High-strength aluminum alloy motor shell for new energy automobile

Abstract

The invention discloses a high-strength aluminum alloy motor shell for a new energy automobile. The high-strength aluminum alloy motor shell comprises a motor shell body, a liquid cooling circulation assembly, an NVH system and a shaft end cover. A clamping cavity layer located between the inner shell and the outer shell is arranged on the inner side of the motor shell, and heat exchange fin columns and rotational flow ribs are arranged in the clamping cavity layer. An NVH system is arranged in the clamping cavity layer, the NVH system comprises a fixing ring, a sheath frame, a resonance fork and a vibration resistance seat, and the sheath frame divides the clamping cavity layer into a plurality of independent vibration resistance cavities; different resonance forks have different inherent frequencies and are used for tuning and absorbing multi-band structural vibration generated in the operation process of the motor. A magnetic core is arranged on the resonance fork, a metal guide ring is arranged on the vibration damping seat, and eddy current magnetic damping is generated through relative movement of the magnetic core and the guide ring to dissipate vibration energy when the resonance fork vibrates. While efficient heat dissipation is achieved, vibration and noise of the motor are effectively reduced, and high strength, light weight and operation reliability of the shell are considered.

Description

Technical Field

[0001] This invention relates to the field of motor housing technology, specifically a high-strength aluminum alloy motor housing for new energy vehicles. Background Technology

[0002] New energy vehicle drive motors typically operate under conditions of high speed, high power density, and long-term continuous operation. Their housings not only need to accommodate the installation and positioning of the stator, rotor, and shaft system, but also must meet requirements for structural strength, heat dissipation, and vibration and noise control. Therefore, the structural design and functional integration level of the motor housing directly affects the reliability, comfort, and service life of the entire vehicle.

[0003] In existing technologies, motor housings for new energy vehicles mostly adopt a one-piece aluminum alloy casting structure. Their heat dissipation methods typically involve setting heat dissipation fins on the outer surface of the housing or arranging a single cooling water channel inside the housing, allowing the coolant to carry away the heat generated during motor operation. However, in this type of structure, the flow path of the cooling medium is relatively simple, and the flow pattern is mostly straight-line or locally circumferential. The residence time of the cooling medium inside the housing is short, limiting the heat exchange area and heat exchange uniformity. This makes it prone to localized heat accumulation under high power or high ambient temperature conditions, thus affecting motor efficiency and long-term operational stability.

[0004] Meanwhile, as the requirements for overall vehicle comfort in new energy vehicles continue to increase, the vibration and noise issues generated during motor operation are receiving increasing attention. Current motor housing NVH control methods largely rely on increasing housing wall thickness, adding simple reinforcing ribs, or installing external rubber damping pads to suppress vibration. While these solutions improve structural rigidity or isolate vibration transmission paths to some extent, they often lead to increased housing weight and lack targeted control over multi-frequency vibrations generated under different speed conditions, making it difficult to effectively suppress complex vibration problems caused by factors such as electromagnetic force pulsation and rotor imbalance.

[0005] In view of this, we will study and improve upon the existing problems to provide a high-strength aluminum alloy motor housing for new energy vehicles, so as to solve the current problems and improve the practical value through this technology. Summary of the Invention

[0006] This invention aims to solve the problems of insufficient heat dissipation efficiency, significant local heat accumulation, and difficulty in effectively suppressing multi-frequency structural vibrations in existing motor housings for new energy vehicles under high-power operation conditions. This invention proposes a high-strength aluminum alloy motor housing for new energy vehicles. By constructing a cavity layer structure inside the motor housing and integrating a liquid-cooled heat exchange structure and a multi-frequency tuned NVH system within the cavity layer, the invention achieves a synergistic improvement in heat dissipation performance and vibration suppression capability without significantly increasing the weight and structural complexity of the housing.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A high-strength aluminum alloy motor housing for new energy vehicles includes a motor housing, a liquid cooling circulation assembly, an NVH system, and a shaft end cap fixedly disposed at one end of the motor housing. A cavity layer is provided circumferentially inside the motor housing, the cavity layer being located between the inner shell and the outer shell of the motor housing to form a circumferentially closed cavity. A heat exchange structure and a vibration suppression structure are arranged simultaneously within the cavity layer, enabling the motor housing to simultaneously achieve efficient heat dissipation and multi-frequency vibration absorption during operation.

