Integrated high-voltage motor and assembly method thereof

Abstract

The invention provides an integrated high-voltage motor. The integrated high-voltage motor comprises an aluminum alloy front shell; the stator assembly is fixedly mounted in the inner cavity of the aluminum alloy front shell; the rotor assembly is rotatably arranged on the inner side of the stator assembly; the motor rear cover is in sealed butt joint with the aluminum alloy front shell; the motor controller is integrated and fixed in the inner cavity of the motor rear cover; all gaps between the stator assembly and the inner wall of the aluminum alloy front shell are filled with first high-thermal-conductivity insulating pouring sealant to form a first pouring solidified body; all gaps between the motor controller and the inner wall of the motor rear cover are filled with second high-thermal-conductivity insulating pouring sealant to form a second pouring solidified body; after the aluminum alloy front shell and the motor rear cover are in butt joint and sealed, the first potting solidified body and the second potting solidified body compress residual air space in the motor except a rotor working air gap and a bearing chamber to the minimum. The structure reliability, the heat dissipation performance, the environment sealing stability and the high-voltage insulation safety of the motor can be improved.

Description

Technical Field

[0001] This application relates to the field of motor technology, specifically to an integrated high-voltage motor with a compact structure, good heat dissipation performance, low internal residual air, and high sealing reliability, and its assembly method. Background Technology

[0002] With the rapid development of new energy vehicles and high-end industrial drives, high-voltage motors (operating voltage typically ≥600V DC) are widely used due to their high power density and efficiency. However, improving the performance of high-voltage motors faces many challenges: 1. Heat dissipation problem: High power density generates a large amount of heat. If it cannot be dissipated in time, it will lead to demagnetization of the motor magnets, aging of winding insulation, decreased controller performance, or even burnout. 2. Structural strength and vibration: High-voltage motors operate under high-speed and high-torque conditions, and their internal structure is subjected to enormous electromagnetic forces, centrifugal forces, and vibrations. Traditional fixing methods may cause fretting wear and structural loosening under long-term alternating stress. 3. Internal condensation and insulation risks: Air remaining in the completely sealed motor cavity will produce a "breathing effect" when the ambient temperature changes drastically, which may lead to seal failure. More importantly, condensation will drastically reduce insulation resistance, causing fatal risks such as short circuit breakdown. 4. Space and integration contradiction: Integrating the motor and controller into one unit is a trend, but how to achieve connection, heat dissipation, and electromagnetic compatibility without increasing the size is a major challenge.

[0003] In existing technologies, some methods for solving heat dissipation problems include water cooling or oil cooling of the casing, but these methods are complex in structure, costly, and carry the risk of leakage. To solve the stator fixing problem, some methods use epoxy resin potting, but this is usually limited to the stator section. For internal condensation problems, common practices include filling with dry inert gas or placing desiccants, but this increases process complexity and cost.

[0004] Therefore, an innovative overall structural design and assembly method for high-voltage motors is needed to comprehensively solve problems such as high strength, high thermal conductivity, minimizing the internal space of harmful air, and achieving highly compact integration. Summary of the Invention

[0005] The purpose of this application is to provide an integrated high-voltage motor and its assembly method. Through a unique structural design and potting process, the stator assembly and motor controller are simultaneously reinforced and fixed and efficiently cooled, and the residual air space inside the motor is minimized, thereby improving the motor's structural reliability, heat dissipation performance, environmental sealing stability and high-voltage insulation safety.

[0006] This application provides an integrated high-voltage motor, including an aluminum alloy front housing; a stator assembly fixedly installed in the internal cavity of the aluminum alloy front housing; a rotor assembly rotatably disposed inside the stator assembly; a motor rear cover sealed and connected to the aluminum alloy front housing; and a motor controller integrated and fixed in the internal cavity of the motor rear cover. All gaps between the stator assembly and the inner wall of the aluminum alloy front housing are filled with a first high thermal conductivity insulating potting compound to form a first potting cured body. All gaps between the motor controller and the inner wall of the motor rear cover are filled with a second high thermal conductivity insulating potting compound to form a second potting cured body. The armature winding output terminal of the stator assembly and the power input terminal of the motor controller are electrically connected via a plug-in electrical connector. After the aluminum alloy front housing and the motor rear cover are sealed together, the first and second potting cured bodies minimize the residual air space inside the motor, excluding the rotor working air gap and bearing chamber.

