Electric drive system and new energy vehicle
By setting vibration sensors and circuit components on the integrated housing of the electric drive system to collect and analyze vibration signals, the early mechanical failure and noise problems of the electric drive system are solved, and early fault monitoring and active noise control are achieved.
Patent Information
- Application Number
- CN202422663277.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-01
- Publication Date
- 2025-10-14
- Estimated Expiration
- 2034-11-01
AI Technical Summary
Existing electric drive systems lack the ability to detect early mechanical failures and actively control mechanical noise. Failures usually only become apparent when the fault seriously affects power output, and existing solutions lack active control measures for mechanical noise.
A vibration sensor is set on the integrated housing of the electric drive system, which communicates with the circuit components to collect vibration signals for early mechanical fault monitoring, and generates reverse compensating harmonic current through the controller to control mechanical noise.
It achieves early detection of mechanical failures in the electric drive system and active control of mechanical noise, reducing the risk of failures and optimizing noise levels.
Smart Images
Figure CN223432197U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to new energy vehicle technical field especially relates to a kind of electric drive system and new energy vehicle. BACKGROUND
[0002] In current new energy vehicles, the electric drive system lacks proactive detection of early mechanical failure, and usually only when the fault is serious enough to affect power output. In addition, pure electric vehicles have increasingly high requirements for the noise of the electric drive system. The mainstream solution usually optimizes the mechanical structure to reduce the electromagnetic noise of the motor or the mechanical noise of the reduction gearbox. Although there are methods of actively injecting harmonic current to suppress electromagnetic noise, there is no proactive control solution for mechanical noise. SUMMARY
[0003] The utility model aims at providing a kind of electric drive system and new energy vehicle, to solve the problem of the existing electric drive system lacking detection of early mechanical failure and proactive control of mechanical noise.
[0004] To solve the above technical problems, the utility model provides an electric drive system, comprising: a vibration sensor, a circuit assembly, a motor, a controller and a reduction gearbox; wherein the motor, the controller and the reduction gearbox have an integrated housing, and the vibration sensor is arranged in the integrated housing; the vibration sensor is communicatively connected to the circuit assembly, and the circuit assembly is arranged in the controller to collect vibration signals of the vibration sensor.
[0005] Optionally, the vibration sensor has a mounting hole passing through in the axial direction of itself, and the vibration sensor is fixed to a threaded hole of the integrated housing by a bolt passing through the mounting hole.
[0006] Optionally, the integrated housing has an end cover corresponding to a portion of the reduction gearbox, and the threaded hole is arranged in the end cover and parallel or perpendicular to an output shaft of the reduction gearbox.
[0007] Optionally, the electric drive system further comprises a wire harness, and the vibration sensor is communicatively connected to the circuit assembly through the wire harness.
[0008] Optionally, the vibration sensor has a signal plug-in terminal, the circuit assembly includes a board terminal connector, the board terminal connector is arranged in a portion of the integrated housing corresponding to the controller, and the two ends of the wire harness are respectively and removably connected to the signal plug-in terminal and the board terminal connector.
[0009] Optionally, the vibration sensor includes a sensor body, a wireless module and a power module, the wireless module is wirelessly communicatively connected to the circuit assembly, and the power module supplies power to the sensor body and the wireless module.
[0010] Optionally, the vibration sensor is piezoelectric induction type, magnetostrictive type or MEMS type, and the output signal type of the vibration sensor is an analog voltage signal or a digital signal after sampling.
[0011] Optionally, the electric drive system further comprises at least one of a charger, a DCDC, a VCU, a BMS, a TMS and a PDU.
[0012] Optionally, the circuit assembly is configured to count when the vibration signal exceeds a preset threshold, and output a fault signal when the count exceeds a count limit within a predetermined time.
[0013] To solve the above technical problems, the utility model also provides a new energy vehicle, it includes the electric drive system as described above.
[0014] To sum up, in the electric drive system and the new energy vehicle provided by the utility model, the electric drive system comprises a vibration sensor, a circuit assembly, a motor, a controller and a reducer, wherein the motor, the controller and the reducer have an integrated shell, and the vibration sensor is arranged on the integrated shell; the vibration sensor is in communication connection with the circuit assembly, and the circuit assembly is arranged on the controller and used to collect the vibration signal of the vibration sensor.
[0015] In this way, by arranging the vibration sensor on the integrated shell, the vibration signal of the mechanical moving part in the electric drive system can be obtained, so that early monitoring of the electric drive mechanical failure and active control of the mechanical noise can be realized at low cost. BRIEF DESCRIPTION OF DRAWINGS
[0016] Those skilled in the art will understand that the provided drawings are for better understanding of the utility model and do not constitute any limitation on the scope of the utility model.
