Coaxial light-weight integrated electric drive axle of axial flux motor

Abstract

The utility model provides an axial magnetic flux motor coaxial light-weight integrated electric drive axle, and belongs to the technical field of vehicle manufacturing, the axial magnetic flux motor coaxial light-weight integrated electric drive axle comprises an axial magnetic flux motor, the output end of the axial magnetic flux motor is fixedly connected with the input end of a speed reducer, and the output end of the speed reducer is fixedly connected with CVJ shaft heads located on the two sides; the CVJ shaft heads are respectively connected with one ends of the half shafts; the other ends of the half shafts are respectively connected with the hub assemblies; a shell of the axial magnetic flux motor is fixedly connected with an axle housing, the two ends of the axle housing are fixedly connected with half-shaft sleeves respectively, and the half-shaft sleeves are of hollow structures and allow half shafts to penetrate through. The axial magnetic flux motor is adopted, so that the size and the weight of the electric drive axle are reduced; the light-weight design is adopted, the structure is compact, the weight is obviously reduced, and the size is reduced; light weight and integration are achieved, the motor, the speed reducer, the half shaft, the hub assembly and other components are integrated together through the compact structural design, and therefore the transmission efficiency and the power performance of an electric automobile are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle manufacturing, and in particular to a coaxial lightweight integrated electric drive bridge of an axial flux motor. Background Art

[0002] With the rapid development of the electric commercial vehicle market, electric drive axle technology has ushered in unprecedented development opportunities. However, most existing electric commercial vehicles adopt the traditional solution, that is, using electric motors to replace the original engine and transmission. The principle of this technical solution is that the power provided by the drive motor is transmitted to the ordinary drive axle through the drive shaft, and finally drives the wheels to make the vehicle run. This traditional layout method has significant shortcomings, especially in pure electric and hybrid models, which will limit the layout of the chassis space, as well as the layout of batteries and other key components.

[0003] Disadvantages of existing technologies: 1. In traditional coaxial electric drive axles, the mass of the motor reducer assembly is relatively large, and the motor housing assembly and the bridge housing are jointly loaded, which poses a risk of fatigue failure. 2. The motor axis of the parallel-axis electric drive axle is parallel to the wheel axis but not coaxial. Its disadvantages include: a. The motor is integrated into the reducer, which has a complex structure and is difficult to repair and replace, resulting in increased costs; b. The reduction mechanism is complex and often equipped with a shift mechanism, which has a large overall weight, which has an adverse effect on the performance of the suspension system and the service life of the bridge housing. At the same time, the safety of the reducer connector is difficult to guarantee; c. The motor and reducer are too large, which makes it difficult to configure drum air brakes and shock absorbers, and has poor adaptability. 3. The wheel-side electric drive axle places the motor at the wheel side. Although the power transmission route is short and the efficiency is high, it is suitable for low-floor buses, but its disadvantages include: a. It is difficult to arrange the reducer, which makes it difficult to coordinate the large output torque and the maximum vehicle speed; b. The motor and reducer are both unsprung masses, which greatly increases the unsprung mass and affects the smoothness of the vehicle; c. The motor works in a harsh environment with large vibration and impact. Summary of the invention

[0004] Purpose of the invention: The purpose of the present invention is to address the deficiencies in the prior art and provide an axial flux motor coaxial lightweight integrated electric drive bridge. The axial flux motor is adopted to reduce the size and weight of the electric drive bridge; and a lightweight design is adopted with a compact structure, which significantly reduces the weight and size. The present invention achieves lightweight and integration, and through a compact structural design, components such as motors, reducers, half shafts and hub assemblies are integrated together to improve the transmission efficiency and power performance of electric vehicles.