[0008] In a preferred embodiment, the present invention provides a circumferentially extending cavity layer on the inner side of the motor housing, the cavity layer being located between the inner shell and the outer shell of the motor housing, for forming a circumferentially closed cavity inside the motor housing; under the action of the liquid cooling circulation assembly, the cooling medium is introduced into the cavity layer for circulation.

[0009] In a preferred example, the cavity layer is provided with a plurality of heat exchange fins arranged in an array along the circumference or axial direction of the cavity layer, and in a columnar or prismatic structure, to increase the heat exchange contact area between the cooling medium and the motor housing.

[0010] Specifically, by setting up heat exchange fins, the cooling medium forms multiple flow paths and return paths within the jacket layer, thereby improving the overall heat exchange efficiency without significantly increasing flow resistance.

[0011] In a preferred example, the inner wall surface of the cavity layer is provided with swirling ribs, which are spiral, arc-shaped or periodically corrugated and extend circumferentially to introduce a rotational component during the flow of the cooling medium.

[0012] Specifically, the swirling ribs enable the cooling medium to form a spiral or turbulent flow state within the cavity layer, thereby extending the effective heat exchange path of the cooling medium, improving the uniformity of temperature distribution within the cavity layer, and reducing local heat accumulation.

[0013] In a preferred example, the NVH system is disposed inside the cavity layer and includes a retaining ring arranged circumferentially along the inner side of the motor housing, the retaining ring being fixedly connected to the inner side of the motor housing to provide a stable mounting base for the NVH system.

[0014] In a preferred example, a plurality of sheath frames are fixedly installed on the surface of the fixing ring, and each sheath frame is sealed against the inner wall of the cavity layer, thereby dividing the cavity layer in the circumferential direction to form a plurality of mutually independent vibration damping cavities.

[0015] Specifically, by separating the vibration damping cavities, crosstalk propagation of vibration energy within the cavity layer can be avoided, allowing different cavities to respond independently to vibrations in different frequency bands.

[0016] In a preferred example, each vibration damping cavity is provided with at least one set of resonant forks, and several resonant forks are arranged at circumferential intervals along the fixed ring. Each resonant fork has at least one difference in structural parameters such as length, thickness, or fork arm spacing, so that different resonant forks have different natural vibration frequencies.

[0017] In a preferred example, the resonant fork includes a fixed end and two elastic fork arms extending inward from the fixed end. The free ends of the elastic fork arms are located inside the vibration damping cavity and form a non-rigid coupling relationship with the vibration damping seat.

[0018] Specifically, through the synergistic effect of multiple sets of resonant forks with different natural frequencies, the multi-order structural vibrations generated by the motor housing under different speed conditions can be absorbed by the resonant forks of the corresponding frequency bands, thereby forming a passive vibration absorption system covering multiple frequency bands.

[0019] In a preferred example, each resonant fork cooperates with a corresponding damping seat disposed in the damping cavity, the surface of which is provided with a first guide ring and a second guide ring.

[0020] The axial direction of the first guide ring is consistent with the radial direction of the motor housing, and the axial direction of the second guide ring is perpendicular to the axial direction of the first guide ring, thereby forming a multi-directional magnetic damping interface on the vibration damping seat.

[0021] In a preferred example, both the first and second guide rings are metal copper ring structures and are fixedly embedded inside or on the surface of the vibration damping seat to form a stable induced current loop during magnetic field changes.

[0022] Specifically, this structure provides a clear and controllable physical basis for the subsequent generation of magnetic damping effect.

[0023] In a preferred example, a magnetic core is fixedly disposed on the surface of the resonant fork, and each magnetic core is coaxially arranged with the first guide ring and the second guide ring and sleeved inside them.

