All-in-one electric drive system for automobiles
Patent Information
- Application Number
- CN202510538563.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-27
- Publication Date
- 2026-10-27
AI Technical Summary
冷却水管和换热器的加入增加了电驱的附件数量、电驱的外部尺寸和复杂程度，不利于集成度的提升
[0015]本申请的实施例提供的用于汽车的多合一电驱系统，通过创新设计了一个集成式的具有油水分配功能的电机端盖，可以实现电路组件中的冷却水、电机组件中的冷却油和油水换热器之间实现冷却介质分配传输和热量交换，两个冷却系统高度集成在共用的壳体上，壳体与油水分配端盖和油水换热器共同组成完整的冷却回路，提升了系统集成度。
Smart Images
Figure CN122993362A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of vehicle technology, and more specifically to an all-in-one electric drive system for automobiles. Background Technology
[0002] With the development of new energy pure electric vehicles, the drive motors used in new energy vehicles have also undergone tremendous changes. From separate electric drives to three-in-one electric drives, and now to the increasingly emerging multi-in-one electric drives, the integration level of drive motors is getting higher and higher. The integration of electric drives can improve product performance and reduce weight and cost, which is of great significance. At the same time, with the integration of key modules, research on the cooling system of multi-in-one electric drives is crucial. The cooling of motors in multi-in-one electric drives has evolved from air cooling and water cooling to the current oil cooling system.
[0003] To balance integration and advanced cooling methods, a combination of all-in-one electric drives and oil-water hybrid cooling is often employed. Compared to indirect cooling technologies like air and water cooling, oil-cooled motors significantly improve the cooling efficiency of electric drive systems, increase power density, and enhance product performance. Cooling oil, as an insulating medium, not only lubricates components but also removes heat from their surfaces. However, the controller in all-in-one electric drives still uses water cooling because water has a high specific heat capacity, allowing it to remove heat from the power chips within the controller via copper cooling plates.
[0004] However, in related technologies, the cooling systems using two different cooling media are not integrated. This difference in cooling media prevents the controller and motor from being directly connected via cooling pipes on the housing, often requiring additional cooling water pipes and radiators for connection and heat exchange. There are obvious water pipe interfaces between the oil-cooled and water-cooled systems, requiring additional cooling water pipes and heat exchangers for connection and heat exchange. The addition of cooling water pipes and heat exchangers increases the number of accessories, the external size, and the complexity of the electric drive, hindering improvements in integration. Summary of the Invention
[0005] To at least partially solve the above problems, embodiments of this application provide a multi-functional electric drive system for automobiles, comprising: a housing; a motor assembly disposed in a first chamber of the housing, wherein components in the first chamber are cooled by cooling oil; a circuit assembly disposed in a second chamber of the housing, the second chamber being isolated from the first chamber, wherein components in the second chamber are cooled by cooling water, and the second chamber being connectable to the vehicle's water-cooling system; and an oil-water distribution end cap disposed at one end of the housing and sealing the first chamber, wherein the oil-water distribution end cap has an oil inlet channel and an oil outlet channel. The system includes an oil-water heat exchanger, an inlet channel, and an outlet channel; the oil-water heat exchanger is located on the oil-water distribution end cover and outside the first chamber, and is used for heat exchange between cooling oil and cooling water. The oil-water heat exchanger contains mutually isolated cooling oil channels and cooling water channels; the oil inlet and outlet ends of the cooling oil channels are connected to the inlet and outlet channels respectively, the water inlet and outlet ends of the cooling water channels are connected to the inlet and outlet channels respectively, the oil inlet and outlet channels are connected to the first chamber, the water inlet channel is connected to the second chamber, and the outlet channel is used to connect to the water cooling system of the vehicle.
[0006] In some embodiments, the motor assembly includes a rotor, a first cylindrical flow channel extending through the rotor shaft is provided inside the rotor shaft, and a plurality of oil-throwing holes are also provided on the rotor shaft. The first flow channel communicates with the outside of the rotor shaft through the oil-throwing holes. An oil-water distribution end cap is formed on one side of the first chamber with a cylindrical positioning shaft. The end of the rotor shaft is rotatably mounted on the positioning shaft, and the opening of the first flow channel is engaged with the positioning shaft. The positioning shaft is provided with a first oil outlet, which communicates with the oil flow channel.
