Non-co-shell oil-cooled electric drive three-phase connection sealing structure and electric drive assembly

Abstract

The application discloses a non-co-shell oil-cooled electric drive three-phase connection sealing structure, which comprises a terminal seat, a sealing end face for being connected with a motor shell, the sealing end face protrudes towards the motor shell to form an extension part penetrating through the motor shell, three-phase copper bars are fixed on the terminal seat and penetrate through the extension part, a first sealing assembly is arranged on the sealing end face to form a seal between the sealing end face and the motor shell, and a second sealing assembly is sleeved on the extension part to form a seal between the second sealing assembly and a hole wall of a controller shell. The sealing end face of the terminal seat cooperates with the first sealing assembly to realize end face sealing between the terminal seat and the motor shell and effectively seal the motor oil cavity. The second sealing assembly on the extension part cooperates with the hole wall of the controller shell to realize radial sealing and effectively seal the controller cavity.

Description

Technical Field

[0001] This invention belongs to the field of new energy electric drive assembly technology, specifically a non-common shell oil-cooled electric drive three-phase connection sealing structure and electric drive assembly. Background Technology

[0002] With the increasing demand for multi-functional electric drive assemblies in new energy vehicles, the high integration and shared housing of electric drive assemblies have led to increased difficulties in product assembly and after-sales maintenance. Due to the height restrictions imposed by the vehicle on the electric drive system, the electric drive controller is mostly located on the side or axial end face of the motor.

[0003] Most oil-cooled electric drive assemblies employ a non-co-casing design for the controller and motor to ensure assemblability and reduce after-sales difficulties. The controller and motor are pre-assembled into the main assembly before final assembly, reducing the frequency of defective parts requiring repair. The requirement for side-mounted controllers necessitates three-phase copper busbar connections involving sealing both the oil-lubricated motor cavity and the controller cavity. Traditional wire-spinning or copper busbar connection methods cannot simultaneously satisfy both oil cavity sealing and assembly convenience. Therefore, a non-co-casing three-phase connection sealing structure for oil-cooled electric drives is needed to address the sealing issues during the assembly of the controller and motor cavities.

[0004] The information disclosed in the background section of this invention is only intended to enhance the understanding of the general background of the invention and should not be construed as an admission or any implication that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide a non-common-shell oil-cooled electric drive three-phase connection sealing structure and electric drive assembly to solve at least one of the above-mentioned technical problems.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A non-common-casing oil-cooled electric drive three-phase connection sealing structure includes: A terminal block has a sealing end face for connecting to a motor housing, the sealing end face protruding toward the motor housing to form an extension that passes through the motor housing, and a three-phase copper busbar is fixed on the terminal block, the three-phase copper busbar passing through the extension; A first sealing component is disposed on the sealing end face to form a seal between the sealing end face and the motor housing; The second sealing component is fitted onto the extension to form a seal between itself and the bore wall of the controller housing.

[0007] Furthermore, the connection end of the three-phase copper busbar is provided with an assembly hole to mate with the mounting hole of the controller copper busbar.

[0008] Furthermore, the terminal block is an injection molded part.

[0009] Furthermore, a groove is provided at the connection between the end face of the extension and the three-phase copper busbar, and the groove is filled with sealant to form a seal between the extension and the three-phase copper busbar.

[0010] Furthermore, the sealing end face is provided with a first sealing groove, and the first sealing assembly includes an end face sealing ring embedded in the first sealing groove.

[0011] Furthermore, the outer peripheral surface of the extension is provided with a second sealing groove, and the second sealing assembly includes a radial sealing ring embedded in the second sealing groove.

[0012] Furthermore, the outer ring of the radial sealing ring is provided with a multi-layered protrusion structure, and the multi-layered protrusion structure is arranged sequentially along the axial direction of the radial sealing ring so that the radial sealing ring is interference-fitted with the bore wall of the controller housing.

[0013] Furthermore, the radial sealing ring has an annular cavity inside.

[0014] Furthermore, the radial sealing ring is provided with an annular support skeleton, the cross-section of which is U-shaped.