[0024] When the motor housing vibrates during operation, the resonant fork swings under the vibration excitation, causing the magnetic core to move relative to the metal copper ring.

[0025] Specifically, the relative motion causes a change in the magnetic flux inside the copper ring, thereby inducing eddy currents in the copper ring. These eddy currents generate a magnetic damping force in the opposite direction to the change in magnetic flux according to Lenz's law, thereby dissipating and suppressing the vibration of the resonant fork, avoiding resonance amplification, and reducing the overall vibration response amplitude of the motor housing.

[0026] The beneficial effects achieved by this invention are as follows: 1. In this invention, by setting a cavity layer inside the motor housing and arranging heat exchange fins and swirl ribs in the cavity layer, the cooling medium transported by the liquid cooling circulation assembly forms a controlled spiral flow or turbulent flow state in the cavity layer. This effectively expands the heat exchange area and improves the heat exchange uniformity without significantly increasing the flow resistance, thereby avoiding heat concentration in local areas of the motor housing and improving the heat dissipation efficiency and operational stability of the motor under high power conditions.

[0027] 2. In this invention, by setting multiple independent vibration damping cavities separated by a fixing ring and a sheath frame in the cavity layer, and arranging resonant forks with different natural frequencies in each vibration damping cavity, the multi-order structural vibrations generated by the motor housing under different speed conditions can be tuned and absorbed separately, effectively reducing the transmission and superposition of vibration energy in the housing structure, and significantly improving the NVH performance during motor operation.

[0028] 3. In this invention, by setting a magnetic core on the resonant fork and forming a relative motion relationship with the metal copper ring on the vibration damping seat, the eddy current magnetic damping generated by Lenz's law is used to dissipate and suppress the vibration of the resonant fork. This achieves rapid attenuation of vibration energy without the need for external energy input or active control, avoiding the risk of resonance amplification. Thus, while ensuring the high strength and lightweight of the shell, the reliability and service life of the entire motor system are improved. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of one embodiment of the present invention; Figure 2 This is an exploded structural diagram of an embodiment of the present invention; Figure 3 This is a schematic diagram of the internal structure of the cavity layer according to an embodiment of the present invention; Figure 4 This is a schematic diagram of an NVH system structure according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the resonant fork and vibration damping seat structure according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the surface structure of a vibration damping seat according to an embodiment of the present invention.

[0030] Figure label: 100. Motor housing; 110. Shaft end cover; 120. Jacket layer; 121. Heat exchange fins; 122. Swirl ribs; 200. Liquid cooling circulation assembly; 300, NVH system; 310, fixed ring; 311, sheath frame; 320, resonant fork; 330, vibration damping seat; 331, first guide ring; 332, second guide ring; 333, magnetic core. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0032] It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention.

[0033] The following describes, with reference to the accompanying drawings, some embodiments of the present invention, providing a high-strength aluminum alloy motor housing for new energy vehicles.

[0034] Combination Figures 1-6 As shown, the present invention provides a high-strength aluminum alloy motor housing for new energy vehicles, including a motor housing 100, a liquid cooling circulation assembly 200, an NVH system 300, and a shaft end cap 110 fixedly disposed at one end of the motor housing 100.

[0035] In this embodiment, the motor housing 100 is integrally formed from high-strength aluminum alloy material, and a cavity layer 120 is provided circumferentially on its inner side. The cavity layer 120 is located between the inner shell and the outer shell of the motor housing 100, and is used to form a circumferentially closed cavity inside the motor housing 100. Through the setting of the cavity layer 120, the motor housing 100 can have internal functional integration space while maintaining overall strength, providing a structural basis for the arrangement of heat dissipation structure and NVH system 300.

[0036] In this embodiment, the cavity layer 120 is provided with a plurality of heat exchange fins 121 and swirl ribs 122. The heat exchange fins 121 are arranged in an array along the circumference or axial direction of the cavity layer 120. The heat exchange fins 121 have a columnar or prismatic structure, which is used to expand the heat exchange contact area between the cooling medium and the motor housing 100 without significantly increasing the flow resistance of the cooling medium.

