. The controller housing is disposed above the generator housing, the drive motor housing is disposed on the side of the controller housing, and the gearbox housing is located below the controller housing and on the back of the generator housing. The main housing cooling water channel includes a control section, a power generation section, and an oil cooling section in sequence. The control section is located in the controller housing, the power generation section is located between the generator housing and the controller housing, and the oil cooling section is located between the generator housing and the drive motor housing and is connected to the oil cooler.

[0012] Furthermore, the main housing also includes a drive wiring cavity, which is located between the generator housing and the drive motor housing, and the oil cooling section is disposed in the drive wiring cavity.

[0013] Furthermore, a power generation wiring cavity is provided between the controller housing and the generator housing, and the power generation wiring cavity is located outside the power generation section.

[0014] Furthermore, it also includes a drive adapter copper busbar, which passes through the controller housing and extends into the drive wiring cavity.

[0015] Furthermore, it also includes a power generation adapter copper busbar, which passes through the controller housing and extends into the power generation wiring cavity.

[0016] The above technical solution has the following beneficial effects: This invention features a separate PDM housing connected to the main housing. After connection, the controller module is inserted into the main housing, sharing a portion of the housing. This invention eliminates the need to install the entire controller assembly inside the main housing; only the controller module is installed. This simplifies connector installation by allowing the multiple connectors on the PDM housing to connect directly to the PDM housing, eliminating the need for connections to the main housing. Furthermore, the low height of the controller module facilitates connection of the copper busbars to the motor inside the main housing. In this invention, some of the cooling water channels and interfaces originally located in the main housing are moved to the PDM housing, simplifying the design of the cooling water channels in the main housing. Furthermore, in existing main housing cooling water channels, water must flow from bottom to top into the upper PDM cooling water channels, resulting in significant water resistance. In this invention, water flows directly from the PDM housing into the PDM cooling water channels, reducing water resistance and improving cooling efficiency. Attached Figure Description

[0017] The disclosure of this invention will become more readily understood by referring to the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings: Figure 1 This is a perspective view of the drive system in one embodiment of the present invention; Figure 2 This is an exploded view of the drive system in one embodiment of the present invention; Figure 3 This is a schematic diagram of a cooling circuit in one embodiment of the present invention; Figure 4 This is a perspective view of the controller assembly in one embodiment of the invention; Figure 5 This is a perspective view of the PDM housing and PDM module in one embodiment of the present invention; Figure 6 This is a top view of the PDM housing and PDM module in one embodiment of the present invention; Figure 7 This is a bottom view of the PDM housing and PDM module in one embodiment of the present invention; Figure 8 This is a perspective view of the main housing in one embodiment of the present invention; Figure 9 This is a top view of the main housing in one embodiment of the present invention; Figure 10 This is a longitudinal sectional view of the main housing in one embodiment of the present invention; Figure 11 This is a perspective sectional view of the main housing in one embodiment of the present invention; Figure 12 This is a side view of the main housing in one embodiment of the present invention; Figure 13 This is a partial schematic diagram of the main housing in one embodiment of the present invention; Figure 14 This is a partial schematic diagram of the main housing in one embodiment of the present invention, omitting the drive motor copper busbar assembly and the generator copper busbar assembly; Figure 15 This is a partially enlarged view of an oil cooler in one embodiment of the present invention; Figure 16 This is a partially enlarged view of an embodiment of the present invention, omitting the main housing of the oil cooler; Figure 17 This is an exploded view of the controller assembly in one embodiment of the present invention; Figure 18 This is a perspective view of the upper cover plate in one embodiment of the present invention; Figure 19 This is a perspective view of the lower cover plate in one embodiment of the present invention; Figure 20 This is a perspective view of the lower cover plate and the PDM housing in one embodiment of the present invention; Figure 21 This is a perspective view of the cover plate in one embodiment of the present invention; Figure 22 This is an inverted schematic diagram of the PDM housing and controller module after installation in one embodiment of the present invention; Figure 23 This is an exploded view of the PDM housing and controller module in one embodiment of the present invention; Figure 24 This is an inverted schematic diagram of the controller module in one embodiment of the present invention; Figure 25 This is a perspective view of the generator busbar assembly in one embodiment of the present invention; Figure 26 This is a schematic diagram of the generator busbar assembly omitting the second insulating support sleeve in one embodiment of the present invention. Figure 1 ; Figure 27 This is a schematic diagram of the generator busbar assembly omitting the second insulating support sleeve in one embodiment of the present invention. Figure 2 ; Figure 28 This is a perspective view of the drive motor copper busbar assembly in one embodiment of the present invention; Figure 29 This is a schematic diagram of the drive motor copper busbar assembly omitting the first insulating support sleeve in one embodiment of the present invention. Figure 1 ; Figure 30 This is a schematic diagram of the drive motor copper busbar assembly omitting the first insulating support sleeve in one embodiment of the present invention. Figure 2 .