[0017] Figure 1 is a schematic view of the electric drive system of an embodiment of the utility model, wherein the vibration sensor is arranged on the part of the integrated shell corresponding to the reducer.
[0018] Figure 2 is a schematic view of the electric drive system of an embodiment of the utility model, wherein the vibration sensor is arranged on the part of the integrated shell corresponding to the motor.
[0019] Figure 3 is a schematic view of the electric drive system of an embodiment of the utility model, wherein the vibration sensor is arranged on the part of the integrated shell corresponding to the controller.
[0020] Figure 4 is a front view of the electric drive system of an embodiment of the utility model.
[0021] Figure 5 is a right view of the electric drive system of an embodiment of the present application.
[0022] Figure 6 is an axial sectional view of the vibration sensor of an embodiment of the present application.
[0023] Figure 7 is an installation schematic view of the vibration sensor and the integrated shell of an embodiment of the present application.
[0024] Figure 8 is a top view of the electric drive system of another embodiment of the present application.
[0025] Figure 9 is a rear view of the electric drive system of another embodiment of the present application.
[0026] Figure 10 is a right view of the electric drive system of another embodiment of the present application.
[0027] Figure 11 is a schematic view of the circuit assembly of the present application.
[0028] In the drawings: 1-vibration sensor; 10-base; 11-vibrator; 12-piezoelectric sensing element; 13-mounting hole; 14-sensor body; 15-signal plug-in terminal; 2-circuit assembly; 20-circuit board; 21-microcontroller; 22-signal conditioning circuit; 23-board end connector; 3-motor; 4-controller; 5-reducer; 51-output shaft; 6-integrated shell; 61-screw hole; 62-end cover; 7-bolt; 8-wire harness. DETAILED DESCRIPTION
[0029] In order to make the purpose, advantages and characteristics of the present application more clear, the present application will be further described in detail below in combination with the drawings and specific embodiments. It should be noted that the drawings are all very simplified and not drawn in proportion, and are only used to facilitate and clearly assist the purpose of explaining the embodiments of the present application. In addition, the structures shown in the drawings are often a part of the actual structures. In particular, the emphasis of each drawing is different, and sometimes different proportions are used.
[0030] As used in the present utility model, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. The term "or" is generally employed in its sense including "and / or" unless the context clearly dictates otherwise. The term "plurality" is generally employed in its sense including "at least one" unless the context clearly dictates otherwise. The term "at least two" is generally employed in its sense including "two or more" unless the context clearly dictates otherwise. In addition, the terms "first," "second," "third," etc. are used only to describe different instances and do not imply or suggest relative importance or imply a number of the indicated technical features. Thus, features qualified with "first," "second," "third," etc. can expressly or implicitly include one or at least two of the features. The terms "one end" and "the other end" and "proximal" and "distal" generally refer to two parts corresponding to each other, which not only includes the end point. In addition, as used in the present utility model, "mounting", "connection", "connection", "one element is provided in another element" should be understood broadly, generally only indicates that there is a connection, coupling, cooperation or transmission relationship between the two elements, and the two elements can be directly or indirectly connected, coupled, cooperated or transmitted through intermediate elements, and cannot be understood as indicating or suggesting the spatial position relationship between the two elements, that is, one element can be in any direction inside, outside, above, below or one side of another element, unless the content is otherwise clearly indicated. For those of ordinary skill in the art, the specific meaning of the above terms in the present utility model can be understood according to the specific circumstances. In addition, directional terms such as upper, lower, up, down, left, right, etc. are used with respect to the exemplary embodiments as they are shown in the figures, upward or upward direction is toward the top of the corresponding drawing, and downward or downward direction is toward the bottom of the corresponding drawing.
[0031] The utility model aims at providing a kind of electric drive system and new energy vehicle, to solve the problem that the existing electric drive system lacks the detection of early mechanical failure and active control for mechanical noise. The following is described with reference to the accompanying drawings.
[0032] Please refer to Figures 1 to 5 The utility model embodiment provides a kind of electric drive system, it includes: vibration sensor 1, circuit component 2, motor 3, controller 4 and speed reducer 5;Wherein the motor 3, the controller 4 and the speed reducer 5 have integrated housing 6, the vibration sensor 1 is set to integrated housing 6;The vibration sensor 1 is connected with the circuit component 2, and the circuit component 2 is set to the controller 4, to gather the vibration signal of vibration sensor 1.