[0007] In some embodiments, the plug-in electrical connector is a plug-in high-voltage connector or an insulation displacement connector.

[0008] In some embodiments, when a plug-in high-voltage connector is used, its male and female ends are fixed to the stator output end and the controller input end, respectively, and the mating and locking are completed when the aluminum alloy front shell and the motor rear cover are plugged together.

[0009] In some embodiments, when an insulated displacement connector is used, the stator winding leads are directly crimped into the pierced terminals on the controller PCB and the connection is completed before potting, and then they are encapsulated together with potting compound.

[0010] In some embodiments, the first high thermal conductivity insulating potting compound and the second high thermal conductivity insulating potting compound are the same potting compound material, with a thermal conductivity ≥1.0 W / (m·K) and a volume resistivity ≥1×10^15 Ω·cm.

[0011] In some embodiments, the potting compound material is an addition-type silicone potting compound or a high thermal conductivity epoxy resin potting compound.

[0012] In some embodiments, the mating surfaces of the aluminum alloy front shell and the motor rear cover are provided with a precision stop and a sealing groove that cooperate with each other. The sealing groove is equipped with a static sealing ring and is locked by circumferentially distributed fastening bolts.

[0013] In some embodiments, after assembly and sealing, the ratio of the total volume of residual air inside the motor to the total volume of the motor interior enclosed by the aluminum alloy front shell and the motor rear cover is less than or equal to 5%.

[0014] On the other hand, this application also provides a method for assembling the above-mentioned integrated high-voltage motor, including: Step S1: fixing the stator assembly inside the aluminum alloy front housing, installing the front bearing, and installing or preparing the stator end portion of the mating connector; Step S2: fixing the motor controller inside the motor rear cover, installing the rear bearing, and installing or preparing the controller end portion of the mating connector; Step S3: fixing the front housing assembly and the rear cover assembly respectively, with their potting cavity opening facing upwards, and performing preheating and sealing treatment; Step S4: injecting high thermal conductivity insulating potting compound into the stator cavity of the aluminum alloy front housing and the controller cavity of the motor rear cover respectively in a vacuum environment, so as to fully fill the gap, and then performing curing treatment to form a first potting cured body and a second potting cured body; Step S5: installing the rotor assembly into the potted stator cavity, aligning the aluminum alloy front housing and the motor rear cover, mating and closing, so that the mating electrical connector accurately docks and completes the fastening and sealing between the housings.

[0015] In some embodiments, the vacuum level of the vacuum environment is not lower than -0.09 MPa, and the potting compound is kept under vacuum for a period of time to ensure that air bubbles are expelled.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit the disclosure of this application. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic diagram of the overall structure of an integrated high-voltage motor according to this application is shown.

[0019] Figure 2 A schematic diagram of the axial CC cross-sectional structure of an integrated high-voltage motor according to this application is shown.

[0020] Figure 3 A schematic diagram of the stator potting area of ​​an integrated high-voltage motor according to this application is shown.

[0021] Figure 4 This application shows Figure 3 A cross-sectional view along the AA direction.

[0022] Figure 5 A schematic diagram of the structure of the electronically controlled potting area of ​​an integrated high-voltage motor according to this application is shown.

[0023] Figure 6This application shows Figure 5 A cross-sectional view along the BB direction.

[0024] Figure 7 A partially enlarged schematic diagram of the connection portion of the plug-in connector in this application is shown.

[0025] Figure 8 A partially enlarged schematic diagram of the connection portion of the insulating displacement connector (puncture terminal) in this application is shown.