[0015] The present invention also provides an electric drive assembly, including a motor housing, a controller housing, and a non-co-hub oil-cooled three-phase connection sealing structure as described above.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention achieves end-face sealing between the terminal block and the motor housing by mates with the first sealing component, effectively isolating the motor oil cavity; and achieves radial sealing by mates with the second sealing component on the extension and the bore wall of the controller housing, effectively isolating the controller cavity. The combination of these two sealing structures in different directions allows the entire sealing structure to adapt to the accumulation of assembly tolerances in various degrees of freedom, effectively preventing leakage.

[0017] 2. In this invention, the multi-layered raised structure of the outer ring of the radial sealing ring undergoes elastic deformation during assembly, which enables self-centering during the assembly process of the terminal block and ensures that the compression amount at each position in the circumferential direction is consistent, thereby ensuring reliable radial sealing performance even under lower assembly precision requirements.

[0018] 3. In this invention, the mounting hole at the end of the three-phase copper busbar is larger than the mounting hole of the controller copper busbar, which can effectively absorb the cumulative assembly error between the motor and the controller, ensure that the screws can pass through and be tightened normally, greatly reduce the assembly difficulty and improve the assembly convenience.

[0019] 4. In this invention, the terminal block uses injection molded parts to fix the three-phase copper busbars into one piece, and a groove is set at the junction of the three-phase copper busbars and the terminal block and filled with sealant, which provides sealing and oil-proof capability between the three-phase copper busbars and the terminal block. The structure is compact and highly integrated. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the non-common-shell oil-cooled electric drive three-phase connection sealing structure in this embodiment; Figure 2 This is a schematic diagram of another part of the non-common-shell oil-cooled electric drive three-phase connection sealing structure in this embodiment; Figure 3 This is a cross-sectional view of the non-common-shell oil-cooled electric drive three-phase connection sealing structure in this embodiment; Figure 4 This is a diagram showing the installation relationship between the three-phase copper busbar and the controller copper busbar in this embodiment; Figure 5 This is a diagram showing the positional relationship between the radial sealing ring and the annular cavity in this embodiment; Figure 6 This is a diagram showing the positional relationship between the radial sealing ring and the support frame in this embodiment; In the diagram: 1. Terminal block; 2. End face sealing ring; 3. Radial sealing ring; 4. Sealant; 5. Three-phase copper busbar; 6. First sealing groove; 7. Second sealing groove; 8. Groove; 9. Motor housing; 10. Protruding structure; 11. Controller housing; 12. Controller copper busbar; 13. Assembly hole; 14. Screw; 15. Annular cavity; 16. Support frame; 17. Extension. Detailed Implementation

[0021] The technical solution of this application will now be clearly and completely described with reference to the accompanying drawings. The following embodiments are exemplary and are only used to explain this application, and should not be construed as limiting this application. In the following description, the same reference numerals are used to denote the same or equivalent elements, and repeated descriptions are omitted.

[0022] In the description of this application, it should be understood that the terms "upper," "lower," "inner," "outer," "left," and "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this application is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the equipment or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In addition, the prepositions "first," "second," and "third," etc., are only used for the purpose of distinguishing the modified objects, and should not be construed as indicating or implying relative importance.

[0023] Furthermore, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0024] It should also be further understood that the term "and / or" as used in this application specification and the corresponding claims refers to any combination of one or more of the listed items and all possible combinations.

[0025] like Figure 1-4 As shown, this embodiment provides a non-common-casing oil-cooled electric drive three-phase connection sealing structure, including: terminal block 1, first sealing component and second sealing component.

[0026] Terminal block 1 has a sealing end face for connecting with motor housing 9. The sealing end face protrudes towards motor housing 9 to form an extension 17 that passes through motor housing 9. Three-phase copper busbars 5 are fixed on terminal block 1, and the three-phase copper busbars 5 pass through the extension 17. Terminal block 1 is an injection molded part, that is, terminal block 1 is made by injection molding process. Terminal block 1 uses injection molding process to embed and fix the three-phase copper busbars 5 into the terminal block 1 as an integrated wiring assembly. Compared with the split wiring structure, the injection molding integrated design greatly reduces the number of parts, and at the same time precisely defines the relative position between each copper busbar of the three-phase copper busbars 5, avoiding assembly interference and electrical short circuit risk caused by misalignment of the three-phase copper busbars 5, and improving the integration and reliability of the structure. The material of terminal block 1 can be flexibly adjusted according to the type of cooling oil inside the electric drive assembly, the long-term operating temperature range, and the structural strength requirements. The grade of the plastic matrix and the content of reinforcing fibers such as glass fiber can be adjusted to ensure that terminal block 1 can maintain stable mechanical properties and aging resistance under long-term oil immersion, high and low temperature alternation, and vibration conditions, and avoid failure problems such as cracking and deformation.

