Composite cooling enclosure

Abstract

The application provides a composite cooling shell and belongs to the technical field of new energy automobile electric motors. The composite cooling shell comprises a reducer first shell, a motor shell arranged on one side of the reducer first shell, an integrated structure of a motor rear end cover and a motor shell, a motor inner shell sleeved on the inner cavity wall of the motor shell, a first cooling medium flow channel comprising a first medium first flow channel arranged in the motor shell and a first medium second flow channel arranged in the motor inner shell, and a second cooling medium flow channel arranged between the motor shell and the motor inner shell and used for taking away the heat of the motor shell and the motor inner shell. The composite cooling electric motor can solve the technical problems of poor cooling effect, low integration, poor compactness and poor universality in extreme working conditions in the prior art.

Description

Technical Field

[0001] This invention relates to the field of electric motor technology for new energy vehicles, and in particular to a composite cooling housing. Background Technology

[0002] As the core power component of new energy vehicles, the electric motor generates a significant amount of heat during operation. The main heat sources are the internal stator, rotor, controller module, and reducer module, with the stator and rotor generating particularly noticeable heat. If heat is not dissipated promptly and effectively, the accumulated heat will cause the motor to overheat and prematurely enter a protection state, leading to performance degradation and affecting the overall performance of the new energy vehicle. In severe cases, it can even cause the motor to burn out, endangering the lives of the driver and passengers. Furthermore, because electric motors are typically installed in the enclosed environment of the engine compartment, heat is more easily accumulated there.

[0003] Currently, the cooling solutions for electric motors in new energy vehicles are mainly divided into two categories: air cooling and liquid cooling. Liquid cooling includes water cooling, oil cooling, and composite cooling (oil-water hybrid cooling) solutions. As the name suggests, composite cooling solutions include both oil and water cooling systems.

[0004] In existing technologies, electric motors in new energy vehicles employ composite cooling systems. The cooling oil circuit is located close to the stator, while the cooling channels are situated outside the oil circuit. The main characteristic is that the water circuit circulates within the motor housing, indirectly removing heat from the internal stator through heat conduction. The cooling oil circuit cools the stator ends via corresponding oil guide pipes or rings, with the water and oil circuits operating independently. However, under certain extreme conditions, the cooling oil's temperature rises after prolonged circulation and heat absorption, reducing its cooling effect on the motor stator and leading to poor motor heat dissipation and performance degradation. Furthermore, these cooling structures suffer from low integration, poor compactness, and limited component interchangeability, making it difficult to quickly adapt the electric motors for different vehicle models, increasing development costs and time. Summary of the Invention

[0005] This invention provides a composite cooling housing that solves the technical problems of poor cooling effect, low integration, poor compactness, and poor versatility of existing composite cooling motors under extreme operating conditions. The technical solution is as follows: This invention provides a composite cooling housing, comprising: First housing of the reducer; The motor housing is located on one side of the first housing of the reducer. The motor housing is an integrated structure in which the rear end cover of the motor and the motor housing are integrated. The motor inner housing is fitted inside the inner cavity wall of the motor outer housing; The first cooling medium flow channel includes a first medium first flow channel disposed inside the motor housing and a first medium second flow channel disposed inside the motor inner housing, which are connected to each other and are used to lubricate the bearing and cool the flat wire stator assembly. The second cooling medium flow channel is located between the motor housing and the motor inner housing to remove heat from the motor housing and the motor inner housing.

[0006] In a preferred embodiment, the second cooling medium flow channel includes an internal cooling channel disposed between the motor housing and the motor inner housing; The motor housing is provided with a coolant inlet and a coolant outlet. The internal cooling channel is connected to the coolant inlet and coolant outlet. The coolant outlet is connected to an external cooling pipe, and the other end of the external cooling pipe is connected to a radiator.

[0007] In this embodiment, the radiator is integrated and connected to the first housing of the reducer.

[0008] In a preferred embodiment, a first cooling medium flows through the first cooling medium channel, and a second cooling medium flows through the second cooling medium channel. The first and second cooling media then flow into the radiator for heat dissipation.

[0009] In a preferred embodiment, the first medium first flow channel includes: The first cooling channel has its input end connected to the heat sink. The second cooling channel is located inside the motor housing and communicates with the first cooling channel. It is used to lubricate the motor bearings and cool them down. The return flow channel connects the first cooling channel and the second cooling channel, and the output end of the return flow channel is connected to the heat sink.

[0010] In a preferred embodiment, the first cooling channel includes a first cooling hole formed in the first housing of the reducer, a main cooling hole for the motor housing formed in the motor housing, and an intermediate cooling hole for the housing. The radiator, the first cooling hole, the main cooling hole of the motor housing, and the intermediate cooling hole of the housing are connected in sequence.

[0011] In a preferred embodiment, the first cooling medium flow channel is used to guide the first cooling medium to flow sequentially through the motor housing and the motor inner housing, and then into the flat wire stator assembly to directly cool its core in the slot, and then return to the radiator through the return channel.

[0012] In a preferred embodiment, the second flow channel of the first medium includes: An inner shell intermediate cooling hole is formed on the inner shell of the motor and communicates with the main cooling hole of the outer shell of the motor, and an inner shell fan-shaped groove is formed on the inner wall of the inner shell of the motor and communicates with the inner shell intermediate cooling hole. An internal cooling channel is provided inside the core of the flat wire stator assembly. The inner shell fan-shaped groove is connected to the internal cooling channel.