[0018] Reference table for attached figures: Controller assembly 10: Controller cover 1: upper cover 11, upper cover body 111, protrusion 112, lower cover 12, lower cover body 121, connector mounting platform 122, connector plate 1221, support plate 1222, connector hole 1221a, first bolt hole 1221b, first connector 13, connector end 131, sealing plate 132, sealing ring 1321, second bolt hole 1322; PDM Module 2: Water Inlet 21, High Voltage Wiring Harness 22; Controller module 3: drive motor power module 31, generator power module 32, drive motor copper busbar group 33, first copper busbar 331, second copper busbar 332, third copper busbar 333, first insulating support sleeve 334, generator copper busbar group 34, fourth copper busbar 341, fifth copper busbar 342, sixth copper busbar 343, second insulating support sleeve 344; PDM housing 4: Inlet 41, return outlet 42, outlet 43, high pressure connector 44, boss 45, mounting platform 46, positioning pin 47, fixing pin 48; Cooling circuit 5: PDM cooling water channel 51, controller cooling water channel 52, transfer water channel 53, main shell cooling water channel 54, control section 541, power generation section 542, oil cooling section 543, guide plate 5421; 6. Drive converter copper busbar; 7. Power generation converter copper busbar; 8. Oil cooler; Main housing 20: controller housing 201, drive motor housing 202, generator housing 203, gearbox housing 204, drive wiring cavity 205, generator wiring cavity 206, motor cover 207, water channel cover 208, drive wiring hole 2011, generator wiring hole 2012, drive side mounting port 2013, generator side mounting port 2014. Detailed Implementation

[0019] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0020] It is readily understood that, based on the technical solution of this invention, various structural and implementation methods can be interchanged by those skilled in the art without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of the invention.

[0021] The directional terms such as up, down, left, right, front, back, front, back, top, and bottom mentioned or possibly used in this specification are defined relative to the structures shown in the accompanying drawings. They are relative concepts and may therefore vary depending on their location and usage. Therefore, these or other directional terms should not be interpreted as restrictive.

[0022] In some embodiments of the present invention, such as Figures 1-4 As shown, the drive system includes a controller assembly 10, a drive motor, a generator, and a main housing 20. The controller assembly 10 includes a PDM housing 4, a PDM module 2, and a controller module 3. The PDM module 2 is installed inside the PDM housing 4, and the controller module 3 is installed below the PDM housing 4. The PDM housing 4 is installed above the main housing 20, and the controller module 3 is inserted into the main housing 20. It also includes a cooling circuit 5, which includes a PDM cooling water channel 51 in the PDM module 2, a controller cooling water channel 52 in the controller module 3, a transfer water channel 53 in the PDM housing 4, and a main housing cooling water channel 54 in the main housing 20. The PDM cooling water channel 51, the controller cooling water channel 52, the transfer water channel 53, and the main housing cooling water channel 54 are connected in sequence.

[0023] Specifically, such as Figure 1 As shown, the controller assembly 10 is mounted on top of the main housing 20, wherein the PDM housing 4 of the controller assembly 10 is directly connected to the main housing 20.

[0024] like Figure 2 As shown, the controller assembly 10 includes a controller cover 1, a PDM module 2 and a PDM housing 4. The PDM module 2 is installed inside the PDM housing 4, and the controller cover 1 is placed on top of the PDM housing 4.

[0025] The controller cover 1 is installed on top of the PDM housing 4, and the edge of the controller cover 1 is aligned with the upper edge of the PDM housing 4 and connected by multiple bolts. Multiple wire harnesses of the PDM module 2 are arranged in the PDM housing 4 and connected to multiple connectors provided on the PDM housing 4.

[0026] The main housing 20 includes a controller housing 201, a drive motor housing 202, a generator housing 203, and a motor cover 207. The controller housing 201 is used to install the controller module 3, the drive motor housing 202 is used to install the drive motor, and the generator housing 203 is used to install the generator.

[0027] like Figure 4 As shown, the controller module 3 is installed below the PDM housing 4, and the controller module 3 is used to insert into the controller housing 201 of the main housing 20.

[0028] When assembling the controller assembly 10 with the external main housing 20, the controller module 3 is inserted into the main housing 20 from top to bottom; then, the lower edge of the PDM housing 4 is aligned with the upper edge of the main housing 20 and connected by multiple bolts. In the assembled controller assembly 10, the controller cover 1 and the PDM housing 4 are located above the main housing 20, and the controller module 3 is located inside the main housing 20.

[0029] In this embodiment, a separate PDM housing 4 is provided. The controller assembly 10 shares a housing portion with the main housing 20. The PDM module 2, controller cover 1, and PDM housing 4 are located above the main housing 20. In this embodiment, it is not necessary to install the entire controller assembly 10 inside the main housing 20; only the controller module 3 is installed inside. This means that the multiple connectors on the PDM housing 4 do not need to be connected to the main housing 20, but can be directly connected to the PDM housing 4 or the controller cover 1, simplifying the installation of the connectors. Furthermore, the controller module 3 has a lower height, facilitating the connection of its copper busbars to the motor inside the main housing 20, further simplifying the installation process. For ease of understanding, Figure 3 The hollow portion of the cooling circuit through which the coolant flows has been solidified; in fact... Figure 3 What is shown are the hollow structures, pipes, or interfaces set in the various modules and housings.

[0030] The cooling circuit 5 passes through the PDM cooling water channel 51, the controller cooling water channel 52, the transfer water channel 53 and the main housing cooling water channel 54 in sequence, that is, it passes through the PDM module 2, the controller module 3, the PDM housing 4 and the main housing 20 in sequence, realizing the series connection of the cooling circuit 5 from the controller assembly 10 to the main housing 20, which is beneficial to improving the cooling efficiency.