[0026] Figure 9 The main flowchart of the method for assembling an integrated high-voltage motor in this application is shown. Detailed Implementation

[0027] The embodiments of this application are described in detail below. Examples of the embodiments are shown 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 are only used to explain this application, and should not be construed as limiting this application.

[0028] To enable those skilled in the art to better understand the solutions of this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0029] In the embodiments of this application, it should be noted that, in this document, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0030] Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one…" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0031] In the description of the embodiments of this application, the words "example" or "for example" are used to indicate exemplification, illustration, or description. Any embodiment or design described as "example" or "for example" in the embodiments of this application is not to be construed as being more preferred or having more advantages than another embodiment or design. The use of the words "example" or "for example" is intended to present relative concepts in a clear manner.

[0032] In addition, "multiple" in the embodiments of this application refers to two or more. Therefore, "multiple" can also be understood as "at least two" in the embodiments of this application. "At least one" can be understood as one or more, such as one, two or more. For example, including at least one means including one, two or more and is not limited to which ones are included. For example, including at least one of A, B and C, then it can be A, B, C, A and B, A and C, B and C, or A and B and C.

[0033] It should be noted that in the embodiments of this application, "and / or" describes the relationship between associated objects, indicating that there can be three relationships. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. In addition, the character " / ", unless otherwise specified, generally indicates that the associated objects before and after it are in an "or" relationship.

[0034] It should be noted that in the embodiments of this application, "connection" can be understood as electrical connection. The connection between two electrical components can be a direct or indirect connection between the two electrical components. For example, the connection between A and B can be a direct connection between A and B, or an indirect connection between A and B through one or more other electrical components.

[0035] This application provides an integrated high-voltage motor, such as Figure 1-6 As shown, the integrated high-voltage motor includes: an aluminum alloy front housing 1; a stator assembly 2, fixedly installed in the internal cavity of the aluminum alloy front housing 1; a rotor assembly 4, rotatably disposed inside the stator assembly 2; a motor rear cover 7, sealed and connected to the aluminum alloy front housing 1; and a motor controller 8, integrated and fixed in the internal cavity of the motor rear cover 7. All gaps between the stator assembly 2 and the inner wall of the aluminum alloy front housing 1 are filled with a first high thermal conductivity insulating potting compound 3, forming a first potting cured body. All gaps between the motor controller 8 and the inner wall of the motor rear cover 7 are filled with a second high thermal conductivity insulating potting compound 9, forming a second potting cured body. The armature winding 202 output terminal of the stator assembly 2 and the power input terminal of the motor controller 8 are electrically connected via a plug-in electrical connector. After the aluminum alloy front housing 1 and the motor rear cover 7 are sealed together, the first potting cured body and the second potting cured body minimize the residual air space 15 inside the motor, excluding the rotor working air gap 14 and the bearing chamber.

[0036] The first potting compound can also be referred to as the stator potting area, and the second potting compound can also be referred to as the electronic control potting area.

[0037] The aluminum alloy front shell 1 is made of ADC12 die-cast aluminum alloy and has a cylindrical structure with external heat dissipation fins 16. Its inner diameter is φ120mm (H7 tolerance) and its depth is 80mm. The motor rear cover 7 is also made of ADC12 die-cast aluminum alloy, forming a controller mounting cavity with a depth of 40mm. The main dimensions of the cavity are 100mm x 80mm x 40mm. The mating end faces of the aluminum alloy front shell 1 and the motor rear cover 7 are respectively machined with a φ150mm stepped stop (fitting tolerance H7 / js6) and have rectangular sealing grooves for installing fluororubber O-ring static seals 12 with a cross-sectional diameter of φ2.5mm. Eight M8-12.9 grade high-strength internal hexagonal head bolts 13 are evenly distributed around the circumference.