[0027] The first sealing component is disposed on the sealing end face so as to form a seal between the sealing end face and the motor housing 9; The second sealing assembly is fitted onto the extension 17 to form a seal between it and the bore wall of the controller housing 11.

[0028] Furthermore, the connection end of the three-phase copper busbar 5 is provided with an assembly hole 13 to mate with the mounting hole of the controller copper busbar 12. The assembly hole 13 is specifically an oblong hole, and the diameter and length of the oblong hole are larger than the size of the circular mounting hole on the controller copper busbar 12. This can effectively absorb the cumulative axial and radial tolerances between the motor housing 9 and the controller housing 11 caused by component processing errors and sub-assembly assembly errors. Without the need for secondary shaping or position adjustment of the copper busbar, the screw 14 can be smoothly passed through the holes of the two copper busbars and locked, which greatly reduces the assembly difficulty and improves the assembly efficiency and first-time assembly pass rate.

[0029] Furthermore, a groove 8 is provided at the connection between the end face of the extension 17 and the three-phase copper busbar 5. The groove 8 is filled with sealant 4 to form a seal between the extension 17 and the three-phase copper busbar 5. The groove 8 is an annular groove 8 individually provided around the root of each copper busbar of the three-phase copper busbar 5. After the terminal block 1 is injection molded, the sealant 4 is evenly filled into the groove 8 and allowed to fully cure. This effectively fills the tiny gaps between the plastic matrix and the metal surface of the copper busbar caused by material shrinkage and insufficient interfacial bonding during the injection molding process, forming a reliable interfacial seal and preventing the cooling oil in the motor oil cavity from leaking into the controller cavity through the joint surface between the three-phase copper busbar 5 and the terminal block 1. At the same time, the sealant 4 also plays a buffering and shock absorption role, absorbing the vibration transmitted to the connection part of the three-phase copper busbar 5 during vehicle operation and reducing the risk of fatigue fracture of the three-phase copper busbar 5. The type of sealant 4 can be selected specifically according to the chemical properties and operating temperature range of the oil inside the electric drive assembly, ensuring that the sealant 4 will not crack, peel off, swell or harden and fail under long-term contact with cooling oil and high and low temperature environments, thus maintaining long-term stable sealing performance.

[0030] Furthermore, a first sealing groove 6 is provided on the sealing end face, and the first sealing component includes an end face sealing ring 2 embedded in the first sealing groove 6. The first sealing groove 6 is specifically a U-shaped groove. The cross-sectional width and depth dimensions of the first sealing groove 6 and the wire diameter of the end face sealing ring 2 are precisely designed according to the standard compression required for end face sealing, ensuring that the end face sealing ring 2 can obtain a uniform and sufficient compression after assembly, forming a gapless static seal on the end face. The end face sealing ring 2 fits tightly against the flat end face of the motor housing 9. The terminal block 1, the sealant 4, and the assembled end face sealing ring 2 and motor housing 9 together form a complete motor oil cavity sealing structure, which can effectively seal the high-pressure cooling oil cavity inside the motor and prevent cooling oil from leaking outward from the mating surface between the motor housing 9 and the terminal block 1. The rubber material of the end face seal ring 2 can be changed according to the type of cooling oil (such as ATF oil, gear oil) and temperature resistance requirements. Different materials such as nitrile rubber and fluororubber can be selected to adapt to electric drive assemblies under different operating conditions, ensuring that the oil resistance, temperature resistance, and aging resistance of the end face seal ring 2 meet the service life requirements of the entire vehicle. The sealing structure between the end face seal ring 2 and the motor housing 9 allows the terminal block 1 to produce a certain range of planar sliding displacement on the end face of the motor housing 9, which can accommodate the end face flatness tolerance and assembly misalignment between the motor and the controller. During the displacement process, the end face seal ring 2 always maintains effective compression and will not experience sealing failure.