[0031] In this embodiment, some of the cooling water channels and interfaces originally located in the main housing 20 are moved to the PDM housing 4, simplifying the design of the cooling water channels in the main housing 20. Furthermore, in this embodiment, the controller cooling water channel 52 needs to return to the PDM housing 4 before connecting to the main housing 20. This is because the controller cooling water channel 52 is a sub-component mounted on the PDM housing 4. If the controller cooling water channel 52 does not return to the PDM housing 4 and is directly connected to the main housing 20, the connection between the controller cooling water channel 52 and the main housing 20 is unreliable due to the lack of physical connection, making it susceptible to dimensional chain effects, vibrations, etc. Therefore, only by returning to the PDM housing 4 and then connecting to the main housing 20, establishing a physical connection between the PDM housing 4 and the main housing 20, can the installation be reliable.

[0032] Furthermore, such as Figure 5 As shown, the PDM housing 4 has a water inlet 41, which is directly connected to the PDM cooling water channel 51.

[0033] Specifically, such as Figure 5As shown, the water inlet 41 is located on one side wall of the PDM housing 4, directly inside the PDM housing 4, and directly connected to the PDM cooling water channel 51 in the PDM module 2. After the coolant enters from the outside through the water inlet 41, it flows directly into the PDM cooling water channel 51 to cool the PDM module 2. Here, "the water inlet 41 is directly connected to the PDM cooling water channel 51" means that the inlet and the channel are directly connected, and the connection surface is sealed with a sealing ring end face seal.

[0034] In existing main casings, cooling water flows from bottom to top into the upper PDM cooling water channel, resulting in significant resistance. In this embodiment, water flows directly from the inlet 41 of the PDM casing 4 into the PDM cooling water channel 51, reducing channel resistance and improving cooling efficiency.

[0035] Furthermore, such as Figures 5-7 As shown, the PDM housing 4 has a return water inlet 42 and a water outlet 43. The return water inlet 42 is connected to one end of the transfer water channel 53, and the water outlet 43 is connected to the other end of the transfer water channel 53. The return water inlet 42 is directly connected to the controller cooling water channel 52, and the water outlet 43 is directly connected to the main housing cooling water channel 54.

[0036] Specifically, such as Figure 7 As shown, the bottom of the PDM module 2 is provided with a water inlet 21 facing the controller module 3. Since the controller module 3 is installed below the PDM housing 4, the water inlet 21 is directly connected to the controller cooling water channel 52 of the controller module 3. The coolant flows from the PDM cooling water channel 51 through the water inlet 21 to one end of the controller cooling water channel 52 to cool the controller module 3.

[0037] The other end of the controller cooling water channel 52 is directly connected to the return water port 42 of the PDM housing 4, allowing the coolant to return to the PDM housing 4. The return water port 42 is connected to the outlet 43 via a transition water channel 53, which is located inside the PDM housing 4. Here, "direct connection" refers to the direct docking of the water inlet and water channel, with a sealing ring end face seal on the connection surface.

[0038] Since the lower edge of the PDM housing 4 is connected to the main housing 20, and the outlet 42 is directly connected to the main housing cooling water channel 54 in the main housing 20 below, the coolant flows into the main housing 20 after passing through the PDM housing 4.

[0039] Therefore, by directly opening the inlet 41, return 42, and outlet 43 inside the PDM housing 4, the PDM cooling water channel 51, the controller cooling water channel 52, and the main housing cooling water channel 54 are connected in series. This embodiment eliminates the need for separate external piping on the PDM housing 4 and the main housing 20, except that the inlet 41 of the PDM housing 4 may require an external pipe connection to an external coolant supply. The series connection of the cooling water channels within the housing reduces the need for water pipes, lowering costs, assembly time, and assembly difficulty; furthermore, the internal arrangement facilitates heat dissipation from the internal functional modules.

[0040] Furthermore, such as Figure 6 As shown, one side of the PDM housing 4 is provided with a high-voltage connector 44 for inserting a high-voltage connector. At the corner of the adjacent side of the side where the high-voltage connector 44 is located, there is an outwardly protruding boss 45. The interior of the boss 45 forms an installation cavity, and the wiring harness of the high-voltage connector runs through the installation cavity.

[0041] Specifically, such as Figure 6 As shown, after the high-voltage wiring harness 22 of the high-voltage connector enters the PDM housing 4 from the high-voltage connector port 44, the high-voltage wiring harness 22 is bent and runs along the inner wall of the PDM housing 4. The boss 45 is located at the corner of the adjacent side. Because the boss 45 protrudes outward, it forms an installation cavity at the corner, providing space for the bending of the high-voltage wiring harness 22. Furthermore, the boss 45 can resist collisions from the side, reducing deformation of the high-voltage connector port 44 during collisions, ensuring the safety and connection stability of the high-voltage connector port 44.

[0042] Furthermore, such as Figures 5-7 As shown, a mounting platform 46 is also provided on the side where the boss 45 is located, and the water inlet 41, water outlet 42 and water outlet 43 are all located on the mounting platform 46.

[0043] Specifically, such as Figure 5 As shown, a boss 45 is provided at the corner of this side of the PDM housing 4, and the outer wall of the boss 45 extends outward with a certain thickness relative to the side wall of the PDM housing 4. Therefore, a certain space is left outside this side wall of the PDM housing 4. The mounting platform 46 utilizes this space and is set along the bottom surface of this side wall to connect the boss 45 and the side wall of the PDM housing 4 into a whole.

[0044] like Figure 6 As shown, the water inlet 41 is located on the upper surface of the mounting platform 46. The water inlet 41 passes through the side wall of the PDM housing 4 and enters the interior of the PDM housing 4 to communicate with the PDM module 2.