[0013] In a preferred embodiment, a connecting structure is provided between the motor housing and the motor inner housing to connect the first medium first flow channel and the first medium second flow channel and to isolate the two from each other at the intersection of the first cooling medium flow channel and the second cooling medium flow channel.

[0014] In a preferred embodiment, the connection structure includes an intermediate oil guide pipe, one end of which extends into the intermediate cooling hole of the outer shell and the other end of which extends into the intermediate cooling hole of the inner shell. A sealing structure is provided on the outer surface of the intermediate oil guide pipe at the intermediate cooling holes of the outer shell and the inner shell.

[0015] In a preferred embodiment, a third flow channel is provided inside the first housing of the reducer. The third flow channel is connected to the first cooling medium flow channel and is used to divert a portion of the first cooling medium, which has been cooled by the radiator, into the reducer for lubrication and cooling.

[0016] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following: The motor housing features an integrated design, combining the traditional rear end cover of the motor with the motor housing as one piece. While maintaining a compact structure, the increased integration reduces the number of parts, resulting in significant economic benefits, high assembly efficiency, fewer sealing points, and better reliability.

[0017] The motor housing and the motor inner housing adopt a split structure. The structure of the split housing can be changed arbitrarily according to matching and installation requirements. Different combinations of inner and outer housings can be flexibly and freely matched, reducing the development cost and development cycle of the housing in the later stage.

[0018] Because the inner and outer housings of the motor are only installed with an interference fit, the inner housing is quite flexible in use. If the motor system cooling scheme is later changed to a pure oil-cooling scheme, the inner housing, radiator, and other parts can be removed, and a new oil-cooled motor system (internal oil cooling) can be formed simply by matching the outer housing with a new flat wire stator assembly. This greatly reduces the development of related housing-specific parts and lowers development costs.

[0019] The composite cooling housing has two independent cooling circuits, one internal and one external. The first cooling medium channel guides cooling oil sequentially through the first housing of the reducer, the outer housing of the motor, and the inner housing of the motor, entering the flat wire stator assembly to directly cool the iron core within the slots, and lubricating the internal bearings with oil spray at the bearing oil injection holes in the outer housing. The second cooling medium channel introduces coolant through the coolant inlet of the outer housing, flows through the cooling channel of the inner housing, and exits from the coolant outlet of the outer housing, entering the radiator through the external cooling pipe for heat dissipation. This dual-circuit design can simultaneously remove heat from the internal cooling oil and the housing, significantly reducing the motor temperature and maintaining a stable cooling effect even under prolonged high-load conditions.

[0020] If the reducer needs to be cooled at the same time, a third flow channel can be set in the first housing of the reducer. A portion of the first cooling medium after being cooled by the radiator flows into the third flow channel, cools and lubricates the reducer, and then flows back to the first cooling medium after absorbing the heat of the motor, and then enters the radiator together for cooling. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention, 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a three-dimensional structural diagram of the overall structure provided in the embodiment of the present invention; Figure 2 This is a cross-sectional view of the overall structure provided in the embodiment of the present invention; Figure 3 This is provided by the embodiments of the present invention. Figure 2 Enlarged view of a portion of point A in the middle; Figure 4 This is a schematic diagram of the structure of the first housing of the reducer provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the mounting hole structure of the motor housing provided in an embodiment of the present invention; Figure 6 This is a cross-sectional view of the motor housing provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the reinforced heat dissipation fins provided in an embodiment of the present invention; Figure 8 This is a schematic diagram showing the position of the inner shell fixing threaded hole provided in an embodiment of the present invention; Figure 9 This is a cross-sectional view of the motor inner housing provided in an embodiment of the present invention; Figure 10 This is a three-dimensional structural diagram of the motor inner housing provided in an embodiment of the present invention; Figure 11 This is a schematic diagram of the inner shell sector groove provided in an embodiment of the present invention; Figure 12 This is a schematic diagram of the structure of the partition bar provided in an embodiment of the present invention; Figure 13 This is a schematic diagram of the structure of the second cooling medium flow channel provided in an embodiment of the present invention; Figure 14 This is a schematic diagram of the structure of the first cooling medium flow channel provided in an embodiment of the present invention.

[0023] In the diagram: 100—First housing of the reducer; 1010—Mounting surface of the gearbox; 1020—Gearbox positioning pin hole; 1030—Gearbox positioning inner stop; 1040—First cooling hole; 1050—Fixing threaded hole; 1060—Radiator mounting structure; 200—Motor housing; 2010—Inner cavity wall; 2020—Inner cavity step; 2030—Mounting surface of the gearbox; 2040—Positioning pin hole; 2050—Fixing bolt through hole; 2060—Outer stop; 2070—Main cooling hole of the motor housing; 2080—Bearing oil passage hole; 2090—Intermediate cooling hole of the housing; 2100—Bearing oil injection hole; 2110—Rivet sealing hole; 2120—Oil return chamber; 2130—Coolant inlet; 2140—Coolant outlet; 2150—Strip reinforcing rib; 2160—Annular reinforcing rib; 217 0—Inner housing fixing threaded hole; 300—Motor inner housing; 3010—Inner housing assembly end face; 3020—Inner housing positioning surface; 3030—Inner housing stepped end face; 3040—Inner housing intermediate cooling hole; 3050—Inner housing fan-shaped groove; 3060—Inner housing stator mounting cavity; 3070—Inner housing stepped surface; 3080—Inner housing coolant inlet; 3090—Inner housing coolant outlet; 3100—Partition rib; 3110—Inner cooling flow channel; 3120—Inner housing fixing threaded hole; 3130—Sealing groove; 400—Intermediate oil guide pipe; 4010—Intermediate oil hole; 4020—First sealing protrusion; 4030—Second sealing protrusion; 4040—End face; 500—O-ring seal; 600—Flat wire stator assembly; 700—External cooling pipe; 800—Radiator; 900—Third flow channel. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0025] like Figures 1 to 14As shown, this embodiment of the invention provides a composite cooling housing, which aims to solve the technical problems of poor cooling effect, low integration, poor compactness, and poor versatility of composite cooling motors under extreme operating conditions in the prior art.