[0037] Swirl flow ribs 122 are disposed on the inner wall surface of the cavity layer 120. The swirl flow ribs 122 can extend circumferentially in a spiral, arc, or periodic corrugated shape. When the liquid cooling circulation assembly 200 delivers cooling medium into the cavity layer 120, the swirl flow ribs 122 guide the flow direction of the cooling medium, causing the cooling medium to form a spiral flow or turbulent flow state within the cavity layer 120. This prolongs the flow path of the cooling medium within the cavity layer 120, improves the overall heat transfer uniformity, and reduces the risk of heat accumulation in local areas.

[0038] Combination Figure 3 and Figure 4 As shown, the NVH system 300 is disposed within the cavity layer 120 and includes a retaining ring 310. The retaining ring 310 is arranged along the inner circumferential direction of the motor housing 100 and is fixedly connected to the inner side of the motor housing 100, thereby forming a stable and reliable structural connection between the NVH system 300 and the motor housing 100.

[0039] Several sheath frames 311 are fixedly installed on the surface of the fixed ring 310, and each sheath frame 311 is in sealed contact with the inner wall of the cavity layer 120. The sheath frames 311 divide the cavity layer 120 circumferentially into several independent vibration-damping cavities. This structure effectively prevents crosstalk propagation of vibration energy within the cavity layer 120, allowing each vibration-damping cavity to independently respond to the structural vibration of the motor housing 100 in different frequency bands.

[0040] In this embodiment, each vibration damping cavity is provided with at least one set of resonant forks 320. Several resonant forks 320 are arranged at intervals along the circumference of the fixing ring 310, and each resonant fork 320 has at least one difference in structural parameters such as length, thickness or fork arm spacing, so that different resonant forks 320 have different natural vibration frequencies.

[0041] The resonant fork 320 includes a fixed end and two elastic fork arms extending inward from the fixed end, with the free ends of the elastic fork arms located inside the vibration damping cavity. Through the above structural design, the resonant fork 320 can undergo forced oscillation when the motor housing 100 generates structural vibration, and tune its response to vibrations in the corresponding frequency band near its natural frequency, thereby forming a passive vibration absorption structure system covering multiple frequency bands.

[0042] Combination Figure 5 and Figure 6 As shown, in each vibration damping cavity, the resonant fork 320 and the vibration damping seat 330 are configured to cooperate with each other. The vibration damping seat 330 is fixedly arranged in the corresponding vibration damping cavity, and its surface is provided with a first guide ring 331 and a second guide ring 332.

[0043] The axial direction of the first guide ring 331 is aligned with the radial direction of the motor housing 100, while the axial direction of the second guide ring 332 is perpendicular to the axial direction of the first guide ring 331, thus forming a multi-directional magnetic damping interface on the vibration damping base 330. Both the first guide ring 331 and the second guide ring 332 are copper ring structures and are fixedly embedded inside or on the surface of the vibration damping base 330 to form a stable induced current loop during magnetic field changes.

[0044] In this embodiment, a magnetic core 333 is fixedly disposed on the surface of the resonant fork 320. Each magnetic core 333 is coaxially arranged with the first guide ring 331 and the second guide ring 332, and is sleeved on the inner side of the first guide ring 331 and the second guide ring 332.

[0045] When structural vibration occurs during motor operation, the resonant fork 320 oscillates under vibration excitation, causing the magnetic core 333 to move relative to the first guide ring 331 and the second guide ring 332. This relative motion causes a change in the magnetic flux inside the copper ring, thereby inducing eddy currents in the first guide ring 331 and the second guide ring 332. These eddy currents generate a magnetic damping force opposite to the direction of the magnetic flux change according to Lenz's law. This magnetic damping force acts on the magnetic core 333 and the resonant fork 320, causing the vibration energy of the resonant fork 320 to be converted into electromagnetic losses and rapidly attenuated, thereby suppressing the vibration response amplitude of the resonant fork 320 and the motor housing 100.