[0045] like Figure 7As shown, the return water inlet 42 and the outlet water inlet 43 are located on the lower surface of the mounting platform 46, facing the controller module 3 and the main housing 20 below, so as to facilitate connection with the controller cooling water channel 52 and the main housing cooling water channel 54.

[0046] In this embodiment, the positions of the boss 45 and the mounting platform 46 are arranged in a compact and reasonable manner. In addition to protecting the high-pressure connector 44, the boss 45 also protects the inlet 41 and the outlet 42.

[0047] Preferably, in addition to the high-voltage connector 44, the outer wall of the PDM housing 4 is provided with other connectors. These connectors only need to be directly connected to the PDM housing 4 and do not need to be inserted into the main housing 20. Therefore, the assembly process is simplified and the installation difficulty is reduced.

[0048] Furthermore, such as Figure 8 As shown, the main housing 20 includes a controller housing 201, a drive motor housing 202, a generator housing 203, and a gearbox housing 204. The controller housing 201 is located above the generator housing 203, the drive motor housing 202 is located on the side of the controller housing 201, and the gearbox housing 204 is located below the controller housing 201 and on the back of the generator housing 203.

[0049] like Figures 9-10 As shown, the main housing cooling water channel 54 includes a control section 541, a power generation section 542, and an oil cooling section 543 in sequence. The control section 541 is located in the controller housing 201, the power generation section 542 is located between the generator housing 203 and the controller housing 201, and the oil cooling section 543 is located between the generator housing 203 and the drive motor housing 202 and is connected to the oil cooler 8.

[0050] Specifically, such as Figure 10 As shown, the control section 541 extends longitudinally downward along the side wall of the controller housing 201, and then extends laterally along the bottom surface of the controller housing 201 to connect with the power generation section 542. The control section 541 connects the coolant from the PDM housing 4 to the main housing 20.

[0051] The power generation section 542 is located below the bottom surface of the controller housing 201. For example... Figure 9 As shown, a water channel cover plate 208 is provided on the bottom surface of the controller housing 201. The water channel cover plate 208 covers the top of the power generation section 542 and is sealed to the controller housing 201.

[0052] like Figures 9-11As shown, the power generation section 542 is located above the generator housing 203 and is completely isolated from the generator housing 203. The power generation section 542 can simultaneously cool the controller module 3 above and the generator below.

[0053] like Figures 9-11 As shown, the oil cooling section 543 is connected to the oil cooler 8 from the generator section 542 in a downward inclined direction to cool the oil cooler 8. After circulating in the oil cooler 8, the coolant flows out of the oil cooler 8 and enters the vehicle's coolant system. After cooling the coolant, it is sent back into the inlet 41 from the external coolant supply end.

[0054] Therefore, in this embodiment, the cooling circuit can sequentially cool the PDM module 2, the controller module, the generator, and the oil cooler 8, thereby improving the utilization rate of the coolant.

[0055] Better, such as Figure 15 As shown, the oil cooler 8 is mounted on the outer wall of the main housing 20. Figure 15 As shown, the end of the oil cooling section 543 is inserted into the outer wall of the main housing 20, which is directly connected to the oil cooler 8. The coolant cools the oil cooler 8 in the oil cooler and is finally discharged from the oil cooler 8.

[0056] Better, such as Figure 13 As shown, the generator section 542 also includes a guide plate 5421. Multiple guide plates 5421 are disposed on the outer wall of the generator housing 203. The guide plates 5421 guide the coolant from the control section 541 to the oil cooling section 543, and enable the coolant to flow fully into each area of ​​the generator section 542, thereby improving the cooling efficiency.

[0057] Furthermore, such as Figure 13 As shown, the main housing 20 also includes a drive wiring cavity 205, which is located between the generator housing 203 and the drive motor housing 202. The oil cooling section 543 is disposed in the drive wiring cavity 205.

[0058] Specifically, such as Figure 12 As shown, the oil cooler 8 is installed below the drive wiring cavity 205, which is located between the generator housing 203 and the drive motor housing 202. This makes good use of the space between the generator housing 203 and the drive motor housing 202, making the arrangement of the main housing 20 more compact. like Figure 11 As shown, the oil cooling section 543 passes through the drive wiring cavity 205 and connects to the oil cooler 8. The oil cooling section 543 is integrated in the main housing 20, eliminating the need for external piping and connecting directly to the oil cooler 8, while also utilizing the space of the drive wiring cavity 205.

[0059] Furthermore, such as Figure 12 As shown, it also includes a drive adapter copper busbar 6, which passes through the controller housing 201 and extends into the drive wiring cavity 205.

[0060] Specifically, such as Figure 9 As shown, the bottom surface of the controller housing 201 has a drive wiring hole 2011, and the drive adapter copper busbar 6 passes through the drive wiring hole 2011 and enters the drive wiring cavity 205 below.

[0061] like Figure 12 As shown, the controller housing 201 has a drive-side mounting port 2013 on its side. One end of the drive adapter 6 protrudes from the drive-side mounting port 2013 for easy external wiring connection, while the other end of the drive adapter 6 extends into the drive wiring cavity 205. The drive wiring cavity 205 has a sealing structure to isolate the controller housing from the main housing. The three terminals of the drive adapter 6 located in the drive wiring cavity 205 are arranged longitudinally for easy connection to the drive motor on the right side.

[0062] The drive adapter 6 has three terminals arranged horizontally in the controller housing 201, which facilitates connection with the drive motor busbar 33 of the controller integrated assembly 3.