[0026] like Figure 1 and Figure 2 As shown, an embodiment of the present invention provides a composite cooling housing, which includes: a first housing 100 for a reducer, a housing 200 for a motor, an inner housing 300 for a motor, an O-ring seal 500, a flat wire stator assembly 600, an external cooling pipe 700, and a radiator 800.

[0027] The radiator 800 is installed and fitted with the first housing 100 of the reducer; the motor outer shell 200, the motor inner shell 300, and the O-ring seal 500 are assembled to form a motor housing assembly; the flat wire stator assembly 600 is installed in the inner cavity of the motor housing assembly. The stator core of the flat wire stator assembly 600 adopts an in-slot cooling structure, and internal cooling oil channels are formed by stacking the cores, so that the cooling oil can directly cool the core in the slot.

[0028] External cooling pipes 700 are connected to radiator 800 and motor housing 200 respectively, and are used to connect the second cooling medium flow channel.

[0029] The in-slot cooling structure used in this embodiment is similar to the in-slot cooling structure in CN120915020A. Those skilled in the art can directly refer to it for implementation, so a detailed description is omitted here.

[0030] like Figure 4 As shown, the first housing 100 of the reducer includes: a housing mounting surface 1010, a housing positioning pin hole 1020, a housing positioning inner stop 1030, a first cooling hole 1040, a fixing threaded hole 1050, and a radiator mounting structure 1060.

[0031] The mounting surface 1010, the positioning pin hole 1020, and the positioning inner stop 1030 of the first housing 100 of the reducer together serve as positioning and assembly reference when the first housing 100 of the reducer is assembled with the motor housing 200.

[0032] The first cooling hole 1040 of the first housing 100 of the reducer serves to connect the oil passage after the first housing 100 of the reducer and the motor housing 200 are assembled.

[0033] The fixing threaded hole 1050 of the first housing 100 of the reducer completes the locking and fixing function of the housing surface after the first housing 100 of the reducer and the motor housing 200 are assembled.

[0034] The radiator mounting structure 1060 of the first housing 100 of the reducer is used for matching and mounting with the radiator 800.

[0035] like Figure 2 , Figure 5 , Figure 6 and Figure 7 As shown, the motor housing 200 structurally includes: an inner cavity wall 2010, an inner cavity step 2020, a mounting and fitting surface 2030, a locating pin hole 2040, a fixing bolt through hole 2050, an outer stop 2060, a main cooling hole 2070, a bearing oil passage hole 2080, a middle cooling hole 2090, a bearing oil spray hole 2100, a riveting sealing hole 2110, an oil return chamber 2120, a coolant inlet 2130, a coolant outlet 2140, a strip-shaped reinforcing rib 2150, an annular reinforcing rib 2160, and an inner housing fixing threaded hole 2170. The motor housing 200 is an integrated structure, integrating the traditional motor rear end cover with the motor housing into a single design, resulting in a high degree of integration and a compact structure.

[0036] The inner cavity wall 2010 and inner cavity step 2020 of the motor housing 200 are used for positioning and installation with the motor inner housing 300. Furthermore, the inner cavity wall 2010 of the motor housing 200 and the motor inner housing 300 together form an internal cooling channel.

[0037] The positioning pin hole 2040, fixing bolt through hole 2050, and outer stop 2060 of the motor housing 200 play a positioning and fixing role when assembled with the first housing 100 of the reducer.

[0038] The main cooling hole 2070, bearing oil passage hole 2080, intermediate cooling hole 2090, and bearing oil injection hole 2100 of the motor housing 200 are all oil passages of the motor housing 200. The main cooling hole 2070 of the motor housing 200 is connected to the first cooling hole 1040 of the first housing 100 of the reducer, so that the oil at the reducer end enters the motor housing end.

[0039] The rivet sealing hole 2110 of the motor housing 200 is used for sealing the oil passage of the motor housing 200.

[0040] The oil return chamber 2120 of the motor housing 200 serves to return oil. This structure is connected to the chamber of the first housing 100 of the reducer to realize the recovery of cooling oil.

[0041] The coolant inlet 2130 and coolant outlet 2140 of the motor housing 200 are the inlet and outlet of the external coolant at the end of the motor housing. The second cooling medium enters the internal cooling channel formed by the inner cavity wall 2010 and the inner housing 300 of the motor housing 200 through the coolant inlet 2130, and then flows out through the coolant outlet 2140, connecting to the radiator 800 via the external cooling pipe 700 for heat dissipation. Furthermore, the coolant enters the radiator 800, and through external circulation, it achieves heat dissipation for both the housing and the internal cooling oil.

[0042] Additionally, the coolant inlet 2130 and the radiator 800 are connected via a vehicle-wide medium pipeline (connected to the vehicle's water pipe in this embodiment). A water pump is also installed on the vehicle's water pipe to provide power for coolant circulation. In an feasible technical solution, the second cooling medium is connected to the vehicle's thermal management pipeline to achieve heat exchange with the second cooling medium, including cooling the second cooling medium.