[0038] The stator assembly 2 consists of a stator core 201 made of 0.35mm thick silicon steel sheets and an armature winding 202 wound with flat copper wire. The outer diameter is φ119.8mm (S6 tolerance), and it is press-fitted into the inner hole of the aluminum alloy front housing 1 via an interference fit. Dow Corning SE4420 two-component addition-curing silicone potting compound 3 is selected as the first high thermal conductivity insulating potting compound. Its thermal conductivity is 1.6 W / (m·K), volume resistivity >1×10^15 Ω·cm, dielectric strength >18 kV / mm, and hardness after curing is Shore D 50. Before potting, the front housing assembly is preheated to 80℃. Under a vacuum of -0.095 MPa, the mixed and degassed compound is injected into the stator cavity until the compound completely submerges the winding ends and slightly exceeds the stator core end face. Subsequently, it was cured in an oven at 80°C for 1 hour under normal pressure, and then cured at 120°C for 2 hours to form the first potting cured body that completely fills all gaps between the stator and the front shell and covers the winding ends.

[0039] The PCB board 801 of the motor controller 8 is fixed to a bracket inside the motor rear cover 7 cavity by four M4 screws. The power module 802 is a SiC MOSFET half-bridge module, soldered onto the PCB. A second high thermal conductivity insulating potting compound 9, of the same brand and model as that used in the stator area, is used. This structure also includes an unpotted area 18. The potting process parameters are exactly the same as those in the stator area, ensuring that the compound completely covers the PCB board 801, the power module 802, and all surface-mount components, forming a second potted cured body.

[0040] The three-phase outputs of stator winding 202 are soldered to the male pins of TE Connectivity's HVP 800 series high-voltage mating connector 10. This connector has a rated voltage of 800V DC and a rated current of 150A. The corresponding female socket of the high-voltage mating connector 10 is directly soldered to the PCB input terminal of the motor controller 8. The male and female terminals are reliably fixed to the surface of the stator potting body and the controller potting body, respectively, by brackets.

[0041] After the potting compound has fully cured, remove the temporary protective tape from the mating surfaces and install the static sealing ring 12. Carefully pass the rotor shaft 401 of the rotor assembly 4 with the permanent magnet 402 through the front bearing 5 and place it into the stator cavity. Precisely align the motor rear cover 7 assembly with the stop of the aluminum alloy front shell 1 using the guide pin, and slowly and smoothly insert it. During this process, the male and female ends of the HVP 800 connector automatically align and insert, and a clear "click" locking sound is heard, indicating that the connection is in place. Finally, evenly tighten the 8 fastening bolts 13. Calculations and measurements show that the residual air volume inside the motor accounts for approximately 3.2%, significantly reducing the breathing effect.

[0042] All gaps between the stator assembly 2 and the inner wall of the aluminum alloy front housing 1 are completely filled with a first high thermal conductivity insulating potting compound, which then covers the stator end windings and leads, forming a first potted and cured body that is bonded to the housing as a single unit. Simultaneously, all gaps between the motor controller 8 (including the PCB board, power module, capacitors, and all other components) and the inner wall of the motor rear cover 7 are completely filled with a second high thermal conductivity insulating potting compound, forming a second potted and cured body. The first and second potting compounds are preferably made of the same material. After the two housings are joined, they form a continuous or tightly contacting colloid in the connector area, thereby achieving a physically integrated potting effect.

[0043] The independent plug-in connector 10 is eliminated. The three high-voltage leads of the stator winding 202 use Teflon-insulated silver-plated copper wire, with a 10mm long insulation stripped from the ends beforehand. A three-in-one insulated displacement connector (IDC, piercing terminal) 11 is designed and soldered onto the edge of the PCB board 801 of the motor controller 8. This terminal can be selected from JST's SVH series, with terminal spacing and current carrying capacity matched to the motor phase current. Figure 7 A partial enlargement of the connection portion of the plug-in connector is shown. The plug-in electrical connector is either a plug-in high-voltage connector 10 or an insulation displacement connector 11.

[0044] When the plug-in type high voltage connector 10 is used, its male and female ends are fixed to the stator output end and the controller input end respectively, and the docking and locking are completed when the aluminum alloy front shell 1 and the motor rear cover 7 are plugged together.