[0007] In some embodiments, the system further includes an oil inlet guide ring and an oil outlet guide ring; the motor assembly also includes a stator, which is disposed on the inner wall of the first chamber and distributed along the circumference of the rotor; the oil-water distribution end cap is located on one side of the first chamber and also forms a second oil outlet, which is arc-shaped and communicates with the oil outlet channel; the oil inlet guide ring includes an oil guide plate and an oil guide ring, the oil guide plate is arc-shaped and cooperates with the second oil outlet, one end of the oil guide plate cooperates with the second oil outlet, and the other end of the oil guide plate is connected to the oil guide ring, the oil guide plate and the inner wall of the housing form a flow channel for guiding oil from the second oil outlet to the stator; the oil guide ring is connected to one end of the stator, and the oil outlet guide ring is connected to the other end of the stator, the oil guide ring and the oil outlet guide ring respectively form a flow channel for guiding oil along the circumference of the stator with the two ends of the stator, the oil guide ring has a first oil drain hole along its own circumference, and the oil outlet guide ring has a second oil drain hole along its own circumference.
[0008] In some embodiments, the oil-water distribution end cap is located on one side of the first chamber and a first oil inlet is formed therein, which is connected to the oil inlet channel; an oil inlet pipe is formed at the bottom of the housing and is connected to the first oil inlet; an oil pump is provided on the oil inlet pipe and is used to deliver the cooling oil in the oil inlet pipe to the direction of the first oil inlet.
[0009] In some embodiments, a third oil outlet and a second oil inlet are formed on the side of the oil-water distribution end cap opposite to the first chamber. The third oil outlet is connected to the oil inlet channel, and the second oil inlet is connected to the oil outlet channel. The oil inlet end and the oil outlet end of the cooling oil channel are respectively connected to the third oil outlet and the second oil inlet.
[0010] In some embodiments, a first water inlet is formed on one side of the oil-water distribution end cap located in the second chamber, and the first water inlet is connected to the water inlet channel. A first water outlet and a second water inlet are also formed on the side of the oil-water distribution end cap opposite to the first chamber. The first water outlet is connected to the water inlet channel, and the second water inlet is connected to the water outlet channel. The water inlet end and the water outlet end of the cooling water channel are respectively connected to the first water outlet and the second water inlet.
[0011] In some embodiments, a second water outlet is formed on the side of the oil-water distribution end cap opposite to the first chamber. The second water outlet is connected to the water outlet channel and is provided with a water outlet nozzle for connecting to the water cooling system of the vehicle.
[0012] In some embodiments, the oil inlet channel and the water outlet channel are located at the lower part of the oil-water distribution end cap, and the oil inlet channel and the water outlet channel are arranged vertically and parallelly; the oil outlet channel and the water inlet channel are located at the upper part of the oil-water distribution end cap, and the oil outlet channel and the water inlet channel are arranged obliquely and intersectingly; the line connecting the third oil outlet and the second oil inlet intersects the line connecting the first water outlet and the second water inlet, and the position of the first oil outlet corresponds to the intersection point of the above two lines.
[0013] In some embodiments, the circuit assembly includes an on-board charger and a DC-DC converter integrated unit, a motor controller, and a first cooling water channel and a second cooling water channel are also provided in the second chamber. The first cooling water channel is used to cool the on-board charger and the DC-DC converter integrated unit, and the second cooling water channel is used to cool the motor controller. The first cooling water channel and the second cooling water channel are connected in series, and one end is connected to the first water inlet, and the other end is connected to the water inlet nozzle provided outside the housing. The water inlet nozzle is used to communicate with the water cooling system of the vehicle.
[0014] In some embodiments, a reducer assembly is further included, which includes a reducer input shaft, a reducer housing, and a reducer gear. A second flow channel is provided through the reducer input shaft, one end of which communicates with a first flow channel, and the other end of which enters a third chamber formed by the reducer housing. The reducer input shaft and the reducer gear are located in the third chamber.