[0033] The controller 4 is configured to drive the motor 3 to rotate, and the driving shaft of the motor 3 is connected to the input end of the reducer 5. The electric drive system provided in the embodiment is a three-in-one electric drive system, that is, the motor 3, the controller 4 and the reducer 5 are integrated, and the motor 3, the controller 4 and the reducer 5 have an integrated shell 6. It should be noted that the integrated shell 6 can be an integral shell formed by one piece or a combined shell formed by a plurality of sub-shells. The integrated shell 6 corresponds to the parts of the motor 3, the controller 4 and the reducer 5, and the parts are physically connected or integrally formed, so that the vibrations between the parts can be transmitted to each other. The vibration sensor 1 is arranged on the integrated shell 6, for example, can be arranged on the part of the integrated shell 6 corresponding to the motor 3, the part of the integrated shell 6 corresponding to the controller 4 or the part of the integrated shell 6 corresponding to the reducer 5, and the mechanical vibration signals from the motor 3 or the reducer 5 can be collected. Further, by analyzing the vibration signals collected by the vibration sensor 1, the mechanical failure of the electric drive system can be monitored early. Further, based on the vibration signals collected by the vibration sensor 1, the driving current of the motor 3 can also be supplemented to actively control the mechanical noise (such as gear meshing noise) in the reducer 5. Of course, it can be understood that the electric drive system of the embodiment is not limited to be applied in the three-in-one electric drive system, and can also be a multi-in-one electric drive system with more functions, which is not limited in the embodiment. For example, the electric drive system further includes at least one of the functions of a charger, a DCDC, a VCU, a BMS, a TMS and a PDU. At this time, the integrated shell 6 corresponds to more functional modules, and the vibration sensor 1 can also be arranged on the part of the integrated shell 6 corresponding to other functional modules.
[0034] The frequency of the vibration signal detected by the vibration sensor 1 can be selected to be between 0-20 kHz, and preferably can detect vibration signals in one direction or multiple directions. Considering the cost factor, the vibration sensor 1 can be piezoelectric induction type, magnetostrictive type or MEMS type, and the output signal type of the vibration sensor is analog voltage signal or digital signal after sampling. Please refer to Figure 6 which shows an exemplary piezoelectric induction type vibration sensor, which includes a vibrator 11 and a piezoelectric induction element 12. The vibration of the vibrator 11 can cause the output voltage signal of the piezoelectric induction element 12 to change. Through a certain specific sensitivity function, the vibration acceleration at different frequencies can be converted into a voltage signal. The magnetostrictive type vibration sensor can include coil, core and permanent magnet, etc. which can also realize the function of converting vibration acceleration at different frequencies into voltage signal. The specific principle and structure of the piezoelectric induction type, magnetostrictive type or MEMS type vibration sensor can refer to the prior art, which is not described in detail in the embodiment.
[0035] Please refer to Figure 7 and refer toFigure 4 and Figure 6 Optionally, the vibration sensor 1 has a mounting hole 13 passing through along its axial direction, and the vibration sensor 1 is fixed to the screw hole 61 of the integrated housing 6 by a bolt 7 passing through the mounting hole 13. In one embodiment, the vibration sensor 1 comprises a base 10 and a sensor body 14 (such as including a vibrator 11 and a piezoelectric sensing element 12, etc.) arranged along its axial direction (vertical direction in the figure). The base 10 has a mounting hole 13 passing through along its axial direction, and the sensor body 14 is arranged outside the base 10 in a circumferential direction. The inner diameter of the mounting hole 13 is slightly larger than the outer diameter of the bolt 7, so that the bolt 7 can pass through the mounting hole 13 and be screwed into the corresponding screw hole 61 of the integrated housing 6, thereby locking the vibration sensor 1. Figure 6
[0036] Optionally, the integrated housing 6 has an end cover 62 corresponding to the part of the speed reducer 5, and the screw hole 61 is arranged on the end cover 62 and parallel or perpendicular to the output shaft 51 of the speed reducer 5. Please refer to Figure 4 and Figure 5 which shows an electric drive system arranged coaxially, wherein the speed reducer 5 can be a planetary gear box, and the output shaft 51 of the speed reducer 5 is arranged coaxially with the drive shaft of the motor 3. The speed reducer 5 and the motor 3 are arranged coaxially in series. The end cover 62 corresponds to the part of the speed reducer 5, i.e. located on the side relatively far away from the motor 3. Figure 4 and Figure 5 In the exemplary embodiment shown, the screw hole 61 is parallel to the output shaft 51, i.e. the vibration sensor 1 is biased on the end cover 62 on one side of the output shaft 51 after installation. It can be understood that the main measurement direction of the vibration sensor 1 is parallel to the direction of the drive shaft of the motor 3 and the output shaft 51 of the speed reducer 5.