[0031] Furthermore, the outer circumferential surface of the extension 17 is provided with a second sealing groove 7, and the second sealing assembly includes a radial sealing ring 3 embedded in the second sealing groove 7. The second sealing groove 7 is also a U-shaped groove, and the axial width of the second sealing groove 7 is greater than the axial width of the radial sealing ring 3, providing sufficient space for the assembly deformation and axial sliding of the radial sealing ring 3, ensuring that the radial sealing ring 3 can flexibly slide axially along the hole wall of the controller housing 11 without falling out of the second sealing groove 7. The inner circumference of the radial sealing ring 3 is smaller than the outer circumference of the bottom of the second sealing groove 7, so that after the radial sealing ring 3 is assembled, the inner ring can tightly fit against the bottom of the second sealing groove 7 under its own elastic force, preventing oil leakage from the gap between the radial sealing ring 3 and the extension 17. The rubber material of the radial sealing ring 3 can also be replaced according to the type of oil and temperature resistance requirements, maintaining the same environmental adaptability as the end face sealing ring 2.

[0032] Furthermore, the outer ring of the radial sealing ring 3 is provided with a multi-layered raised structure 10. The multi-layered raised structure 10 is arranged sequentially along the axial direction of the radial sealing ring 3 so that the radial sealing ring 3 is interference-fitted with the hole wall of the controller housing 11. Specifically, the multi-layered raised structure 10 consists of three coaxially arranged annular raised structures. The height of each raised structure 10 is independently designed according to the compression required for radial sealing. During assembly, the three raised structures 10 sequentially contact the hole wall of the controller housing 11 and undergo elastic deformation, forming three independent sealing defense lines, which greatly improves the reliability of radial sealing. Even if one of the raised structures fails slightly due to wear or scratches from impurities, the other two raised structures can still maintain effective sealing performance. During the assembly process, the multi-layered raised structure 10 will generate a circumferentially uniformly distributed elastic reaction force on the terminal block 1, automatically correcting the assembly eccentricity of the terminal block 1, realizing the self-centering function of the terminal block 1 in the hole of the controller housing 11, ensuring that the compression of the radial sealing ring 3 is consistent at all circumferential positions, and avoiding leakage caused by insufficient local compression due to eccentricity or assembly difficulties caused by excessive local compression. This design significantly reduces the machining accuracy requirements for the mounting holes of the controller housing 11 and the assembly accuracy requirements for the terminal block 1, effectively reducing manufacturing costs. The radial sealing structure allows the terminal block 1 to drive the radial sealing ring 3 to slide axially along the hole wall of the controller housing 11, absorbing axial assembly tolerances between the motor and the controller. During the sliding process, the multi-layered protruding structure 10 always maintains an interference fit with the hole wall of the controller housing 11, without affecting the radial sealing effect.

[0033] As a preferred embodiment of this solution, such as Figure 5 As shown, an annular cavity 15 may be provided inside the radial sealing ring 3. The annular cavity 15 is continuously provided along the circumference of the radial sealing ring 3, located inside the rubber body of the radial sealing ring 3 and on the inner side of the multi-layer protrusions. It can significantly increase the elastic deformation capacity of the radial sealing ring 3, reduce the axial insertion force during the assembly of the terminal block 1, and make the assembly process smoother and less labor-intensive. At the same time, the annular cavity 15 can effectively buffer external vibration and impact, and extend the service life of the radial sealing ring 3.

[0034] As another preferred solution in this embodiment, such as Figure 6 As shown, an annular support frame 16 may be provided inside the radial sealing ring 3, and the cross-section of the support frame 16 is U-shaped. The support frame 16 is made of cold-rolled steel plate or other metal materials and is integrally embedded inside the rubber body of the radial sealing ring 3. It can provide sufficient structural support for the radial sealing ring 3, prevent the rubber body from excessively deforming, collapsing or torturing under long-term pressure, oil immersion and temperature alternation, ensure the fitting accuracy between the radial sealing ring 3 and the second sealing groove 7 and the hole wall of the controller housing 11, and maintain long-term stable sealing performance.