[0015] The embodiments of this application provide an all-in-one electric drive system for automobiles. Through an innovative design, an integrated motor end cover with oil-water distribution function is provided, which enables the distribution and transfer of cooling media and heat exchange between the cooling water in the circuit components, the cooling oil in the motor components, and the oil-water heat exchanger. The two cooling systems are highly integrated on a shared housing. The housing, the oil-water distribution end cover, and the oil-water heat exchanger together form a complete cooling circuit, thereby improving the system integration. Attached Figure Description
[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0017] Figure 1 This is a front view of the all-in-one electric drive system provided in the embodiments of this application;
[0018] Figure 2 This is a rear view of the all-in-one electric drive system provided in an embodiment of this application;
[0019] Figure 3 This is a schematic diagram of two angles of the oil-water distribution end cap provided in an embodiment of this application;
[0020] Figure 4 This is a cross-sectional view of the oil-water distribution end cap provided in an embodiment of this application;
[0021] Figure 5 This is a longitudinal sectional view of the all-in-one electric drive system provided in the embodiments of this application;
[0022] Figure 6 This is a schematic diagram of the oil inlet guide ring and the oil outlet guide ring provided in the embodiments of this application;
[0023] Figure 7 This is a cross-sectional view of the all-in-one electric drive system provided in the embodiments of this application;
[0024] Figure 8 This is a schematic diagram of the cooling system of the all-in-one electric drive system provided in the embodiments of this application.
[0025] The attached figures are labeled as follows:
[0026] 1. Housing; 2. Cooling pipe plug; 3. Oil-water distribution end cover; 4. Oil-water heat exchanger; 5. Water outlet nozzle; 6. Controller top cover; 7. Water inlet nozzle; 8. Reducer housing; 9. Oil pump; 10. Power cooling plate; 11. Second cooling water channel; 12. Oil inlet guide ring; 13. Motor balance plate; 14. First cooling water channel; 15. Oil outlet guide ring; 16. Stator; 17. Reducer input shaft; 18. Rotor shaft; 19. Rotor; 301. First water inlet; 302. Pipe process hole; 303. Second oil outlet; 304. First oil inlet; 305. Oil return hole; 306. Lug; 307. Second oil inlet; 308. First water outlet; 309. Third oil outlet; 310. Second water inlet; 311. Second water outlet; 312. First oil drain hole; 121. Second oil drain hole; 151.
[0027] It should be understood that the dimensions of the various parts shown in the accompanying drawings are not drawn to actual scale. Furthermore, the same or similar reference numerals denote the same or similar components. Detailed Implementation
[0028] The preferred embodiments of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are merely some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection claimed in this application.
[0029] The terms "first," "second," and similar words used in this application do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Words such as "including" or "contains" mean that the element preceding the word encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well. Terms such as "above," "below," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, this relative positional relationship may also change accordingly.
[0030] like Figures 1-8 As shown, an embodiment of this application provides an all-in-one electric drive system for automobiles. The all-in-one electric drive system includes a housing 1, a motor assembly, a circuit assembly, an oil-water distribution end cap 3, and an oil-water heat exchanger 4.
[0031] Please combine Figure 1 , Figure 2 , Figure 5 as well as Figure 7The motor assembly is housed in the first chamber of the housing 1. The first chamber can be a cylindrical cavity. The components in the first chamber are cooled by cooling oil, exemplarily, which can be reducer oil. The cooling oil has both cooling and lubricating functions; that is, it not only lubricates the relevant components but also removes heat from the surface of the parts. The circuit assembly is housed in the second chamber of the housing 1. The second chamber is isolated from the first chamber. The components in the second chamber are cooled by cooling water. The second chamber can be connected to the vehicle's water cooling system and cooled by the cooling water connected to the vehicle's cooling system. The circuit assembly can be a controller or other circuit components. The circuit assembly generates a large amount of heat when it is working, while the cooling water has a high specific heat capacity. The cooling water can remove the heat from the power chip in the control circuit assembly through a copper cooling plate.