[0043] The outer side of the motor housing 200 is provided with multiple strip-shaped reinforcing ribs 2150 and ring-shaped reinforcing ribs 2160. These ribs enhance the structural rigidity and strength of the motor housing 200, improving overall structural performance while also acting as heat dissipation ribs. Furthermore, the multiple strip-shaped reinforcing ribs 2150 and ring-shaped reinforcing ribs 2160 on the outer side of the motor housing 200 increase the heat exchange area between the motor housing 200 and the external air, thereby further enhancing heat dissipation capacity and improving the NVH performance of the housing.

[0044] The inner shell fixing threaded hole 2170 of the motor housing 200 is a fixed limiting structure. The inner shell fixing threaded hole 2170 of the motor housing 200 is installed by matching with the corresponding inner shell fixing threaded hole 3120 of the motor inner shell 300. The assembly and fixing of the motor housing 200 and the motor inner shell 300 are completed by screwing in the bolts.

[0045] like Figure 2 , Figure 8 , Figure 9 , Figure 10 , Figure 11 and Figure 12 As shown, the motor inner housing 300 has a cylindrical structure, which includes: an inner housing assembly end face 3010, an inner housing positioning surface 3020, an inner housing stepped end face 3030, an inner housing intermediate cooling hole 3040, an inner housing fan-shaped groove 3050, an inner housing stator mounting cavity 3060, an inner housing stepped surface 3070, an inner housing coolant inlet 3080, an inner housing coolant outlet 3090, a partition rib 3100, an inner cooling flow channel 3110, an inner housing fixing threaded hole 3120, and a sealing groove 3130.

[0046] The inner shell assembly end face 3010 of the motor inner shell 300 is the mounting positioning surface. During the installation of the motor inner shell 300 and the motor outer shell 200, this structure fits against the inner cavity step 2020 of the motor outer shell 200. The inner cavity step 2020 structure of the motor outer shell 200 is used for axial positioning of the motor inner shell 300.

[0047] The inner housing positioning surface 3020 of the motor inner housing 300 serves a positioning function during installation. During the installation of the motor inner housing 300 and the motor outer housing 200, this structure mates with the inner cavity wall 2010 of the motor outer housing 200, providing radial coarse positioning. Optionally, the fit between the inner housing positioning surface 3020 of the motor inner housing 300 and the inner cavity wall 2010 of the motor outer housing 200 can be a small interference fit. If the fit between the inner housing positioning surface 3020 of the motor inner housing 300 and the inner cavity wall 2010 of the motor outer housing 200 is a small interference fit, then during the assembly of the motor inner housing 300 and the motor outer housing 200, the inner cavity of the motor outer housing 200 needs to be appropriately heated to facilitate the assembly of the inner and outer housings.

[0048] The intermediate cooling hole 3040 of the inner housing of the motor housing 300 serves as an internal oil passage, connecting the oil passages of the outer housing 200 and the inner housing 300. Furthermore, after the outer housing 200 and the inner housing 300 are assembled, the intermediate cooling hole 3040 of the inner housing 300 connects with the intermediate cooling hole 2090 of the outer housing of the motor housing 200. Further, cooling oil flows from the main cooling hole 2070 of the outer housing of the motor housing 200 into the intermediate cooling hole 2090 of the outer housing of the motor housing 200, and then enters the intermediate cooling hole 3040 of the inner housing of the motor housing 300.

[0049] The inner shell sector groove 3050 of the motor inner shell 300 serves as an oil chamber for cooling the internal flat wire stator. Cooling oil enters the inner shell sector groove 3050 structure of the motor inner shell 300 from the cooling hole 3040 in the middle of the inner shell. Furthermore, the inner shell sector groove 3050 of the motor inner shell 300 is connected to the internal oil passage of the flat wire stator assembly 600. Cooling oil enters the internal oil passage of the flat wire stator assembly 600 through the inner shell sector groove 3050 of the motor inner shell 300, flowing from the middle of the flat wire stator assembly 600 to both ends, thereby cooling the subsequent flat wire stator core and flat copper wire.

[0050] The inner shell stator mounting cavity 3060 and the inner shell stepped surface 3070 of the motor inner shell 300 serve as mounting and limiting structures for the internal flat wire stator. Furthermore, during assembly, the end face of the flat wire stator assembly 600 fits against the inner shell stepped surface 3070 of the motor inner shell 300, completing the axial limiting of the flat wire stator assembly 600. Furthermore, the outer surface of the flat wire stator assembly 600 is interference-fitted with the inner shell stator mounting cavity 3060 of the motor inner shell 300, completing the radial positioning of the flat wire stator assembly 600.

[0051] The inner housing 300 has two inner housing fixing threaded holes 3120, which are used to fix the motor outer housing 200 and the motor inner housing 300. Optionally, provided that the structural arrangement is feasible, the number of inner housing fixing threaded holes 3120 in the motor inner housing 300 can be appropriately increased. Furthermore, after the motor inner housing 300 is installed into the inner cavity of the motor outer housing 200, the inner housing fixing threaded holes 3120 of the motor inner housing 300 and the inner housing fixing threaded holes 2170 of the motor outer housing 200 are structurally matched and correspond, and the fixing of the motor inner housing 300 and the motor outer housing 200 is completed by screwing in bolts.