[0005] Technical solution: The axial-flux motor coaxial lightweight integrated electric drive axle of the present invention is used in electric vehicles and includes an axial-flux motor. The output end of the axial-flux motor is fixedly connected to the input end of a speed reducer. The input shaft of the axial-flux motor and the hollow output shaft of the speed reducer are coaxially arranged. The output end of the speed reducer is fixedly connected to the first CVJ axle head and the second CVJ axle head located on both sides. The first CVJ axle head and the second CVJ axle head are respectively connected to one end of the first half shaft and the second half shaft. The other ends of the first half shaft and the second half shaft are respectively connected to the first wheel hub assembly and the second wheel hub assembly. The housing of the axial-flux motor is fixedly connected to a bridge housing. Both ends of the bridge housing are respectively fixedly connected to a first half shaft sleeve and a second half shaft sleeve. The first half shaft sleeve and the second half shaft sleeve are hollow structures for the first half shaft and the second half shaft to pass through. The first half shaft sleeve is fixedly connected to the housing of the speed reducer, and the second half shaft sleeve is floatingly connected to the axial-flux motor. This design allows a certain degree of freedom of movement to adapt to vibrations and deformations during vehicle driving.

[0006] In the present invention, the axial-flux motor is the core part of the electric drive axle, responsible for converting electrical energy into mechanical energy to drive the vehicle. The output end of the axial-flux motor is fixedly connected to the input end of the speed reducer. The function of the speed reducer is to reduce the high-speed rotation of the motor and convert it into the low-speed high-torque rotation required by the wheels. The CVJ axle head, that is, the constant velocity universal joint axle head, is used to transmit torque while allowing a certain angle of axial deflection to adapt to dynamic changes during vehicle driving. The half shaft is an important component connecting the axle head and the wheel hub, responsible for transmitting power to the wheel hub. The wheel hub assembly is the core part of the wheel. The half shaft transmits power here to drive the wheel to rotate. The bridge housing plays a role in supporting and protecting the motor and the speed reducer.

[0007] Furthermore, the second half shaft sleeve is floatingly connected to the axial-flux motor through a rubber dust cover. Rubber materials have good shock absorption performance, which can absorb vibrations and noises generated during motor operation, reducing the impact on the overall vehicle structure. At the same time, to protect the motor, the rubber dust cover can prevent dust, moisture and other impurities from entering the motor interior, protecting the motor from damage by the external environment and extending the service life of the motor. In addition, since heat is generated during motor operation, causing component expansion. The rubber dust cover can provide a certain amount of telescopic space to compensate for the axial length change caused by temperature variation. The floating connection achieved through the rubber dust cover simplifies the connection method between the motor and the half shaft sleeve, facilitating assembly and maintenance. The rubber dust cover can also absorb impacts caused by uneven road surfaces, improving the driving smoothness of the vehicle.

[0008] Furthermore, the first half shaft sleeve is rollingly connected to the first wheel hub assembly through a first bearing.

[0009] Furthermore, the second half shaft sleeve is rollingly connected to the second wheel hub assembly through a second bearing.

[0010] The bearing allows the half - shaft sleeve and the wheel hub assembly to be connected in a rolling manner. Compared with a sliding connection, the rolling friction is much smaller, which helps to improve the transmission efficiency and reduce energy loss.

[0011] Further, the first CVJ shaft head is connected to the first half - shaft through an internal spline.

[0012] Further, the second CVJ shaft head is connected to the second half - shaft through an internal spline. The CVJ shaft head (constant velocity joint) allows for an angular change between shafts when transmitting power, which is necessary for a vehicle suspension system because the angle between the wheel and the drive shaft changes due to the up - and - down movement of the suspension during driving. The internal spline connection can effectively transmit the torque from the differential to the half - shaft, thus driving the wheels.

[0013] Further, the first wheel hub assembly and the second wheel hub assembly are disc brake wheel hub assemblies.

[0014] Further, the first wheel hub assembly and the second wheel hub assembly are drum brake wheel hub assemblies.

[0015] Disc brake wheel hub assemblies and drum brake wheel hub assemblies are two common automotive braking systems. Disc brakes: Also known as disc brakes, they generate braking force by clamping brake pads in the brake caliper against the brake disc (rotor). This braking method has a rapid response and stable braking effect. Since the brake disc is exposed to the air, it has good heat dissipation performance and is not easily overheated due to long - term braking, resulting in a decline in braking effect. However, the structure is relatively complex and the maintenance cost is relatively high. Drum brakes: They generate braking force by hydraulically pushing the brake shoes into contact with the inner wall of the brake drum. Drum brakes have a greater braking force, but relatively poor heat dissipation performance. The braking system is enclosed in the brake drum, with poor heat dissipation capacity, and heat attenuation may occur during long - term braking. However, the structure is simple and the maintenance cost is low, but the brake clearance needs to be adjusted regularly, and water ingress or foreign objects may affect the braking effect. The present invention can select the wheel hub assembly according to the design requirements.