[0032] Combination Figure 3 , Figure 4 as well as Figure 8 The oil-water distribution end cap 3 is located at one end of the housing 1 and closes the first chamber. The oil-water distribution end cap 3 has an oil inlet channel, an oil outlet channel, a water inlet channel, and a water outlet channel. The oil-water heat exchanger 4 is located on the oil-water distribution end cap 3 and outside the first chamber. The oil-water heat exchanger 4 can be fixedly connected to the oil-water distribution end cap 3 by bolts. The oil-water heat exchanger 4 is used for heat exchange between cooling oil and cooling water, thereby realizing the heat transfer of cooling oil to cooling water. Then the cooling water flows into the vehicle cooling system and is transferred to the external environment through the vehicle cooling system. The oil-water heat exchanger 4 is equipped with mutually isolated cooling oil channels and cooling water channels. The oil inlet and outlet of the cooling oil channel are connected to the oil inlet channel and the oil outlet channel, respectively. The water inlet and outlet of the cooling water channel are connected to the water inlet channel and the water outlet channel, respectively. The oil inlet channel and the oil outlet channel are connected to the first chamber, the water inlet channel is connected to the second chamber, and the water outlet channel is used to connect to the water cooling system of the vehicle.
[0033] The embodiments of this application provide an all-in-one electric drive system for automobiles. Through an innovative design, an integrated motor end cover with oil-water distribution function, namely oil-water distribution end cover 3, is designed. This enables the distribution and transfer of cooling media and heat exchange between the cooling water in the circuit components, the cooling oil in the motor components, and the oil-water heat exchanger 4. The two cooling systems are highly integrated on a shared housing 1. The housing 1, together with the oil-water distribution end cover 3 and the oil-water heat exchanger 4, form a complete cooling circuit, thereby improving the system integration.
[0034] like Figure 5As shown, in some embodiments, the motor assembly includes a rotor 19. A cylindrical first flow channel penetrating the rotor shaft 18 is formed within the rotor shaft 18 of the rotor 19. Multiple oil-throwing holes are also formed on the rotor shaft 18. The first flow channel communicates with the outside of the rotor shaft 18 through the oil-throwing holes. An oil-water distribution end cap 3 is located on one side of the first chamber and forms a cylindrical positioning shaft. The end of the rotor shaft 18 is rotatably mounted on the positioning shaft, and the opening of the first flow channel engages with the positioning shaft. The positioning shaft has a first oil outlet 304, which communicates with the oil flow channel. In this embodiment, the cooled oil flowing out of the oil-water heat exchanger 4 can enter the first flow channel of the rotor shaft 18 through the first oil outlet 304. Part of the cooled oil in the first flow channel is thrown out through the oil-throwing holes by the rotation of the rotor shaft 18, thereby cooling the iron core and magnets inside the rotor 19.
[0035] In some embodiments, the electric drive system further includes a reducer assembly, which includes a reducer input shaft 17, a reducer housing 8, and a reducer gear. A second flow channel is formed through the reducer input shaft 17, with one end communicating with a first flow channel and the other end leading into a third chamber formed by the reducer housing 8. The reducer input shaft 17 and the reducer gear are located in the third chamber. In this embodiment, the torque output by the rotor 19 can be transmitted to the reducer input shaft 17 via the rotor shaft 18, and then to the reducer gear. A portion of the cooling oil in the first flow channel of the rotor shaft 18 can flow into the second flow channel, and then into the third chamber, thereby cooling and lubricating the internal structures such as the reducer gear in the third chamber. In this embodiment, the motor assembly and the reducer assembly are oil-cooled. The cooling oil can directly contact the stator 16 and the rotor 19, directly carrying away heat from the surfaces of the stator 16 and the rotor 19, resulting in more direct heat dissipation.