[0037] Please refer to Figure 8 which shows an electric drive system arranged coaxially, wherein the screw hole 61 is perpendicular to the output shaft 51 and located on one side of the end cover 62, i.e. the screw hole 61 is arranged along the radial direction of the speed reducer 5. At this time, the main measurement direction of the vibration sensor 1 is perpendicular to the direction of the drive shaft of the motor 3 and the output shaft 51 of the speed reducer 5.
[0038] Please refer to Figure 9 and Figure 10 which shows an electric drive system arranged in parallel shaft, wherein the output shaft 51 of the speed reducer 5 is arranged in parallel with the drive shaft of the motor 3 and not coaxially. Figure 9 and Figure 10 In the exemplary embodiment shown, the screw hole 61 is parallel to the output shaft 51, for example, it can be arranged between the drive shaft of the motor 3 and the output shaft 51 of the speed reducer 5.
[0039] It should be noted that, since the motor 3, the controller 4 and the reducer 5 have an integrated housing 6, the vibration sensor 1 can also be arranged at other parts of the integrated housing 6, such as other parts corresponding to the reducer 5 (such as Figure 1 As shown), corresponding to the part of motor 3 (as shown Figure 2 ) or the part corresponding to the controller 4 (as shown Figure 3 When determining the specific location of the vibration sensor 1, it is also possible to perform simulation based on the modal of the entire electric drive to avoid points with abnormal vibration (such as anti-resonance points).
[0040] Furthermore, the electric drive system also includes a wiring harness 8, through which the vibration sensor 1 is communicatively connected to the circuit assembly 2. In some embodiments, the vibration sensor 1 and the circuit assembly 2 are directly connected by a wired connection via the wiring harness 8, so that the circuit assembly 2 can not only obtain the vibration signal collected by the vibration sensor 1 through the wiring harness 8, but also power the vibration sensor 1 through the wiring harness 8.
[0041] Please refer to Figure 11 , which exemplarily shows a schematic diagram of a circuit assembly 2. The entire circuit assembly 2 includes a circuit board 20, a microcontroller 21, a signal conditioning circuit 22, and a board connector 23. The microcontroller 21 and signal conditioning circuit 22 are preferably disposed on the circuit board 20. The microcontroller 21 is used to sample the vibration signal. The maximum sampling rate of the microcontroller 21 is preferably at least three times the upper frequency limit of the vibration signal. The signal conditioning circuit 22 is used to pre-process the vibration signal, such as for noise reduction.
[0042] The board terminal connector 23 is provided on the portion of the integrated housing 6 corresponding to the controller 4, for example, Figure 5 In the illustrated example, the board-side connector 23 can be disposed through the portion of the integrated housing 6 corresponding to the controller 4. The portion of the board-side connector 23 facing the outside of the controller 4 is used for connection to the wiring harness 8, while the portion of the board-side connector 23 facing the inside of the controller 4 is communicatively connected to the signal conditioning circuit 22. In one embodiment, the board-side connector 23 can be disposed directly on the circuit board 20, thereby directly conductively connecting to the signal conditioning circuit 22 through the circuit board 20. In other embodiments, the board-side connector 23 can also be disposed separately from the circuit board 20 and connected to the signal conditioning circuit 22 via internal wires.
[0043] Furthermore, the vibration sensor 1 has a signal plug-in terminal 15, which is electrically connected to the sensor body 14. The two ends of the wiring harness 8 are pluggably connected to the signal plug-in terminal 15 and the board-side connector 23, respectively. Thus, after the vibration sensor 1 is installed, the wiring harness 8 can be used to conveniently connect the vibration sensor 1 to the circuit assembly 2.
[0044] In some embodiments, the vibration sensor 1 and the circuit assembly 2 are connected by a wired communication connection to transmit the vibration signal collected by the vibration sensor 1. Optionally, the vibration sensor 1 comprises a sensor body 14, a wired module (not shown) and a power module (not shown), the wired module is connected with the circuit assembly 2 by a wired communication connection, and the power module is used to supply power for the sensor body 14 and the wired module. When the vibration sensor 1 adopts the wired communication scheme, it itself needs to have a power module to realize power supply. The power module, for example, comprises a replaceable disposable battery, such as a button cell. The wired module can be adapted to the circuit assembly 2, for example, a wired module for transmitting an analog signal can also be used.