[0045] Figure 8 A partial enlargement of the connection area of ​​the insulated displacement connector is shown. When the insulated displacement connector 11 is used, the stator winding leads are directly crimped into the pierced terminals on the controller PCB board 801, and the connection is completed before potting, after which they are encapsulated together with potting compound.

[0046] The armature winding output terminals of the stator assembly 2 are connected to the power input terminals of the motor controller via plug-in electrical connectors. Specifically, there are two types: one is a plug-in high-voltage connector, with the male and female ends pre-installed on the stator and controller ends respectively, completing the connection when the front and rear housings are plugged in; the other is an insulated displacement connector, where the stator winding leads are directly crimped into the pierced terminals of the controller PCB board before potting, achieving the connection and then being potted together. This connection method completely replaces traditional flexible wire harnesses, minimizing the axial and radial space occupied by the connection.

[0047] The first high thermal conductivity insulating potting compound 3 and the second high thermal conductivity insulating potting compound 9 are the same potting compound material, with a thermal conductivity ≥1.0 W / (m·K), a volume resistivity ≥1×10^15 Ω·cm, and a hardness of Shore D 40-70 after curing.

[0048] The potting compound material is an addition-type silicone potting compound or a high thermal conductivity epoxy resin potting compound.

[0049] The aluminum alloy front shell 1 and the motor rear cover 7 have a precision stop and a sealing groove that fit together. The sealing groove is equipped with a static sealing ring 12 and is locked by circumferentially distributed fastening bolts 13.

[0050] The mating surfaces of the aluminum alloy front shell 1 and the motor rear cover 7 are provided with precision stop surfaces that fit together and sealing grooves with static sealing rings installed, and are locked in place by circumferentially distributed fastening bolts. This design ensures that when the two shells are closed, the first potting compound and the second potting compound inside can fit together tightly with minimal gap (or even zero gap). Combined with the compact arrangement of the plug-in connectors, the "ineffective cavities" that can be used to accommodate air in the internal cavity of the motor (enclosed by the front shell and the rear cover) are eliminated or compressed to a minimum, except for the rotor working air gap, bearing chamber, and the micropores of the potting compound itself, which are necessary for rotor operation.

[0051] After assembly and sealing, the ratio of the total volume of residual air inside the motor to the total volume of the motor interior enclosed by the aluminum alloy front shell 1 and the motor rear cover 7 is less than or equal to 5%.

[0052] As a direct result of the aforementioned structural synergy and a key quantitative feature of this invention, after assembly and sealing, the ratio of the total volume of residual air inside the motor (mainly distributed in the rotor working air gap, bearing chamber, and micropores) to the total volume inside the motor (i.e., the geometric volume of the closed cavity enclosed by the aluminum alloy front shell and the motor rear cover) is effectively controlled to ≤5%, preferably ≤2%, and in the best implementation scheme, approximately ≈1%. This significant reduction in ratio is the core manifestation of this invention's fundamental weakening of the "breathing effect" and suppression of internal condensation. This application also provides a method for assembling the aforementioned integrated high-voltage motor, such as... Figure 9 As shown, the method includes the following steps: Step S1: Fix the stator assembly 2 inside the aluminum alloy front housing 1, install the front bearing 5, and install or prepare the stator end portion of the mating connector; Step S2: Fix the motor controller 8 inside the motor rear cover 7, install the rear bearing 6, and install or prepare the controller end part of the mating connector; Step S3: Fix the front shell assembly and the rear cover assembly respectively, so that the opening of their potting cavity faces upward, and perform preheating and sealing treatment; Step S4: In a vacuum environment, inject high thermal conductivity insulating potting compound into the stator cavity of the aluminum alloy front shell 1 and the controller cavity of the motor rear cover 7 respectively, so that it can fully fill the gap, and then perform curing treatment to form the first potting cured body 3 and the second potting cured body 9. Step S5: Install the rotor assembly 4 into the potted stator cavity, align the aluminum alloy front shell 1 and the motor rear cover 7, and plug them together to ensure accurate docking of the plug-in electrical connectors and complete the tight sealing between the shells.