[0046] Working principle and usage process of this invention: The high-strength aluminum alloy motor housing for new energy vehicles of this invention achieves comprehensive regulation of motor heat and structural vibration during motor operation through the synergistic effect of the liquid cooling heat exchange structure in the cavity layer 120 and the NVH system 300.

[0047] When the motor is running, the liquid cooling circulation assembly 200 delivers cooling medium into the cavity layer 120. Under the guidance and diversion of the heat exchange fins 121, the cooling medium forms a large-area heat exchange contact with the motor housing 100. At the same time, the swirling ribs 122 set on the inner wall surface of the cavity layer 120 guide the flow direction of the cooling medium, so that the cooling medium forms a spiral flow or turbulent flow state in the cavity layer 120, thereby extending the flow path of the cooling medium in the cavity layer 120 and improving the heat exchange uniformity, avoiding heat concentration in local areas.

[0048] When the motor operates at different speeds, rotor electromagnetic excitation, shaft imbalance, and electromagnetic force pulsation will cause multi-frequency structural vibrations in the motor housing 100. These vibrations are transmitted to the cavity layer 120 region via the motor housing 100. At this time, the NVH system 300 arranged in the cavity layer 120 is excited synchronously with the motor housing 100.

[0049] The fixed ring 310 serves as the basic support structure of the NVH system 300 and is fixedly connected to the inner side of the motor housing 100, so that the NVH system 300 and the motor housing 100 form a stable mechanical coupling relationship. Multiple sheath frames 311 are sealed and abutted against the inner wall of the cavity layer 120, dividing the cavity layer 120 into several independent vibration damping cavities, thereby preventing crosstalk propagation of vibration energy in the cavity layer 120 and enabling each vibration damping cavity to respond independently to vibrations in different frequency bands.

[0050] Under structural vibration, the resonant forks 320 within each vibration-damping cavity undergo forced oscillation. Due to differences in structural parameters such as length, thickness, or fork arm spacing, each resonant fork 320 possesses a different natural vibration frequency, enabling it to tune to different orders of vibration generated during motor operation, thus forming a multi-frequency-band passive vibration-absorbing system. When the structural vibration of a certain frequency band approaches the natural frequency of the corresponding resonant fork 320, that resonant fork 320 generates a large relative vibration displacement, absorbing the vibration energy of the motor housing 100.

[0051] During the oscillation of the resonant fork 320, the magnetic core 333 fixed to the surface of the resonant fork 320 undergoes relative motion with respect to the first guide ring 331 and the second guide ring 332 on the vibration damping base 330. This causes a time-varying change in magnetic flux within the first guide ring 331 and the second guide ring 332, thereby inducing eddy currents in the first guide ring 331 and the second guide ring 332. These eddy currents generate a magnetic damping force in the opposite direction to the change in magnetic flux according to Lenz's law. This magnetic damping force acts on the magnetic core 333 and the resonant fork 320, causing the vibrational energy of the resonant fork 320 to be converted into electromagnetic losses and rapidly decay, thereby suppressing excessive amplitude of the resonant fork 320 and preventing structural resonance amplification.

[0052] Through the synergistic effect of the above structure and mechanism, the present invention achieves absorption and dissipation of multi-frequency structural vibration of the motor housing 100 without relying on active control or external energy input, effectively reducing the vibration and noise level during motor operation, while ensuring the operational stability and reliability of the motor housing 100 under high strength, lightweight and efficient heat dissipation conditions.