[0016] Further, the axial - flux motor is integrated with a motor controller.

[0017] Further, the axle housing has a diamond structure. Due to its unique geometric shape, the diamond structure can provide good support in different directions, thereby enhancing the stiffness and strength of the axle housing.

[0018] Advantageous effects: Compared with the prior art, the advantages of the present invention are as follows:

[0019] (1) The present invention uses an axial - flux motor to reduce the mass of the electric drive axle, reduce the size, and achieve lightweight and integration;

[0020] (2) The present invention arranges the input shaft of the axial flux motor and the hollow output shaft of the reducer coaxially, which is beneficial to the design and installation of the electric drive axle;

[0021] (3) The present invention adopts an integrated structural design of the powertrain, that is, the axial flux motor and the reducer, which has a compact structure, improves the transmission efficiency, and reduces the power transmission distance;

[0022] (4) The bridge housing of the present invention is connected to the half shaft sleeves on both sides and the motor housing, forming a structural reinforcement frame design, improving the load-bearing capacity of the bridge housing and reducing the fatigue risk. Description of the Drawings

[0023] Figure 1 is the structural schematic diagram of Embodiment 1;

[0024] Figure 2 is the structural schematic diagram of Embodiment 1 with a parking cable;

[0025] Figure 3 is Figure 2 another perspective view of

[0026] Figure 4 is the structural schematic diagram of Embodiment 1 integrated with a motor controller;

[0027] Figure 5 is the structural schematic diagram of Embodiment 2;

[0028] Figure 6 is the structural schematic diagram of Embodiment 2 integrated with a motor controller. Detailed Embodiments

[0029] The technical solution of the present invention will be described in detail below with reference to the drawings, but the protection scope of the present invention is not limited to the described embodiments.

[0030] Embodiment 1

[0031] As Figures 1 to 4 shown, an axial flux motor coaxial lightweight integrated electric drive axle for an electric vehicle includes a bridge housing 5, on which an axial flux motor 7 is provided, and a motor controller 15 is integrated on the axial flux motor 7. The output end of the axial flux motor 7 is fixedly connected to the input end of a reducer 6, and the input shaft of the axial flux motor 7 and the hollow output shaft of the reducer 6 are arranged coaxially; the output end of the reducer 6 is fixedly connected to the first CVJ axle head 13 and the second CVJ axle head 14 on both sides, and the first CVJ axle head 13 and the second CVJ axle head 14 are respectively connected to one end of the first half shaft 4 and the second half shaft 9 through internal splines, and the other ends of the first half shaft 4 and the second half shaft 9 are respectively connected to the first wheel hub assembly 1 and the second wheel hub assembly 12. A brake assembly is arranged near the wheel hub assembly, and a parking cable 16 is fixedly arranged on the brake assembly.

[0032] The housing of the axial flux motor 7 is fixedly connected to the axle housing 5. The two ends of the axle housing 5 are respectively fixedly connected to a first half axle sleeve 3 and a second half axle sleeve 10. The first half axle sleeve 3 and the second half axle sleeve 10 are of hollow structure for the first half axle 4 and the second half axle 9 to pass through. The first half axle sleeve 3 is fixedly connected to the housing of the speed reducer 6, and the second half axle sleeve 10 is floatingly connected to the axial flux motor 7 through a rubber dust cover 8. The first half axle sleeve 3 is rollingly connected to the first wheel hub assembly 1 through a first bearing 2; the second half axle sleeve 10 is rollingly connected to the second wheel hub assembly 12 through a second bearing 11.

[0033] In this embodiment, the first wheel hub assembly 1 and the second wheel hub assembly 12 are disc brake wheel hub assemblies. The axle housing 5 is of a rhombic structure.