[0053] In the pre-assembly of the front housing assembly in step S1, after the stator assembly 2 is cooled in liquid nitrogen, it is quickly pressed into the inner hole of the aluminum alloy front housing 1, which has been heated to about 120°C, to achieve an interference fit; the front bearing 5 (model: 6208 deep groove ball bearing) is pressed into the front housing bearing chamber using a hydraulic press until the shaft shoulder is in place; the stator three-phase output ends are stripped, tinned, and then soldered to the pins of the male end of the HVP800 connector 10, and the male end housing and locking mechanism are installed.

[0054] In the pre-assembly of the rear cover assembly in step S2, the controller PCB board (801) with the components already mounted is fixed to the four copper pillar brackets inside the motor rear cover 7 with screws to ensure that the power module 802 substrate is in close contact with the inner wall of the rear cover (pre-applied with thermal grease); the rear bearing 6 is press-fitted; the female socket of the HVP 800 connector 10 is soldered to the reserved pad at the input end of the PCB and the female shell is fixed.

[0055] In step S3, during the potting preparation, a special potting fixture is designed to horizontally clamp the front housing assembly (opening upwards) and the rear cover assembly (controller cavity opening upwards) respectively. The potting areas (stator cavity and controller cavity) of the two components, along with the internal stator and controller, are sent into an oven and preheated at 85°C for 60 minutes to remove moisture and reduce the viscosity of the subsequent adhesive. High-temperature resistant polyimide tape is carefully applied to the stop steps and sealing grooves on the mating surfaces of the two housings to prevent the adhesive from overflowing and contaminating these critical mating surfaces during potting.

[0056] Before step S3 (encapsulation preparation), a "pre-connection" step is added. The stator assembly and controller assembly are initially aligned using a simple clamp, ensuring that the three stator leads are aligned with the three pierced terminal slots on the controller PCB. Using a dedicated pneumatic crimping tool, the wires are vertically pressed into the terminal slots under constant pressure (e.g., 500N). The U-shaped metal blade of the terminal will pierce the remaining insulation layer of the wire, forming a large-area, low-resistance cold-pressed contact with the copper core. Testing shows that the contact resistance at this point is <0.1mΩ.

[0057] After the "pre-connection" is completed, the stator and controller are rigidly connected by wires. Subsequently, the two components undergo the vacuum potting and curing process described in Example 1, separately but almost simultaneously. The potting compound (3, 9) simultaneously covers the connection points, forming insulation and mechanical protection. During final assembly, since the connection has been pre-completed, only the rotor installation and housing alignment and tightening need to be addressed. This approach further reduces the space occupied by the connector itself; calculations show that the internal residual air volume percentage can be further reduced to approximately 2.1%.

[0058] In step S4, vacuum potting and curing (the core process step), components A and B of Dow Corning SE4420 potting compound are added to a planetary mixer and deaerator at a weight ratio of 10:1. The mixture is stirred at 1000 rpm for 3 minutes and deaerated under a vacuum of -0.1 MPa for 5 minutes. The two components, along with their fixtures, are then moved into the vacuum potting chamber. The chamber door is closed, and the vacuum pump is started to evacuate the chamber to a stable vacuum of -0.098 MPa for 5 minutes. While maintaining the vacuum, the mixed compound is injected into the stator cavity and controller cavity respectively through a metering pump and a dispensing tube. The dispensing speed is controlled at 100 g / min, and the amount of dispensing is such that the compound level is slightly higher than the stator core end face and the top of the highest component of the controller by 2 mm. After dispensing, the vacuum is maintained for another 10 minutes to allow the compound to fully penetrate into all microscopic gaps, such as between winding turns and at the bottom of components, and to observe that no more bubbles overflow from the surface. Dry nitrogen is then slowly introduced into the vacuum chamber until atmospheric pressure is reached. The components were left to stand at atmospheric pressure for 30 minutes to further compact the colloid. The components were then transferred to a curing oven and the following curing profile was executed: Stage 1: 4 hours at room temperature (25°C) for initial curing; Stage 2: Temperature increased to 80°C at a rate of 1°C / min and held for 2 hours; Stage 3: Temperature increased to 120°C at a rate of 0.5°C / min and held for 3 hours. The components were then cooled in the oven to below 60°C before being removed from the oven.