[0036] like Figure 5 and Figure 6As shown, in some embodiments, the electric drive system further includes an oil inlet guide ring 12 and an oil outlet guide ring 15; the motor assembly further includes a stator 16, which is disposed on the inner wall of the first chamber and distributed circumferentially along the rotor 19; the oil-water distribution end cover 3 is located on one side of the first chamber and also forms a second oil outlet 303, which is arc-shaped and communicates with the oil outlet channel; the oil inlet guide ring 12 includes an oil guide plate and an oil guide ring, the oil guide plate being arc-shaped to cooperate with the second oil outlet 303, and the oil guide plate... One end of the guide plate is connected to the second oil outlet 303, and the other end of the guide plate is connected to the guide ring. The guide plate and the inner wall of the housing 1 form a flow channel for guiding oil from the second oil outlet 303 to the stator 16. The guide ring is connected to one end of the stator 16, and the oil outlet guide ring 15 is connected to the other end of the stator 16. The guide ring and the oil outlet guide ring 15 respectively form a flow channel for guiding oil along the circumference of the stator 16 with the two ends of the stator 16. The guide ring has a first oil drain hole 121 along its own circumference, and the oil outlet guide ring 15 has a second oil drain hole 151 along its own circumference. In this embodiment, the oil inlet guide ring 12 forms a sealed flow channel with the end of the stator 16 and the inner wall of the housing 1. The cooling oil in the oil outlet flow channel is divided into two paths after entering the sealed flow channel. One path enters the rotor shaft 18 through the first oil outlet 304, and the other path enters the flow channel for guiding oil to the stator 16 through the second oil outlet 303. After the cooling oil reaches the oil guide ring 12, a portion of it flows along the circumferential flow channel of one end of the stator 16 and is sprayed out through the first oil drain hole 121 to cool the end winding of the stator 16 and carry away the heat of the end winding. Under the influence of gravity, the oil accumulates and flows back at the bottom of the first chamber; another portion flows axially along the stator 16 to the surface of the stator 16 body, cooling the iron core of the stator 16, and then reaches the sealed flow channel formed by the oil outlet guide ring 15 and the inner wall of the housing 1. It then flows circumferentially along the oil outlet guide ring 15 and is ejected from the second oil drain hole 151, cooling the winding at the other end of the stator 16 and carrying away the heat from the end winding. Under the influence of gravity, the oil accumulates and flows back at the bottom of the first chamber. The bottom of the oil-water distribution end cap 3 can also be provided with an oil return hole 306, from which the cooling oil flows back to the third chamber. In this embodiment, the cross-section of the oil guide ring and the oil outlet guide ring 15 can be L-shaped, and the number of the first oil drain holes 121 can be 24, as can the number of the second oil drain holes 151.
[0037] Combination Figure 2In some embodiments, the oil-water distribution end cap 3 has a first oil inlet 305 on one side of the first chamber, which is connected to the oil inlet channel. An oil inlet pipe is formed at the bottom of the housing 1, connected to the first oil inlet 305. An oil pump 9 is installed on the oil inlet pipe, which pumps the cooling oil in the oil inlet pipe towards the first oil inlet 305. The other end of the oil inlet pipe can be connected to the third chamber, allowing the cooling oil collected in the third chamber to re-enter the cooling oil circulation. In this embodiment, the oil pump 9 draws cooling oil from the bottom of the housing 1 and pumps it from the oil inlet pipe in the housing 1 to the first oil inlet 305 in the oil-water distribution end cap 3. The cooling oil flows through the oil inlet channel in the oil-water distribution end cap 3 into the oil-water heat exchanger 4, where it is cooled by cooling water. After cooling, the cooling oil flows from the oil-water heat exchanger 4 into the oil outlet channel of the oil-water distribution end cover 3, and then splits into two paths. One path flows into the rotor shaft 18 through the first oil outlet 304, and the other path flows into the oil inlet guide ring 12 through the second oil outlet 303.
[0038] Specifically, in some embodiments, a third oil outlet 310 and a second oil inlet 308 are formed on the side of the oil-water distribution end cap 3 opposite to the first chamber. The third oil outlet 310 is connected to the oil inlet channel, and the second oil inlet 308 is connected to the oil outlet channel. The oil inlet end and the oil outlet end of the cooling oil channel are respectively connected to the third oil outlet 310 and the second oil inlet 308. In this embodiment, the oil pump 9 draws cooling oil from the bottom of the housing 1 and transports the cooling oil from the oil inlet pipe in the housing 1 to the first oil inlet 305 in the oil-water distribution end cap 3. The cooling oil flows through the oil inlet channel in the oil-water distribution end cap 3 and enters the oil-water heat exchanger 4 through the third oil outlet 310. The cooling oil is cooled by cooling water in the oil-water heat exchanger 4. After cooling, the cooling oil flows from the oil-water heat exchanger 4 through the second oil inlet 308 into the oil outlet channel of the oil-water distribution end cover 3, and then splits into two paths: one path flows into the rotor shaft 18 through the first oil outlet 304, and the other path flows into the oil inlet guide ring 12 through the second oil outlet 303.