[0063] like Figure 14 As shown, the drive adapter 6 is installed in the controller housing 201. Figure 13 As shown, the drive motor copper busbar group 33 is connected to the drive adapter 6.

[0064] Furthermore, such as Figure 12 As shown, a power generation wiring cavity 206 is also provided between the controller housing 201 and the generator housing 203, and the power generation wiring cavity 206 is located on the outside of the power generation section 542.

[0065] Since the generator housing 203 is cylindrical, the generator wiring cavity 206 makes good use of the triangular space in the upper left corner of the generator housing 203, making the structure of the main housing 20 more compact and the layout more reasonable.

[0066] like Figure 11 As shown, the power generation wiring cavity 206 is located outside the power generation section 542. Since the space of the power generation wiring cavity 206 is relatively small, interference with the cooling circuit is avoided.

[0067] Furthermore, such as Figures 12-14 As shown, it also includes a power generation adapter 7, which extends into the power generation wiring cavity 206 after passing through the controller housing 201.

[0068] like Figure 14 As shown, one end of the power generation adapter 7 is installed in the controller housing 201. Figure 12As shown, the generator adapter 7 is connected to the generator busbar 34 of the controller module 3. Figure 11 As shown, a generator side mounting port 2014 is provided on the side wall of the controller housing 201. One end of the generator adapter 7 protrudes from the generator side mounting port 2014, which facilitates the insertion of bolts from the outside to connect the generator adapter 7 to the generator busbar 34.

[0069] like Figure 12 As shown, the other end of the generator adapter 7 passes through the controller housing 201 and enters the generator wiring cavity 206 below. The other end of the generator adapter 7 is used to connect to the generator.

[0070] Furthermore, such as Figures 17-19 As shown, the controller cover 1 includes an upper cover 11 and a lower cover 12; The lower cover plate 12 includes a lower cover plate body 121 and a connector mounting platform 122. The connector mounting platform 122 is located on one side of the cover plate body and is integrally formed with the lower cover plate body 121. The connector mounting platform 122 is used to install the first connector 13. The upper cover plate 11 includes an upper cover plate body 111 and a protrusion 112. The edge of the protrusion 112 is aligned with the edge of the insertion mounting platform 122. The upper cover plate body 111 covers the lower cover plate body 121.

[0071] Specifically, such as Figure 17 As shown, the controller cover 1 includes an upper cover 11, a domain control board 14, and a lower cover 12. A mounting cavity is formed between the upper cover 11 and the lower cover 12 for mounting the domain control board 14. The area of ​​the upper cover 11 is smaller than that of the lower cover 12. The shape and area of ​​the lower cover 12 need to be set according to the shape and area of ​​the PDM housing 4 in order to connect with the edge of the PDM housing 4 below.

[0072] like Figure 18 As shown, the upper cover plate 11 includes an upper cover plate body 111 and a protrusion 112. The protrusion 112 protrudes upward from the upper cover plate body 111. Therefore, the cavity formed between the protrusion 112 and the lower cover plate 12 has a relatively large height, while the cavity formed between the upper cover plate body 111 and the lower cover plate 12 has a relatively small height. The cavity between the protrusion 112 and the lower cover plate 12 is used to install the first connector 13, so a relatively large space needs to be reserved. The cavity formed between the cover plate body 111 and the lower cover plate 12 is used to install the domain control board 14. The domain control board 14 is relatively thin, and it generates a lot of heat when it is working. The low height of the cavity is conducive to heat dissipation, and the heat can be quickly dissipated through the upper cover plate 11.

[0073] like Figure 19As shown, the lower cover plate 12 includes a lower cover plate body 121 and a connector mounting platform 122. The connector mounting platform 122 is located longitudinally on one side of the lower cover plate body 121, forming a longitudinal single-wall structure. The lower cover plate body 121 is a flat plate structure, and the edges connecting it to the upper cover plate body 111 are on the same horizontal plane.

[0074] In this embodiment, the lower cover plate body 121 and the insertion mounting platform 122 are integrally formed, resulting in a very stable structure. Figure 2 As shown, the connector mounting platform 122 is used to install the first connector 13. The first connector 13 can be installed on the connector mounting platform 122 from the side. The connector mounting platform 122 provides a stable mounting structure for the first connector 13, and the first connector 13 and the connector mounting platform 122 can be better sealed.

[0075] The existing method of assembling connectors typically involves directly installing the connector between the upper and lower cover plates, and then applying adhesive between the edges of the connector and the upper and lower cover plates to achieve a seal. However, because the shape of the connector's edges does not completely fit the upper and lower cover plates, the seal is poor, and the connector's stability is also relatively poor.

[0076] In this embodiment, a connector mounting platform 122 is integrally formed on the lower cover plate body 121, and the connector mounting platform 122 itself has high stability. After the connector mounting platform 122 is connected to the first connector 13, the stability of the first connector 13 is also high. Furthermore, the first connector 13 and the connector mounting platform 122 can be completely fitted and sealed on all four sides, resulting in better sealing performance; at the same time, it also facilitates the assembly of the first connector 13.

[0077] In traditional designs for upper and lower cover plates, the edges of the upper and lower cover plates are usually placed on the same plane to accommodate tolerances, and a longitudinal single-wall structure is generally avoided. This embodiment breaks with traditional design principles by providing a connecting mounting platform 122 for a longitudinal single-wall mechanism on one side of the lower cover plate 12, offering a stable and sealed connection for the installation of the first connector 13.