[0053] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0054] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A high-strength aluminum alloy motor housing for new energy vehicles, characterized in that, The device includes a motor housing (100), a liquid cooling circulation assembly (200), an NVH system (300), and a shaft end cap (110) fixedly disposed at one end of the motor housing (100). The inner side of the motor housing (100) is provided with a cavity layer (120) extending in the circumferential direction. The cavity layer (120) is located between the inner shell and the outer shell of the motor housing (100) and is used to form a circumferentially closed cavity inside the motor housing (100). The cavity layer (120) is provided with heat exchange fins (121) and swirl ribs (122) to guide the cooling medium to form a controlled flow path in the cavity layer (120) under the action of the liquid cooling circulation assembly (200); The NVH system (300) is disposed in the cavity layer (120) and includes a fixing ring (310). The fixing ring (310) is arranged along the inner circumference of the motor housing (100) and is fixedly connected to the inner side of the motor housing (100). A plurality of protective frames (311) are fixedly installed on the surface of the fixing ring (310). Each of the protective frames (311) is sealed and abutted against the inner wall of the cavity layer (120) to divide the cavity layer (120) into a plurality of independent vibration damping cavities.

2. The high-strength aluminum alloy motor housing for new energy vehicles according to claim 1, characterized in that, Each of the vibration damping cavities is provided with at least one set of resonant forks (320) and vibration damping seats (330). The surface of the vibration damping seat (330) is provided with a first guide ring (331) and a second guide ring (332). The surface of the resonant fork (320) is fixedly provided with a magnetic core (333). Each magnetic core (333) is coaxially arranged with the first guide ring (331) and the second guide ring (332) and sleeved inside it. The resonant fork (320) and the vibration damping seat (330) cooperate with each other to form a tuned passive vibration absorption unit, which is used to suppress the structural vibration generated by the motor housing (100) during operation in multiple frequency bands.

3. The high-strength aluminum alloy motor housing for new energy vehicles according to claim 1, characterized in that, The heat exchange fins (121) are arranged in a circumferential or axial array along the cavity layer (120). The heat exchange fins (121) are columnar or prismatic structures, which are used to expand the heat exchange area between the cooling medium and the motor housing (100) without significantly increasing the flow resistance.

4. The high-strength aluminum alloy motor housing for new energy vehicles according to claim 1, characterized in that, The swirling ribs (122) are disposed on the inner wall surface of the cavity layer (120) and extend circumferentially in a spiral, arc or periodic corrugated shape to introduce a rotational component during the flow of the cooling medium, so that the cooling medium forms a spiral flow or turbulent flow in the cavity layer (120), thereby improving the heat exchange uniformity and reducing local heat accumulation.

5. A high-strength aluminum alloy motor housing for new energy vehicles according to claim 2, characterized in that, Several of the resonant forks (320) are arranged circumferentially along the fixed ring (310), and at least one of the structural parameters of the length, thickness or fork arm spacing of each resonant fork (320) is different from each other, so that different resonant forks (320) have different natural vibration frequencies, thereby absorbing the multi-order vibration generated by the motor housing (100) under different speed conditions in a frequency band coverage manner.

6. A high-strength aluminum alloy motor housing for new energy vehicles according to claim 5, characterized in that, The resonant fork (320) includes a fixed end and two elastic fork arms extending inward from the fixed end. The free ends of the elastic fork arms are located inside the vibration damping cavity and form a non-rigid coupling relationship with the vibration damping seat (330) to avoid structural hard collisions under resonance conditions.

7. A high-strength aluminum alloy motor housing for new energy vehicles according to claim 2, characterized in that, The axial direction of the first guide ring (331) is consistent with the radial direction of the motor housing (100), and the axial direction of the second guide ring (332) is perpendicular to the axial direction of the first guide ring (331), thereby forming a multi-directional magnetic damping interface on the vibration damping seat (330).

8. A high-strength aluminum alloy motor housing for new energy vehicles according to claim 7, characterized in that, The first guide ring (331) and the second guide ring (332) are both metal copper ring structures and are fixedly embedded inside or on the surface of the vibration damping seat (330) to form an induced current loop during the magnetic field change process.

9. A high-strength aluminum alloy motor housing for new energy vehicles according to claim 2, characterized in that, When the resonant fork (320) swings under structural vibration excitation, the magnetic core (333) generates relative motion with respect to the copper ring, thereby inducing eddy currents in the copper ring and generating a reverse magnetic damping force according to Lenz's law, so as to suppress the vibration response amplitude of the resonant fork (320) and the motor housing (100).

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