[0059] In step S4, the vacuum level of the vacuum environment is not lower than -0.09 MPa, and the potting compound is kept under vacuum for a period of time to ensure that air bubbles are expelled.

[0060] In step S5, during the mating connection and assembly, carefully remove all temporary protective tape from the mating surfaces; correctly insert the fluororubber O-ring 12 into the sealing groove of the motor rear cover 7; carefully insert the rotor shaft 401 of the rotor assembly 4 from the front end, ensuring that the permanent magnet 402 does not scrape against the stator core 201, and that the rear end of the shaft falls into the inner ring of the rear bearing 6; install two diagonally arranged guide pins on the stop of the aluminum alloy front shell 1 and the motor rear cover 7. Hoist the rear cover assembly, allowing it to fall smoothly along the guide pins and mate with the front shell assembly. During this process, the operator must visually confirm that there are no signs of misalignment at the male and female ends of the connector, and when fully closed, confirm through the observation window next to the mounting hole that the red indicator of the connector locking mechanism turns green, indicating that the electrical connection is fully in place and locked; remove the guide pins, install all eight M8 fastening bolts 13, and tighten them in two rounds using a torque wrench in a diagonal sequence, with a final torque of 28 N·m.

[0061] In step S5, the insertion and closing process ensures that the stops of the aluminum alloy front shell 1 and the motor rear cover 7 are precisely aligned through the guide positioning device.

[0062] The assembly method in this application also includes subsequent assembly and testing in step S6, which involves installing the rotary transformer and PT100 temperature sensor in their respective positions; installing a double-lip skeleton oil seal as a shaft seal; and performing final testing, including: three-phase winding DC resistance, insulation resistance (≥1000 MΩ @ 1000V DC), power frequency withstand voltage test (stator to ground: 3000V AC / 60s; controller input to ground: 2500V AC / 60s), low-speed no-load operation test, and controller function test.

[0063] Compared with existing technologies, this application significantly improves structural rigidity and reliability: the high thermal conductivity potting compound bonds the stator core, windings, and controller components to their respective housings as a whole, providing uniform support across the entire surface. This significantly improves the overall mechanical rigidity, vibration resistance, and impact resistance of the motor, completely eliminating the risk of fretting wear and extending its service life in harsh environments such as vehicles and construction machinery. As a highly efficient heat transfer medium, the potting compound fills all air gaps with poor contact, establishing a low thermal resistance path from the winding copper wires and power device junctions to the aluminum alloy housing. Actual measurements show that it can reduce stator winding temperature rise by 15%-25% and controller key power device junction temperature by 20%-30%, thereby improving continuous overload capacity. The potting compound itself provides excellent insulation and three-proof (moisture-proof, corrosion-proof, and condensation-proof) protection. Most importantly, by compressing the internal residual air volume ratio to an extremely low level of ≤5%, based on the ideal gas law and dew point principle, the pressure amplitude of the "breathing effect" under temperature cycling is fundamentally and significantly reduced, and the amount of condensate that may be generated is reduced to negligible levels. This completely eliminates the root cause risk of high-voltage insulation failure caused by internal condensation, enabling the motor to reliably withstand temperature cycles from -40℃ to 125℃ and even more stringent conditions. The traditional wiring harness is abandoned, and a plug-in connection with a precise stop joint on the housing is adopted, greatly saving the space required for connections. This facilitates the shortening of the motor's axial length or the compactness of its radial dimensions, achieving a high degree of integration between the motor and the controller and improving the system's power density. The "separate potting followed by final assembly" process avoids the difficulties of potting a complex integral cavity, and combined with vacuum potting technology, ensures the potting body is dense and defect-free. The assembly process is clear, easily achieving automated and standardized production, ensuring high product consistency and reliability.