[0078] When assembling the upper cover plate 11 and the lower cover plate 12, a protrusion 112 is provided to cooperate with the connection of the insertion mounting platform 122. The edge of the protrusion 112 aligns with the upper edge of the insertion mounting platform 122 and is tightened by multiple bolts. The gap between the protrusion 112 and the upper edge of the insertion mounting platform 122 can also be eliminated by applying glue.

[0079] Furthermore, such as Figure 20As shown, the connector mounting platform 122 includes a connector plate 1221 and a support plate 1222. The connector plate 1221 is perpendicular to the lower cover plate body 121. The support plate 1222 is located on opposite sides of the connector plate 1221 and is perpendicular to the connector plate 1221. The connector plate 1221 is provided with a connector hole 1221a and a first bolt hole 1221b. A plurality of first bolt holes 1221b are located around the connector hole 1221a. The first connector 13 includes a connector end 131 and a sealing plate 132. The sealing plate 132 is provided with a sealing ring 1321 and a second bolt hole 1322. After the connector end 131 passes through the connector hole 1221a, the sealing plate 132 fits against one side of the connector plate 1221. After the first bolt hole 1221b is aligned with the second bolt hole 1322, they are connected by bolts, so that the sealing ring 1321 is pressed onto the connector plate 1221.

[0080] Specifically, such as Figure 20 As shown, the connector plate 1221 is a trapezoidal plate, and the connector plate 1221 is arranged longitudinally on one side of the lower cover plate body 121. There are two support plates 1222, which are located on the left and right sides of the connector plate 1221 respectively, and are located on the outer side of the connector plate 1221 and perpendicular to the connector plate 1221. The support plates 1222 increase the structural strength of the connector plate 1221.

[0081] The connector plate 1221 has a connector hole 1221a and a first bolt hole 1221b. Multiple first bolt holes 1221b are located around the connector hole 1221a. The connector hole 1221a is roughly rectangular, and there is a certain width between the connector hole 1221a and the edge of the connector plate 1221.

[0082] The first connector 13 includes a connector end 131 and a sealing plate 132. The sealing plate 132 is provided with a sealing ring 1321 and a second bolt hole 1322. The connector end 131 is a rectangular frame. The sealing plate 132 is located inside the connector end 131, and the area of ​​the sealing plate 132 is larger than the cross-sectional area of ​​the connector end 131. The sealing plate 132 is also roughly rectangular. The sealing ring 1321 runs continuously around the edge of the sealing plate 132. The number and position of the second bolt holes 1322 correspond to the first bolt holes 1221b.

[0083] During installation, such as Figure 21 As shown, firstly, the connector 131 passes through the connector hole 1221a from the inside of the connector plate 1221, so that the connector 131 protrudes to the outside of the connector hole 1221a; then, the first bolt hole 1221b and the second bolt hole 1322 are aligned, and the bolt is inserted into the first bolt hole 1221b and the second bolt hole 1322; finally, the bolt is tightened, and the sealing plate 132 is pulled toward the connector plate 1221, so that the sealing ring 132 is pressed against the inner side of the connector plate 1221, forming a sealing structure.

[0084] Better, such as Figure 18 As shown, the upper cover plate 11 is also provided with a sound-absorbing structure 113. The sound-absorbing structure 113 protrudes slightly from the upper cover plate body 111, which can improve the noise reduction performance of the upper cover plate 11.

[0085] Preferably, the upper cover 11 is a silent cover with a damping layer and a sheet metal thickness of 2mm, which makes the upper cover 11 thinner, heats up faster, and achieves a better silent effect.

[0086] Furthermore, such as Figure 17 and Figure 22 As shown, the controller module 3 includes a drive motor power module 31 and a generator power module 32. The drive motor power module 31 is located above the generator power module 32. The drive motor power module 31 is connected to an external drive motor through a drive motor copper busbar group 33, and the generator power module 32 is connected to an external generator through a generator copper busbar group 34.

[0087] Specifically, such as Figure 17 As shown, the controller module 3 includes a drive motor power module 31 and a generator power module 32, with the drive motor power module 31 located above the generator power module 32.

[0088] like Figure 22 As shown, the controller module 3 is installed in an inverted state on the lower surface of the PDM housing 4.

[0089] Since the controller module 3 needs to be inserted into the main housing 20, the drive motor copper busbar group 33 and the generator copper busbar group 34 need to be set close to the two power modules and cannot extend beyond the edge of the PDM housing 4. Therefore, the design requirements for the drive motor copper busbar group 33 and the generator copper busbar group 34 are relatively high, taking into account both space utilization and the routing of the copper busbars themselves, as well as structural interference and electrical anti-interference issues between multiple copper busbars.

[0090] Optionally, the controller module 3 in this invention is not limited to only including the drive motor power module 31 and the generator power module 32, but may also include other power modules.

[0091] Furthermore, such as Figure 24 , Figures 28-30 As shown, the drive motor copper busbar group 33 includes a first copper busbar 331, a second copper busbar 332, a third copper busbar 333 and a first insulating support sleeve 334. The first insulating support sleeve 334 is used to be sleeved on the first copper busbar 331, the second copper busbar 332 and the third copper busbar 333 and to isolate adjacent copper busbars.

[0092] Specifically, such as Figure 24As shown, the three terminals of the first copper busbar 331, the second copper busbar 332, and the third copper busbar 333 are all arranged in a row along the horizontal direction to facilitate connection with the wiring harness of the drive motor.