[0052] The inner housing 300 has an inner coolant inlet 3080 and an inner coolant outlet 3090, which serve as the inlet and outlet for the external coolant. The partition ribs 3100 of the inner housing 300 act as partitions in the cooling channel, altering the flow direction of the external coolant. Furthermore, the multiple partition ribs 3100 in the inner housing 300 enhance its structural strength. These partition ribs 3100 and the inner housing 300 together form multiple interconnected and zigzag-shaped internal cooling channels 3110, allowing the coolant to flow along the zigzag path, extending the heat exchange path, and improving heat exchange efficiency.

[0053] The inner cooling channel 3110 of the motor housing 300 is a flow channel cavity for the second cooling medium. This structure connects the coolant inlet 2130 and coolant outlet 2140 of the motor housing 200. The sealing groove 3130 of the motor housing 300 is used to install the O-ring seal 500.

[0054] like Figure 2 and Figure 3 As shown, a connecting structure is provided between the motor housing 200 and the motor inner housing 300 to connect the first medium first flow channel and the first medium second flow channel and isolate the two at the intersection of the first cooling medium flow channel and the second cooling medium flow channel. The connecting structure includes an intermediate oil guide pipe 400, one end of which extends into the intermediate cooling hole 2090 of the housing and the other end of which extends into the intermediate cooling hole 3040 of the inner housing. A sealing structure is provided on the outer surface of the intermediate oil guide pipe 400 at the intermediate cooling hole 2090 of the housing and the intermediate cooling hole 3040 of the inner housing.

[0055] In addition, an intermediate oil hole 4010 is provided at the center of the intermediate oil guide pipe 400, which penetrates the intermediate oil guide pipe 400.

[0056] The sealing structure includes a first sealing protrusion 4020 and a second sealing protrusion 4030. The first sealing protrusion 4020 is located inside the intermediate cooling hole 2090 of the outer shell, and the second sealing protrusion 4030 is located inside the intermediate cooling hole 3040 of the inner shell, used for sealing and connecting the cooling oil passage. Further, the intermediate oil guide tube 400 is made of a temperature- and oil-resistant material. The first sealing protrusion 4020 and the second sealing protrusion 4030 are respectively used for sealing between the outer surface of the intermediate oil guide tube 400 and the intermediate cooling hole 2090 of the outer shell and the intermediate cooling hole 3040 of the inner shell; optional structures include, but are not limited to, radially protruding structures where the first sealing protrusion 4020 and the second sealing protrusion 4030 are integrally formed with the intermediate oil guide tube 400, or structures based on sealing rings or sealing rings of the assembly.

[0057] An intermediate oil guide pipe 400 is installed between the motor housing 200 and the motor inner housing 300. Further, the intermediate oil hole 4010 of the intermediate oil guide pipe 400 is used to connect the first flow channel and the second flow channel of the first medium. Specifically, after the intermediate oil guide pipe 400 is installed, this structure connects the inner housing intermediate cooling hole 3040 of the motor inner housing 300 and the outer housing intermediate cooling hole 2090 of the motor housing 200.

[0058] The first sealing protrusion 4020 and the second sealing protrusion 4030 of the intermediate oil guide pipe 400 have a sealing function. They seal the oil passages of the intermediate cooling hole 3040 of the inner shell of the motor inner shell 300 and the intermediate cooling hole 2090 of the outer shell of the motor outer shell 200, and separate the first cooling medium and the second cooling medium to prevent the two cooling media from mixing.

[0059] After the intermediate oil guide pipe 400 is installed, the end face 4040 of the intermediate oil guide pipe 400 is located in the inner cavity of the motor inner housing 300 and is kept in a distance from the flat wire stator assembly 600. The purpose of this structure is to control the gap between the end face 4040 and the outer diameter of the flat wire stator assembly 600 to prevent interference between the relevant structural components after installation.

[0060] The cooling hole 3040 in the middle of the inner shell is not located at the inner cooling channel 3110. In the embodiment, the cooling hole 3040 in the middle of the inner shell is located at the partition rib 3100 on the inner shell 300 of the motor.

[0061] The assembly process of the composite cooling shell of the present invention is as follows: The radiator 800 is mounted on the radiator mounting structure 1060 of the first housing 100 of the reducer. An external cooling pipe 700 is installed between the radiator 800 and the motor housing 200, and the external cooling pipe 700 connects the coolant outlet 2140 of the radiator 800 and the motor housing 200. Further, one end of the external cooling pipe 700 is connected to the coolant outlet 2140 of the motor housing 200, and the other end is connected to the radiator 800.

[0062] Before installation, the inner wall 2010 of the motor housing 200 is preheated. The purpose of preheating is to facilitate the subsequent assembly of the inner motor housing 300 and the outer motor housing 200. Furthermore, the O-ring 500 is installed in the sealing groove 3130 of the inner motor housing 300.

[0063] The motor inner housing 300 with O-ring 500 installed is installed with the motor outer housing 200. During this process, the inner housing mating end face 3010 of the motor inner housing 300 fits against the inner cavity step 2020 of the motor outer housing 200. The inner housing positioning surface 3020 of the motor inner housing 300 and the inner cavity wall 2010 of the motor outer housing 200 play an auxiliary positioning role.

[0064] After the motor inner housing 300 is installed into the inner cavity of the motor outer housing 200, the inner housing fixing threaded hole 3120 of the motor inner housing 300 and the inner housing fixing threaded hole 2170 of the motor outer housing 200 are structurally matched, and the motor inner housing 300 is fixed by screwing in the bolts.