[0035] The specific assembly process of the non-common-shell oil-cooled electric drive three-phase connection sealing structure provided in this embodiment is as follows: First, insert the end face sealing ring 2 into the first sealing groove 6 of the sealing end face of the terminal block 1, and insert the radial sealing ring 3 into the second sealing groove 7 of the extension 17 of the terminal block 1, ensuring that the radial sealing ring 3 is installed in place without twisting; then, evenly fill the three annular grooves 8 at the root of the three-phase copper busbar 5 with sealant 4, and after the sealant 4 has completely cured, a pre-assembled sealing component is formed; next, slowly push the sealing component axially along the mounting hole of the controller housing 11 until the sealing end face of the terminal block 1 is completely flush with the corresponding end face of the motor housing 9; finally, align the mounting hole of the controller copper busbar 12 with the assembly hole 13 of the three-phase copper busbar 5, and use screws 14 to pass through the mounting hole and assembly hole 13 in sequence and tighten them to the specified torque, thus completing the assembly of the entire three-phase connection sealing structure. The entire assembly process does not require complex tooling fixtures and can automatically adapt to the processing and assembly tolerances of each component, making the operation simple and convenient, and the assembly efficiency high.

[0036] This embodiment also provides an electric drive assembly, including a motor housing 9, a controller housing 11, and a non-co-housing oil-cooled three-phase connection sealing structure as described above. The electric drive assembly adopts a separate design where the controller and motor are not co-housing. The controller is located on the side of the motor, perfectly adapting to the height restrictions of the vehicle on the electric drive assembly. At the same time, it facilitates the pre-assembly of the controller and motor into the assembly before final assembly, greatly reducing the overall assembly difficulty, reducing the frequency of rework of defective products, and improving production efficiency and after-sales maintenance convenience.

[0037] It should be noted that although the present invention has been disclosed above with specific embodiments, the above embodiments are not intended to limit the present invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the scope defined in the claims.

Claims

1. A non-common-shell oil-cooled electric drive three-phase connection sealing structure, characterized in that, include: A terminal block has a sealing end face for connecting to a motor housing, the sealing end face protruding toward the motor housing to form an extension that passes through the motor housing, and a three-phase copper busbar is fixed on the terminal block, the three-phase copper busbar passing through the extension; A first sealing component is disposed on the sealing end face to form a seal between the sealing end face and the motor housing; The second sealing component is fitted onto the extension to form a seal between itself and the bore wall of the controller housing.

2. The non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 1, characterized in that, The connection end of the three-phase copper busbar is provided with an assembly hole to mate with the mounting hole of the controller copper busbar.

3. The non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 1, characterized in that, The terminal block is an injection molded part.

4. The non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 1, characterized in that, A groove is provided at the connection between the end face of the extension and the three-phase copper busbar, and the groove is filled with sealant to form a seal between the extension and the three-phase copper busbar.

5. The non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 1, characterized in that, The sealing end face is provided with a first sealing groove, and the first sealing component includes an end face sealing ring embedded in the first sealing groove.

6. The non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 1, characterized in that, The outer peripheral surface of the extension is provided with a second sealing groove, and the second sealing assembly includes a radial sealing ring embedded in the second sealing groove.

7. The non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 6, characterized in that, The outer ring of the radial sealing ring is provided with a multi-layered protrusion structure, and the multi-layered protrusion structure is arranged sequentially along the axial direction of the radial sealing ring so that the radial sealing ring is interference-fitted with the bore wall of the controller housing.

8. The non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 6, characterized in that, The radial sealing ring has an annular cavity inside.

9. A non-common-shell oil-cooled electric drive three-phase connection sealing structure as described in claim 6, characterized in that, The radial sealing ring is provided with an annular support skeleton, and the cross-section of the support skeleton is U-shaped.

10. An electric drive assembly, comprising a motor housing, a controller housing, and a non-co-casing oil-cooled three-phase connection sealing structure as described in any one of claims 1 to 9.

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