[0064] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Although this application has disclosed preferred embodiments as above, it is not intended to limit this application. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the technical solution of this application. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. An integrated high-voltage motor, characterized in that, The integrated high-voltage motor includes: Aluminum alloy front shell; The stator assembly is fixedly installed in the internal cavity of the aluminum alloy front housing; The rotor assembly is rotatably disposed inside the stator assembly; The motor rear cover is sealed and connected to the aluminum alloy front shell; The motor controller is integrated and fixed in the internal cavity of the motor rear cover; All the gaps between the stator assembly and the inner wall of the aluminum alloy front housing are filled with a first high thermal conductivity insulating potting compound to form a first potting cured body. All the gaps between the motor controller and the inner wall of the motor rear cover are filled with a second high thermal conductivity insulating potting compound to form a second potting cured body; The armature winding output terminal of the stator assembly is electrically connected to the power input terminal of the motor controller via a plug-in electrical connector. After the aluminum alloy front shell is sealed to the motor rear cover, the first potting and curing body and the second potting and curing body compress the residual air space inside the motor, excluding the rotor working air gap and bearing chamber, to a minimum.

2. The integrated high-voltage motor according to claim 1, characterized in that, The plug-in electrical connector is a plug-in high-voltage connector or an insulation displacement connector.

3. The integrated high-voltage motor according to claim 2, characterized in that, When using a plug-in type high-voltage connector, its male and female ends are fixed to the stator output end and the controller input end, respectively, and the mating and locking are completed when the aluminum alloy front shell and the motor rear cover are plugged together.

4. The integrated high-voltage motor according to claim 2, characterized in that, When using an insulated displacement connector, the stator winding leads are directly crimped into the pierced terminals on the controller PCB and the connection is completed before potting, after which they are encapsulated together with potting compound.

5. The integrated high-voltage motor according to claim 1, characterized in that, The first high thermal conductivity insulating potting compound and the second high thermal conductivity insulating potting compound are the same potting compound material, with a thermal conductivity ≥1.0 W / (m·K) and a volume resistivity ≥1×10^15 Ω·cm.

6. The integrated high-voltage motor according to claim 5, characterized in that, The potting compound material is an addition-type silicone potting compound or a high thermal conductivity epoxy resin potting compound.

7. The integrated high-voltage motor according to claim 1, characterized in that, The mating surfaces of the aluminum alloy front shell and the motor rear cover are provided with a precision stop and a sealing groove that fit together. The sealing groove is equipped with a static sealing ring and is locked by circumferentially distributed fastening bolts.

8. The integrated high-voltage motor according to claim 1, characterized in that, After assembly and sealing, the ratio of the total volume of residual air inside the motor to the total volume of the motor interior enclosed by the aluminum alloy front shell and the motor rear cover is less than or equal to 5%.

9. A method for assembling the integrated high-voltage motor according to any one of claims 1 to 8, characterized in that, Includes the following steps: Step S1: Secure the stator assembly inside the aluminum alloy front housing, install the front bearing, and install or prepare the stator end portion of the mating connector. Step S2: Fix the motor controller inside the motor rear cover, install the rear bearing, and install or prepare the controller end portion of the mating connector; Step S3: Fix the front shell assembly and the rear cover assembly respectively, so that the opening of their potting cavity faces upward, and perform preheating and sealing treatment; Step S4: In a vacuum environment, inject high thermal conductivity insulating potting compound into the stator cavity of the aluminum alloy front shell and the controller cavity of the motor rear cover respectively to fully fill the gaps, and then perform curing treatment to form a first potting cured body and a second potting cured body. Step S5: Install the rotor assembly into the potted stator cavity, align the aluminum alloy front shell and the motor rear cover, and plug them together to ensure accurate docking of the plug-in electrical connector and complete the tight sealing between the shells.

10. The method according to claim 9, characterized in that, In step S4, the vacuum level of the vacuum environment is not lower than -0.09 MPa, and the potting compound is kept under vacuum for a period of time to ensure that air bubbles are expelled.

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