[0065] After the motor inner housing 300 is installed, the inner housing stepped end face 3030, the inner housing coolant inlet 3080, the inner housing coolant outlet 3090, the partition rib 3100, and the inner cavity wall 2010 of the motor outer housing 200 together constitute the inner cooling channel 3110. Furthermore, the inner cooling channel 3110 of the motor inner housing 300 is used for the circulation of external coolant.

[0066] The O-ring 500 contacts the inner cavity wall 2010 of the motor housing 200. The O-ring 500 and the sealing groove 3130 structure of the motor inner housing 300 together achieve the seal between the motor housing 200 and the motor inner housing 300, improving the sealing performance of the second cooling medium flow channel.

[0067] After the motor housing 200 and the motor inner housing 300 are installed, they form a motor housing assembly.

[0068] An intermediate oil guide pipe 400 is installed at the intermediate cooling hole 3040 of the inner housing 300 within the inner cavity of the motor housing assembly. The first sealing protrusion 4020 of the intermediate oil guide pipe 400 mates with the intermediate cooling hole 2090 of the outer housing of the motor housing 200, and the second sealing protrusion 4030 of the intermediate oil guide pipe 400 mates with the intermediate cooling hole 3040 of the inner housing of the motor housing 300. Further, after the intermediate oil guide pipe 400 is installed, its intermediate oil hole 4010 connects the intermediate cooling hole 2090 of the outer housing of the motor housing 200 and the intermediate cooling hole 3040 of the inner housing of the motor housing 300. Further, after the intermediate oil guide pipe 400 is installed, its intermediate oil hole 4010 connects with the sector-shaped groove 3050 of the inner housing of the motor housing 300.

[0069] The flat wire stator assembly 600 is installed inside the motor housing assembly. The end face of the flat wire stator assembly 600 is in contact with the inner housing assembly end face 3010 of the inner housing of the motor inner housing 300, and the outer diameter of the iron core of the flat wire stator assembly 600 mates with the inner housing stator mounting cavity 3060 of the inner housing of the motor inner housing 300. Furthermore, the flat wire stator assembly 600 and the motor housing assembly are assembled to form a flat wire stator motor housing assembly.

[0070] The flat wire stator motor housing assembly is assembled with the reducer first housing 100. During assembly, the mounting surface 1010 of the reducer first housing 100 is in contact with the mounting surface 2030 of the motor housing 200, and the positioning pin hole 1020 of the reducer first housing 100 matches the positioning pin hole 2040 of the motor housing 200 for positioning. Furthermore, the inner positioning stop 1030 of the reducer first housing 100 engages with the outer stop 2060 of the motor housing 200 for positioning. Further, the fixing threaded hole 1050 of the reducer first housing 100 matches the fixing bolt through hole 2050 of the motor housing 200, and the assembly is secured by screwing in bolts.

[0071] After the reducer first housing 100 is assembled with the flat wire stator motor housing assembly, the overall structure forms the composite cooling housing of the present invention.

[0072] In addition, a first cooling medium flow channel and a second cooling medium flow channel are provided inside the composite cooling housing. The first cooling medium flow channel includes a first medium flow channel located inside the motor housing 200 and a second medium flow channel located inside the motor inner housing 300. The two are connected and are used to lubricate the bearing and cool the flat wire stator assembly 600. The second cooling medium flow channel is located between the motor housing 200 and the motor inner housing 300 and is used to remove the heat from the motor housing 200 and the motor inner housing 300.

[0073] The first cooling medium flow channel guides the first cooling medium to flow sequentially through the motor housing 200 and the motor inner housing 300, and then into the flat wire stator assembly 600 to directly cool its iron core in the slot, and then flows back to the radiator 800 through the return channel.

[0074] The first medium and the first flow channel include: The first cooling channel has its input end connected to the radiator 800; The return flow channel connects the first cooling channel and the second cooling channel, and the output end of the return flow channel is connected to the heat sink 800.

[0075] The input end of the first cooling channel is connected to the radiator 800. The first cooling channel includes a first cooling hole 1040 opened in the first housing 100 of the reducer. The first cooling hole 1040 is connected to the radiator 800. A main cooling hole 2070 is opened in the motor housing 200. The main cooling hole 2070 is connected to the first cooling hole 1040. An intermediate cooling hole 2090 is opened on the inner side wall of the motor housing 200 and is connected to the main cooling hole 2070.

[0076] The second cooling channel is located inside the motor housing 200 and communicates with the first cooling channel. It is used to lubricate the motor bearing and cool the motor bearing. The second cooling channel includes a bearing oil passage hole 2080 and a bearing oil spray hole 2100 located inside the motor housing 200. The bearing oil passage hole 2080 communicates with the main cooling hole 2070 of the motor housing, and the bearing oil spray hole 2100 communicates with the bearing oil passage hole 2080. The other end of the bearing oil spray hole is located at the motor bearing and communicates with the inner cavity of the motor housing 200.

[0077] The return channel connects the first cooling channel and the second cooling channel. The output end of the return channel is connected to the radiator 800. The return channel includes an oil return chamber 2120 opened in the bottom wall of the motor housing 200. The oil return chamber 2120 is connected to the inner cavity of the motor housing 200. The outlet end of the oil return chamber 2120 is connected to the oil pump. An oil return hole is opened in the first housing 100 of the reducer. The other end of the oil pump is connected to the oil return hole. The other end of the oil return hole is connected to the radiator 800.

[0078] The first medium second flow channel includes an inner shell intermediate cooling hole 3040 and an inner shell fan-shaped groove 3050. The intermediate cooling hole 3040 is connected to the inner shell fan-shaped groove 3050. The inner shell fan-shaped groove 3050 is connected to the internal cooling oil channel of the flat wire stator assembly 600. The inner shell intermediate cooling hole 3040 and the outer shell intermediate cooling hole 2090 are connected by a connecting structure.