[0093] like Figure 29 As shown, the first copper busbar 331 includes a first access end 3311, a first extension section 3312 and a first output end 3313. The first access end 3311 is connected to the drive motor power module 31. The first access end 3311 is arranged in the horizontal direction. The first extension section 3312 is bent relative to the first access end 3311 and extends in the horizontal direction. The first output end 3313 is bent twice relative to the first extension section 3312 and extends downward in the longitudinal direction.

[0094] The second copper busbar 332 includes a second access terminal 3321, a second extension section 3322, and a second output terminal 3323. The second access terminal 3321 is connected to the drive motor power module 31 and is arranged horizontally. The second extension section 3322 is bent relative to the second access terminal 3321 and extends horizontally. The second output terminal 3323 is bent twice relative to the second extension section 3322 and extends vertically downward. The second extension section 3322 is parallel to the first extension section 3312 and is spaced apart from it. The length of the second extension section 3322 is less than the length of the first extension section 3312.

[0095] The third copper busbar 333 includes a third access terminal 3331 and a third output terminal 3332. The third access terminal 3331 is connected to the drive motor power module 31. The third access terminal 3331 is arranged in a horizontal direction. The third output terminal 3332 is arranged in a longitudinal direction after being bent relative to the third access terminal 3331. The third access terminal 3331 is arranged perpendicularly to the second extension section 3322 and the first extension section 3312 and is spaced at a certain distance.

[0096] The first output terminal 3313, the second output terminal 3323, and the third output terminal 3332 are located at the same height and arranged side by side.

[0097] like Figure 28 As shown, the first insulating support sleeve 334 is a single unit, and it is fitted around at least a portion of the outer periphery of the first copper busbar 331, the second copper busbar 332, and the third copper busbar 333. The first insulating support sleeve 334 also serves to isolate adjacent copper busbars. Additionally, the first insulating support sleeve 334 has several mounting positions formed on it to facilitate the installation of the drive motor copper busbar assembly 33.

[0098] Specifically, the first insulating support sleeve 334 includes a first insulating plate 3341, a second insulating plate 3342, and a third insulating plate 3343. The first insulating plate 3341 is used to isolate the third access terminal 3331 from the second extension section 3322 and the first extension section 3312. The second insulating plate 3342 is used to isolate the third output terminal 3332 and the second output terminal 3323. The third insulating plate 3343 is used to isolate the second output terminal 3323 and the first output terminal 3313.

[0099] The first insulating support sleeve 334 also includes a first mounting position 3344 and a second mounting position 3345, which are used to connect with the main housing 20.

[0100] The first insulating support sleeve 334 also includes a first support sleeve 3347, which is sleeved on the outside of the third access terminal 3331 and provides support for the third access terminal 3331.

[0101] The first insulating support sleeve 334 also includes a main sleeve 3346, which is fitted over the entire first extension 3312 and isolated between the first extension 3312 and the second extension 3322. For example... Figure 18 As shown, the gap between the first extension segment 3312 and the second extension segment 3322 is very narrow and easily causes interference. The main sleeve 3346 can isolate the interference between them.

[0102] like Figure 22 As shown, the drive motor copper busbar assembly 33 is installed on the edge of the PDM housing 4, and when inserted into the main housing 20, it is very close to the inner wall of the main housing 20. The main sleeve 3346 also serves to isolate the main housing 20.

[0103] In this embodiment, the design of the drive motor copper busbar group 33 makes the thickness of the entire drive motor copper busbar group 33 very thin, which can adapt to the narrow installation space of the main housing 20, and avoids positional interference and electromagnetic interference between the copper busbars. The three output terminals are arranged in the same row, which facilitates the connection with the motor wiring harness.

[0104] Furthermore, such as Figure 24 As shown, the generator copper busbar assembly 34 includes a fourth copper busbar 341, a fifth copper busbar 342, a sixth copper busbar 343, and a second insulating support sleeve 344. The second insulating support sleeve 344 is used to be fitted onto the fourth copper busbar 341, the fifth copper busbar 342, and the sixth copper busbar 343 and to isolate adjacent copper busbars.

[0105] Specifically, such as Figure 26As shown, the fourth copper busbar 341 includes a fourth access terminal 3411 and a fourth extension section 3412. The fourth access terminal 3411 is arranged in a horizontal direction, and the fourth extension section 3412 is bent downward and extended in a horizontal direction. The end of the fourth extension section 3412 serves as the output terminal.

[0106] The fifth copper busbar 342 includes a fifth access terminal 3421, a fifth extension section 3422, and a fifth output terminal 3423. The fifth access terminal 3421 is arranged in a horizontal direction. The fifth extension section 3422 bends downward first, then bends again and extends horizontally. The fifth extension section 3422 is arranged perpendicular to the fourth extension section 3412. The fifth output terminal 3423 bends again relative to the fifth extension section 3422 and is arranged in a longitudinal direction.

[0107] The sixth copper busbar 343 includes a sixth access terminal 3431 and a sixth output terminal 3432. The sixth access terminal 3431 is arranged in a horizontal direction, and the sixth output terminal 3432 is arranged in a longitudinal direction after being bent relative to the sixth access terminal 3431.

[0108] The end of the fourth extension section 3412, the fifth output terminal 3423, and the sixth output terminal 3432 are arranged side by side to facilitate connection with the motor wiring harness.