[0039] Combination Figure 3 and Figure 4In some embodiments, the oil-water distribution end cap 3 is further provided with a first water inlet 301 on one side of the second chamber, the first water inlet 301 being connected to the water inlet channel, and a first water outlet 309 and a second water inlet 311 being provided on the side of the oil-water distribution end cap 3 opposite to the first chamber, the first water outlet 309 being connected to the water inlet channel, the second water inlet 311 being connected to the water outlet channel, and the water inlet end and water outlet end of the cooling water channel being connected to the first water outlet 309 and the second water inlet 311 respectively. In this embodiment, after the cooling water flows out of the second chamber, it enters the inlet channel of the oil-water distribution end cover 3 from the first inlet 301, and then enters the cooling water channel of the oil-water heat exchanger 4 from the first outlet 309. After entering the cooling water channel, the cooling water fully exchanges heat with the cooling oil in the cooling oil channel, carrying away the heat in the cooling oil to achieve cooling. Finally, the cooling water enters the outlet channel of the oil-water distribution end cover 3 from the cooling water channel of the oil-water heat exchanger 4 through the second inlet 311. In some embodiments, a second outlet 312 is also formed on the side of the oil-water distribution end cover 3 opposite to the first chamber. The second outlet 312 is connected to the outlet channel, and a water nozzle 5 is provided on the second outlet 312 for connecting to the water cooling system of the vehicle. In this embodiment, the cooling water in the water outlet channel flows out of the electric drive system through the second water outlet 312 and the water outlet nozzle 5, completing the water cooling cycle inside the electric drive system and flowing into the vehicle cooling system.
[0040] Please refer to Figure 4 In some embodiments, the oil inlet channel and the water outlet channel are located at the lower part of the oil-water distribution end cover 3, and are arranged vertically and parallelly; the oil outlet channel and the water inlet channel are located at the upper part of the oil-water distribution end cover 3, and are arranged at an angle and intersecting each other, for example, at an angle of 45° relative to the extension direction of the oil inlet channel and the water outlet channel; the line connecting the third oil outlet 310 and the second oil inlet 308 intersects the line connecting the first water outlet 309 and the second water inlet 311, and the position of the first oil outlet 304 corresponds to the intersection point of the above two lines. In this embodiment, this arrangement is reasonable, combining the structures of water cooling circulation and oil cooling circulation, making full use of the space of the oil-water distribution end cover 3, realizing the integrity of water cooling circulation and oil cooling circulation, and improving the integration of the electric drive system.
[0041] In some embodiments, the circuit components include an onboard charger and DC-DC converter integrated unit (OCDC) and a motor control unit (MCU). The second chamber is also provided with a first cooling water channel 14 and a second cooling water channel 11. The first cooling water channel 14 is used to cool the onboard charger and DC-DC converter integrated unit, and the second cooling water channel 11 is used to cool the motor control unit. The first cooling water channel 14 and the second cooling water channel 11 are connected in series, and one end is connected to the first water inlet 301, and the other end is connected to the water inlet 7 disposed outside the housing 1. The water inlet 7 is used to communicate with the water cooling system of the vehicle. In this embodiment, the cooling water of the vehicle's water cooling system enters the internal water channel of the second chamber from the water inlet 7. The internal water channel is connected to the first cooling water channel 14, which can be U-shaped. When the cooling water flows through the first cooling water channel 14, it cools the power devices and chips that are in close contact with it, and carries away the heat on their surface, ultimately cooling the entire OCDC module. After the cooling water flows out of the first cooling water channel 14, it flows into the second cooling water channel 11. The power chip of the motor controller is usually fixed on the power cooling plate 10 with a fixed package. The power cooling plate 10 installed on the motor controller and the second cooling water channel 11 cooperate to form a sealed cavity. The cooling water flows through the heat dissipation column in the power cooling plate 10, carries away the heat dissipated by the MCU power module to achieve cooling, and then flows out of the second cooling water channel 11 and flows into the oil-water distribution end cover 3 through the first water inlet 301.
[0042] In some embodiments, a controller top cover 6 may be provided on the top of the second chamber, and the controller top cover 6 and the housing 1 together form the second chamber. A pipe process hole 302 is provided on the oil-water distribution end cover 3 at a position corresponding to the second oil outlet 303. A cooling pipe plug 2 may be provided on the pipe process hole 302. A lug 307 may be formed on the oil-water distribution end cover 3 at a position corresponding to the first water inlet 301 to facilitate connection with the second cooling water channel 11. Motor balance plates 13 may be provided on both sides of the rotor 19 to ensure the dynamic balance of the rotor 19.