[0079] The second cooling medium flow channel includes an internal cooling channel disposed between the motor housing 200 and the motor inner housing 300; The motor housing 200 is provided with a coolant inlet 2130 and a coolant outlet 2140. The internal cooling channel is connected to the coolant inlet 2130 and the coolant outlet 2140. The coolant outlet 2140 is connected to an external cooling pipe 700. The other end of the external cooling pipe 700 is connected to a radiator 800. The coolant inlet 2130 connects to the vehicle's water hose.

[0080] The radiator 800 is a dual-purpose oil-water heat exchanger (with two sets of channels, one for oil and one for water), used to dissipate heat from both oil and water simultaneously.

[0081] like Figure 13As shown, the working process of the second cooling medium flow channel of the composite cooling shell in this embodiment of the invention is as follows: the external coolant enters the inner shell coolant inlet 3080 of the inner shell 300 from the coolant inlet 2130 of the motor housing 200, and then enters the inner cooling flow channel 3110 of the inner shell 300; the flow direction of the external coolant is changed by the partition rib 3100 of the inner shell 300, and after flowing along the reversal path, it enters the inner shell coolant outlet 3090 of the inner shell 300; the inner shell coolant outlet 3090 of the inner shell 300 is connected to the coolant outlet 2140 of the motor housing 200, and the external coolant flows out from the coolant outlet 2140 of the motor housing 200 into the external cooling pipe 700, and then into the radiator 800 for heat dissipation, thereby completing the circulation process of the external coolant. During this cycle, when the external coolant passes through the internal cooling channel 3110 on the inner wall of the motor inner housing 300, it carries away the heat of the motor housing through heat conduction, thereby achieving effective cooling of the motor outer housing 200 and the motor inner housing 300.

[0082] In a preferred embodiment, the cooling medium in the second cooling medium channel includes water and ethylene glycol, which have good heat dissipation and antifreeze properties, and are suitable for the operation requirements of new energy vehicles under different ambient temperatures.

[0083] like Figure 14 As shown, the working process of the first cooling medium flow channel (internal cooling oil circuit) of the composite cooling shell in this embodiment of the invention is as follows: the internal cooling oil is pumped from the oil pump end to the oil return hole, and then enters the radiator 800. After being cooled by the radiator 800, the oil enters the first cooling hole 1040. The first cooling hole 1040 of the reducer first housing 100 is connected to the main cooling hole 2070 of the motor housing 200, and the oil circuit enters the motor housing 200 through this channel. After entering the motor housing 200, the oil circuit flows sequentially through the main cooling hole 2070 of the motor housing 200, the bearing oil passage hole 2080 of the motor housing 200, the intermediate cooling hole 2090 of the motor housing 200, and the bearing oil spray hole 2100 of the motor housing 200, thereby achieving lubrication and cooling of the motor bearing. The internal cooling oil then enters the inner housing fan-shaped groove 3050 of the inner housing 300 through the intermediate oil hole 4010 of the intermediate oil guide pipe 400. The internal cooling oil then enters the internal oil passage of the flat wire stator assembly 600 through the fan-shaped slot 3050 of the inner shell of the motor inner housing 300, directly cooling the flat wire stator core within the slot and removing heat from the flat copper wire and the core. The slot of the flat wire stator core is connected to the motor outer housing 200. Finally, under the action of gravity, the internal cooling oil enters the oil return chamber 2120 of the motor outer housing 200. The oil return chamber 2120 of the motor outer housing 200 is connected to the oil pump, the oil pump is connected to the oil return hole, and the oil return hole is connected to the radiator 800, realizing oil recovery and completing the first cooling medium flow channel.

[0084] In a preferred embodiment, the cooling medium in the first cooling medium channel includes oil, which has good lubrication and cooling properties, and can directly cool the flat wire stator assembly while lubricating the motor bearings.

[0085] In this embodiment of the invention, the composite cooling housing works in concert through two independent cooling circuits: a first cooling medium channel and a second cooling medium channel. The first cooling medium channel directly cools the core of the flat wire stator assembly 600 within its slots using cooling oil, and also lubricates and cools the motor bearings. The second cooling medium channel carries away heat from both the motor outer shell 200 and the inner shell 300 through a zigzag internal cooling channel 3110 formed by coolant flowing through it. Both cooling circuits are connected to a radiator 800 to dissipate heat from the cooling medium. Even under prolonged high-load conditions, the composite cooling housing of this invention can continuously and efficiently remove heat from various parts of the motor, preventing heat buildup, ensuring stable motor performance, and significantly extending the motor's service life.

[0086] Furthermore, the motor outer shell 200 and motor inner shell 300 of the composite cooling housing of this invention adopt a split structure. The structure of the split shell can be arbitrarily changed according to matching and installation requirements, allowing for flexible and free combination of different inner and outer shells, reducing the later development cost and development cycle of the housing. Because the motor inner shell 300 and the motor outer shell 200 are only installed by interference fit, the motor inner shell 300 is more flexible in use. If the cooling scheme of the motor system is changed to a pure oil cooling scheme in the later stage, the motor inner shell 300, O-ring seal 500, radiator 800 and other parts can be removed. Only the motor outer shell 200 is matched with a new flat wire stator assembly 600 to form a new oil-cooled motor system (internal oil cooling). This greatly reduces the development of related housing-specific parts, lowers development costs, and improves the versatility of parts.