[0034] The working process of this embodiment:

[0035] When the electric vehicle starts, the electric drive axle system is ready. The motor controller receives a drive signal and is ready to control the axial flux motor 7. The axial flux motor 7 receives an instruction from the motor controller, starts to operate and generate power. The output end of the axial flux motor 7 is fixedly connected to the input end of the speed reducer 6. The power generated by the motor is transmitted and decelerated through the speed reducer 6. The power is transmitted to the speed reducer 6. The output end of the speed reducer 6 is fixedly connected to a first CVJ axle head 13 and a second CVJ axle head 14. The power is thus distributed to the CVJ axle heads on both sides. The power is transmitted through the half axles. The other ends of the first half axle 4 and the second half axle 9 are respectively connected to the first wheel hub assembly 1 and the second wheel hub assembly 12. The power is finally transmitted to the wheel hub assembly, and the wheel hub assembly receives the power. The entire working process is continuous. From the start of the electric drive axle system to the transmission of power to the wheel hub assembly, each step is closely connected to ensure the efficient and stable operation of the power transmission system of the electric vehicle.

[0036] Embodiment 2

[0037] As Figures 5 to 6 shown, an axially-flux motor coaxial lightweight integrated electric drive axle. The difference between this embodiment and Embodiment 1 is that the wheel hub assembly is a drum brake wheel hub assembly.

[0038] As described above, although the present invention has been shown and described with reference to specific preferred embodiments, it should not be construed as a limitation of the present invention itself. Various changes can be made in its form and details without departing from the spirit and scope of the present invention defined by the appended claims.

Claims

1. An axially-flux motor coaxial lightweight integrated electric drive axle for an electric vehicle, characterized in that: It includes an axial flux motor (7), the output end of the axial flux motor (7) is fixedly connected to the input end of a speed reducer (6), the input shaft of the axial flux motor (7) and the output shaft of the speed reducer (6) are coaxially arranged in a hollow manner, the output end of the speed reducer (6) is fixedly connected to the first CVJ axle head (13) and the second CVJ axle head (14) located on both sides, the first CVJ axle head (13) and the second CVJ axle head (14) are respectively connected to one end of the first half shaft (4) and the second half shaft (9), and the other ends of the first half shaft (4) and the second half shaft (9) are respectively connected to the first wheel hub assembly (1) and the second wheel hub assembly (12); The housing of the axial flux motor (7) is fixedly connected to a bridge housing (5), both ends of the bridge housing (5) are respectively fixedly connected to a first half shaft sleeve (3) and a second half shaft sleeve (10), the first half shaft sleeve (3) and the second half shaft sleeve (10) are of a hollow structure for the first half shaft (4) and the second half shaft (9) to pass through; the first half shaft sleeve (3) is fixedly connected to the housing of the speed reducer (6), and the second half shaft sleeve (10) is floatingly connected to the axial flux motor (7).

2. An axially-flux motor coaxial lightweight integrated electric drive axle according to claim 1, characterized in that: The second half shaft sleeve (10) and the axial flux motor (7) are floatingly connected through a rubber dust cover (8).

3. The coaxial lightweight integrated electric drive axle of an axial flux motor according to claim 1, characterized in that: The first half shaft sleeve (3) is in rolling connection with the first wheel hub assembly (1) through a first bearing (2).

4. An axially-flux motor coaxial lightweight integrated electric drive axle according to claim 1, characterized in that: The second half shaft sleeve (10) is in rolling connection with the second wheel hub assembly (12) through a second bearing (11).

5. An axially-flux motor coaxial lightweight integrated electric drive axle according to claim 1, characterized in that: The first CVJ axle head (13) is connected to the first half shaft (4) through an internal spline.

6. The axial flux motor coaxial lightweight integrated electric drive axle according to claim 1, characterized in that: The second CVJ axle head (14) is connected to the second half shaft (9) through an internal spline.

7. An axially-flux motor coaxial lightweight integrated electric drive axle according to claim 1, characterized in that: The first wheel hub assembly (1) and the second wheel hub assembly (12) are disc brake wheel hub assemblies.

8. An axially-flux motor coaxial lightweight integrated electric drive axle according to claim 1, characterized in that: The first wheel hub assembly (1) and the second wheel hub assembly (12) are drum brake wheel hub assemblies.

9. The axial flux motor coaxial lightweight integrated electric drive axle according to claim 1, wherein: The axial flux motor (7) is integrated with a motor controller (15).

10. The coaxial lightweight integrated electric drive axle of an axial flux motor according to claim 1, characterized in that: The bridge housing (5) is of a diamond structure.

Images