[0043] In a preferred embodiment, the electric drive system may consist of only one water inlet 7 and one water outlet 5. The oil-water heat exchanger 4 does not require an external cooling interface. The water inlet 7 and the water outlet 5 are connected to the vehicle's cooling system to facilitate the flow and transfer of cooling water. The all-in-one electric drive system of this application can be designed to be more compact and have a higher power density.
[0044] This application innovatively designs a multi-functional cooling system for electric drives. This system provides simple and efficient cooling for the OCDC, MCU, motor, and reducer, improving system integration and reducing costs. Specifically, the oil-water distribution end cap, when fitted with the housing, allows for the collection and distribution of cooling water and oil, facilitating heat exchange and transfer of the cooling media. The oil-water distribution end cap integrates flow distribution, oil-water heat exchanger fixation, rotor shaft support, and high-voltage motor maintenance, enhancing component integration and serving as a crucial part of the cooling system. The oil inlet direction differs from conventional methods. In conventional methods, cooling oil typically flows from the reducer housing into the reducer shaft and then into the rotor shaft. In this invention, cooling oil enters the stator and rotor of the motor from the three-phase copper busbar side. This method directly delivers the cooled oil to the motor, reducing the cooling path, shortening intermediate pipe length, and improving cooling efficiency. This invention also innovatively designs a housing shared by the motor assembly, reducer assembly, and circuit assembly. This housing can realize the assembly and fixation of the OCDC, MCU, motor, and reducer. At the same time, the housing also integrates the cooling water channels of the OCDC and MCU. Inside the housing, the OCDC module and MCU module are arranged in parallel, and the OCDC cooling water channels and MCU cooling water channels are connected in series, which improves the integration of the housing and reduces the weight of the housing.
[0045] Based on the various embodiments of this application described above, in the absence of explicit denial or conflict, the technical features of one embodiment may be advantageously combined with one or more other embodiments.
[0046] While specific embodiments of this application have been described in detail by way of examples, those skilled in the art should understand that the above examples are for illustrative purposes only and are not intended to limit the scope of this application. Those skilled in the art should understand that modifications can be made to the above embodiments or equivalent substitutions can be made to some technical features without departing from the scope and spirit of this application. The scope of this application is defined by the appended claims.
Claims
1. An all-in-one electric drive system for automobiles, characterized in that, include: case; The motor assembly is disposed in the first chamber of the housing, and the components in the first chamber are cooled by cooling oil; The circuit assembly is disposed in the second chamber of the housing. The second chamber is isolated from the first chamber. The components in the second chamber are cooled by cooling water. The second chamber can be connected to the water cooling system of the vehicle. An oil-water distribution end cap is disposed at one end of the housing and closes the first chamber. The oil-water distribution end cap has an oil inlet channel, an oil outlet channel, a water inlet channel, and a water outlet channel. An oil-water heat exchanger is disposed on the oil-water distribution end cap and located outside the first chamber. It is used for heat exchange between cooling oil and cooling water. The oil-water heat exchanger is provided with mutually isolated cooling oil channels and cooling water channels. The oil inlet and outlet of the cooling oil channels are connected to the oil inlet channel and the oil outlet channel, respectively. The water inlet and outlet of the cooling water channels are connected to the water inlet channel and the water outlet channel, respectively. The oil inlet channel and the oil outlet channel are connected to the first chamber. The water inlet channel is connected to the second chamber. The water outlet channel is used to connect to the water cooling system of the vehicle.
2. The system according to claim 1, characterized in that, The motor assembly includes a rotor, and a cylindrical first flow channel is formed inside the rotor shaft of the rotor, which passes through the rotor shaft. The rotor shaft is also provided with a plurality of oil slinger holes, and the first flow channel communicates with the outside of the rotor shaft through the oil slinger holes. The oil-water distribution end cap is located on one side of the first chamber and forms a cylindrical positioning shaft. The end of the rotor shaft is rotatably mounted on the positioning shaft, and the opening of the first flow channel is engaged with the positioning shaft. The positioning shaft has a first oil outlet, which is connected to the oil flow channel.