[0109] like Figure 25 As shown, the second insulating support sleeve 344 includes a first sub-sleeve 3441 and a second sub-sleeve 3442. The first sub-sleeve 3441 is sleeved between the fourth copper busbar 341 and the fifth copper busbar 342, and the second sub-sleeve 3442 is sleeved before the fifth copper busbar 342 and the sixth copper busbar 343.

[0110] Specifically, the first sub-sleeve 3441 includes a second support sleeve 3441b and a fourth isolation piece 3441a. The second support sleeve 3441b is fitted over the fourth extension segment 3412 to support the fourth extension segment 3412. The fourth isolation piece 3441a isolates the fourth extension segment 3412 from the fifth extension segment 3422.

[0111] The second sub-set 3442 includes a third support set 3442a, a fourth support set 3442b, and a fifth support set 3442c. The third support set 3442a is fitted outside the sixth access end 3431. The fourth support set 3442b is fitted outside the fourth extension section 3412 and the fifth extension section 3422. The fifth support set 3442c is fitted outside the fifth extension section 3422.

[0112] like Figure 27 As shown, since the gaps between the sixth access terminal 3431 and the fifth extension segment 3422 and the fourth extension segment 3412 are also very small, the third support sleeve 3442a, the fourth support sleeve 3442b and the fifth support sleeve 3442c also play an isolation role.

[0113] In this embodiment, the design of the generator copper busbar group 34 makes the thickness of the entire generator copper busbar group 34 very thin, which can adapt to the narrow installation space of the main housing 20 and avoid positional interference and electromagnetic interference between the copper busbars. The three terminals are arranged in the same row, which facilitates the connection with the motor wiring harness.

[0114] This invention features a separate PDM housing connected to the main housing. After connection, the controller module is inserted into the main housing, sharing a portion of the housing. This invention eliminates the need to install the entire controller assembly inside the main housing; only the controller module is installed. This simplifies connector installation by allowing the multiple connectors on the PDM housing to connect directly to the PDM housing, eliminating the need for connections to the main housing. Furthermore, the low height of the controller module facilitates connection of the copper busbars to the motor inside the main housing. In this invention, some of the cooling water channels and interfaces originally located in the main housing are moved to the PDM housing, simplifying the design of the cooling water channels in the main housing. Furthermore, in existing main housing cooling water channels, water must flow from bottom to top into the upper PDM cooling water channels, resulting in significant water resistance. In this invention, water flows directly from the PDM housing into the PDM cooling water channels, reducing water resistance and improving cooling efficiency.

[0115] The above description is merely the principle and preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several other modifications can be made based on the principle of the present invention, and these modifications should also be considered within the scope of protection of the present invention.

Claims

1. A drive system, comprising a controller assembly, a drive motor, a generator, and a main housing, characterized in that, The controller assembly includes a PDM housing, a PDM module, and a controller module. The PDM module is installed inside the PDM housing, the controller module is installed below the PDM housing, the PDM housing is installed above the main housing, and the controller module is inserted into the main housing. It also includes a cooling circuit, which includes a PDM cooling water channel in the PDM module, a controller cooling water channel in the controller module, a transfer water channel in the PDM housing, and a main housing cooling water channel in the main housing. The PDM cooling water channel, the controller cooling water channel, the transfer water channel, and the main housing cooling water channel are connected in sequence.

2. The drive system according to claim 1, characterized in that, The PDM housing has a water inlet, which is directly connected to the PDM cooling water channel.

3. The drive system according to claim 1, characterized in that, The PDM housing has a return water inlet and a water outlet. The return water inlet is connected to one end of the transfer water channel, and the water outlet is connected to the other end of the transfer water channel. The return water inlet is directly connected to the controller cooling water channel, and the water outlet is directly connected to the main housing cooling water channel.

4. The drive system according to claim 3, characterized in that, One side of the PDM housing is provided with a high-voltage connector for inserting a high-voltage connector. At the corner of the adjacent side of the side where the high-voltage connector is located, there is an outwardly protruding boss. The interior of the boss forms an installation cavity, and the wiring harness of the high-voltage connector runs through the installation cavity.

5. The drive system according to claim 4, characterized in that, An installation platform is also provided on the side where the boss is located, and the water inlet, the water return outlet and the water outlet are all located on the installation platform.

6. The drive system according to claim 1, characterized in that, The main housing includes a controller housing, a drive motor housing, a generator housing, and a gearbox housing. The controller housing is located above the generator housing, the drive motor housing is located on the side of the controller housing, and the gearbox housing is located below the controller housing and on the back of the generator housing. The main housing cooling water channel includes a control section, a power generation section, and an oil cooling section in sequence. The control section is located in the controller housing, the power generation section is located between the generator housing and the controller housing, and the oil cooling section is located between the generator housing and the drive motor housing and is connected to the oil cooler.

7. The drive system according to claim 6, characterized in that, The main housing also includes a drive wiring cavity, which is located between the generator housing and the drive motor housing, and the oil cooling section is disposed in the drive wiring cavity.

8. The drive system according to claim 6, characterized in that, A power generation wiring cavity is also provided between the controller housing and the generator housing, and the power generation wiring cavity is located on the outside of the power generation section.

9. The drive system according to claim 7, characterized in that, It also includes a drive adapter copper busbar, which passes through the controller housing and extends into the drive wiring cavity.

10. The drive system according to claim 8, characterized in that, It also includes a power generation adapter copper busbar, which passes through the controller housing and extends into the power generation wiring cavity.

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