[0087] In one embodiment, oil covers are provided at both ends of the flat wire stator assembly 600. The first cooling medium in the flat wire stator assembly 600 flows to both ends until it flows into the oil covers, thereby wetting both ends of the flat wire stator assembly 600. Oil drain holes are opened at the bottom of the two oil covers for discharging the second cooling medium. The oil drain holes are directly opposite the oil return chamber 2120.

[0088] In one embodiment, a third flow channel 900 is provided inside the first housing 100 of the reducer. The third flow channel 900 is connected to the first cooling medium flow channel and is used to divert part of the first cooling medium that has been cooled by the radiator into the reducer for lubrication and cooling. The specific structure of the third flow channel 900 is similar to that of the first cooling medium flow channel, except that the third flow channel 900 is provided inside the first housing 100 of the reducer. The inlet end of the third flow channel 900 is connected to the first cooling hole 1040, and the outlet of the third flow channel 900 is connected to the oil return chamber 2120.

[0089] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in this patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an” or “a” and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms “comprising” or “including” and similar terms mean that the elements or objects preceding “comprising” or “including” encompass the elements or objects listed following “comprising” or “including” and their equivalents, and do not exclude other elements or objects. The terms “connected” or “linked” and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. The terms “upper,” “lower,” “left,” and “right” are used only to indicate relative positional relationships; when the absolute position of the described objects changes, the relative positional relationship may also change accordingly.

[0090] The above are merely optional embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A composite cooling housing, characterized in that, include: First housing of the reducer (100); The motor housing (200) is located on one side of the first housing (100) of the reducer. The motor housing (200) is an integrated structure in which the rear end cover of the motor and the motor housing are integrated. The inner housing (300) is fitted inside the inner cavity wall (2010) of the outer housing (200); The first cooling medium flow channel includes a first medium first flow channel disposed in the motor housing (200) and a first medium second flow channel disposed in the motor inner housing (300), which are connected to each other and are used to lubricate the bearing and cool the flat wire stator assembly (600). The second cooling medium flow channel is located between the motor housing (200) and the motor inner housing (300) to remove heat from the motor housing (200) and the motor inner housing (300).

2. The composite cooling housing according to claim 1, characterized in that, The second cooling medium flow channel includes an internal cooling channel disposed between the motor housing (200) and the motor inner housing (300); The motor housing (200) is provided with a coolant inlet (2130) and a coolant outlet (2140). The internal cooling channel is connected to the coolant inlet (2130) and the coolant outlet (2140). The coolant outlet (2140) is connected to an external cooling pipe (700). The other end of the external cooling pipe (700) is connected to a radiator (800).

3. A composite cooling housing according to claim 2, characterized in that, A first cooling medium flows through the first cooling medium channel, and a second cooling medium flows through the second cooling medium channel. The first and second cooling media flow into the radiator for heat dissipation.

4. A composite cooling housing according to claim 2 or 3, characterized in that, The first medium and the first flow channel include: The first cooling channel has its input end connected to the radiator (800); The second cooling channel is located inside the motor housing (200) and communicates with the first cooling channel, and is used to lubricate the motor bearing and cool the motor bearing. The return channel connects the first cooling channel and the second cooling channel, and the output end of the return channel is connected to the radiator (800).

5. A composite cooling housing according to claim 4, characterized in that, The first cooling channel includes a first cooling hole (1040) opened in the first housing (100) of the reducer, a main cooling hole (2070) for the motor housing opened in the motor housing (200) and a middle cooling hole (2090) for the housing. The radiator (800), the first cooling hole (1040), the main cooling hole (2070) of the motor housing, and the intermediate cooling hole (2090) of the housing are connected in sequence.

6. A composite cooling housing according to claim 4, characterized in that, The first cooling medium flow channel is used to guide the first cooling medium to flow sequentially through the motor housing (200) and the motor inner housing (300), and then enter the flat wire stator assembly (600) to directly cool its iron core in the slot, and then flow back to the radiator (800) through the return channel.

7. A composite cooling housing according to claim 6, characterized in that, The second flow channel of the first medium includes: An inner shell intermediate cooling hole (3040) is opened on the inner shell of the motor (300) and communicates with the main cooling hole (2070) of the outer shell of the motor, and an inner shell fan-shaped groove (3050) is opened on the inner wall of the inner shell of the motor (300) and communicates with the inner shell intermediate cooling hole (3040). An internal cooling channel is provided inside the core of the flat wire stator assembly (600); The inner shell fan-shaped groove (3050) is connected to the internal cooling channel.

8. A composite cooling housing according to claim 7, characterized in that, A connection structure is provided between the motor housing (200) and the motor inner housing (300) to connect the first medium first flow channel and the first medium second flow channel and to isolate the two from each other at the intersection of the first cooling medium flow channel and the second cooling medium flow channel.

9. A composite cooling housing according to claim 8, characterized in that, The connection structure includes an intermediate oil guide pipe (400), one end of which extends into the intermediate cooling hole (2090) of the outer shell and the other end extends into the intermediate cooling hole (3040) of the inner shell. A sealing structure is provided on the outer surface of the intermediate oil guide pipe (400) at the intermediate cooling hole (2090) of the outer shell and the intermediate cooling hole (3040) of the inner shell.

10. A composite cooling housing according to claim 1, characterized in that, The first housing (100) of the reducer is provided with a third flow channel (900), which is connected to the first cooling medium flow channel and is used to divert part of the first cooling medium that has been cooled by the radiator into the reducer for lubrication and cooling.

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