3. The system according to claim 2, characterized in that, It also includes an oil inlet guide ring and an oil outlet guide ring; the motor assembly also includes a stator, which is disposed on the inner wall of the first chamber and distributed along the circumference of the rotor; The oil-water distribution end cap is located on one side of the first chamber and also forms a second oil outlet. The second oil outlet is arc-shaped and is connected to the oil outlet channel. The oil inlet guide ring includes an oil guide plate and an oil guide ring. The oil guide plate is arc-shaped and matches the second oil outlet. One end of the oil guide plate matches the second oil outlet, and the other end of the oil guide plate is connected to the oil guide ring. The oil guide plate and the inner wall of the housing form a flow channel for guiding oil from the second oil outlet to the stator. The oil guide ring is connected to one end of the stator, and the oil outlet guide ring is connected to the other end of the stator. The oil guide ring and the oil outlet guide ring respectively form oil flow channels along the circumference of the stator with the two ends of the stator. The oil guide ring has a first oil drain hole along its own circumference, and the oil outlet guide ring has a second oil drain hole along its own circumference.
4. The system according to claim 3, characterized in that, The oil-water distribution end cap is located on one side of the first chamber and also forms a first oil inlet, which is connected to the oil inlet channel; An oil inlet pipe is formed at the bottom of the housing, and the oil inlet pipe is connected to the first oil inlet. An oil pump is installed on the oil inlet pipe, and the oil pump is used to deliver the cooling oil in the oil inlet pipe to the direction of the first oil inlet.
5. The system according to claim 4, characterized in that, The oil-water distribution end cap also has a third oil outlet and a second oil inlet on the side opposite to the first chamber. The third oil outlet is connected to the oil inlet channel, and the second oil inlet is connected to the oil outlet channel. The oil inlet end and the oil outlet end of the cooling oil channel are respectively connected to the third oil outlet and the second oil inlet.
6. The system according to claim 5, characterized in that, The oil-water distribution end cap also has a first water inlet on one side of the second chamber, which is connected to the water inlet channel. The oil-water distribution end cap also has a first water outlet and a second water inlet on the side opposite to the first chamber. The first water outlet is connected to the water inlet channel, and the second water inlet is connected to the water outlet channel. The water inlet and water outlet of the cooling water channel are respectively connected to the first water outlet and the second water inlet.
7. The system according to claim 6, characterized in that, The oil-water distribution end cap also forms a second water outlet on the side opposite to the first chamber. The second water outlet is connected to the water outlet channel. A water nozzle is provided on the second water outlet, and the water nozzle is used to connect to the water cooling system of the vehicle.
8. The system according to claim 7, characterized in that, The oil inlet channel and the water outlet channel are located at the lower part of the oil-water distribution end cap, and the oil inlet channel and the water outlet channel are arranged vertically and parallel to each other; The oil outlet channel and the water inlet channel are located on the upper part of the oil-water distribution end cap, and the oil outlet channel and the water inlet channel are arranged at an inclined cross. The line connecting the third oil outlet and the second oil inlet intersects the line connecting the first water outlet and the second water inlet, and the position of the first oil outlet corresponds to the intersection of the two lines.
9. The system according to claim 6, characterized in that, The circuit assembly includes an on-board charger and a DC-DC converter integrated unit, and a motor controller. The second chamber is also provided with a first cooling water channel and a second cooling water channel. The first cooling water channel is used to cool the on-board charger and the DC-DC converter integrated unit, and the second cooling water channel is used to cool the motor controller. The first cooling water channel and the second cooling water channel are connected in series, with one end connected to the first water inlet and the other end connected to a water inlet nozzle disposed outside the housing. The water inlet nozzle is used to connect to the water cooling system of the vehicle.
10. The system according to claim 2, characterized in that, It also includes a speed reducer assembly, which includes a speed reducer input shaft, a speed reducer housing, and a speed reducer gear. A second flow channel is provided through the speed reducer input shaft. One end of the second flow channel is connected to the first flow channel, and the other end of the second flow channel leads into a third chamber formed by the speed reducer housing. The speed reducer input shaft and the speed reducer gear are located in the third chamber.