[0045] After obtaining the vibration signal collected by the vibration sensor 1, in order to realize early monitoring of electrical drive mechanical faults, the circuit assembly 2 is configured to count when the vibration signal exceeds a preset threshold, and output a fault signal externally when the count exceeds a limit value within a predetermined time.
[0046] Optionally, the vibration signal and the preset threshold can be processed or transformed. For example, the vibration signal can be processed and transformed into an N-dimensional fault indicator quantity, and the preset threshold can be an indicator quantity threshold table calibrated based on the product development stage. Specifically, in an exemplary embodiment, the microcontroller 21 of the circuit assembly 2 comprises a vibration signal processing unit, and the vibration signal processing unit is built-in with a program, the calling period of the program can be selected as 0.01s~3600s, and the program reads a vibration signal of a certain time length from the memory each time it is called, calculates a fault parameter such as kurtosis or peak factor through a statistical algorithm, or calculates the values of different orders through Fourier analysis, further analyzes the vibration situation of a specific part according to the correspondence between the order and the mechanical characteristics, obtains an N-dimensional fault indicator quantity, compares the N-dimensional fault indicator quantity with an indicator quantity threshold table also containing N dimensions, and if the N-dimensional fault indicator quantity exceeds the corresponding value in the indicator quantity threshold table, a count is performed. The purpose of counting is to avoid non-fault vibration signals introduced by road conditions or working conditions. Only when the count exceeds the limit value within a predetermined time (such as several minutes), a fault signal (such as reporting to an upper computer system) is output externally.
[0047] After obtaining the vibration signal collected by the vibration sensor 1, in order to realize active control of mechanical noise, the controller 4 is in communication connection with the circuit assembly 2, and the controller 4 is configured to generate a compensation harmonic current that changes in the opposite direction of the vibration excitation based on the vibration signal, and drive the motor 3 to operate in combination with the compensation harmonic current.
[0048] In one example, the microcontroller 21 of the circuit assembly 2 comprises a vibration signal processing unit, which acquires not only the vibration signal but also the driving signal of the motor 3 (including the rotor angle signal, real-time torque or real-time rotating speed, etc.), and then calculates the reverse compensation harmonic current through an open-loop or closed-loop algorithm. The specific algorithm can refer to the prior art, and will not be described in detail in the present embodiment.
[0049] The utility model embodiment further provides a new energy vehicle, it includes the electric drive system as described above. The new energy vehicle can be pure electric car, also can be hybrid car, the present embodiment is not limited to this. The structure and principle of other components of the new energy vehicle can refer to the prior art, and will not be described in detail in the present embodiment.
[0050] To sum up, in the electric drive system and the new energy vehicle provided by the utility model, the electric drive system comprises a vibration sensor, a circuit assembly, a motor, a controller and a reducer;The motor, the controller and the reducer have an integrated housing, and the vibration sensor is arranged in the integrated housing;The vibration sensor is in communication connection with the circuit assembly, and the circuit assembly is arranged in the controller and used to collect the vibration signal of the vibration sensor. By arranging the vibration sensor on the integrated housing, the vibration signal of the mechanical moving part in the electric drive system can be obtained, so that the early monitoring of the electric drive mechanical failure and the active control of the mechanical noise can be realized at low cost.
[0051] It should be noted that the above several embodiments can be combined with each other. The above description is only a description of the preferred embodiments of the utility model, and does not limit the scope of the utility model. Any modification or modification made by a person skilled in the art according to the above disclosure is within the protection scope of the utility model.
Claims
1. An electric drive system, characterized in that: include: A vibration sensor, a circuit component, a motor, a controller and a reducer; wherein the motor, the controller and the reducer have an integrated housing, and the vibration sensor is arranged in the integrated housing; the vibration sensor is communicatively connected to the circuit component, and the circuit component is arranged in the controller to collect the vibration signal of the vibration sensor.
2. The electric drive system according to claim 1, characterized in that: The vibration sensor has a mounting hole that penetrates along its own axial direction. The vibration sensor is fixed to the screw hole of the integrated housing by a bolt that penetrates the mounting hole.
3. The electric drive system according to claim 2, characterized in that: The portion of the integrated housing corresponding to the reducer has an end cover, and the screw hole is arranged on the end cover and is parallel or perpendicular to the output shaft of the reducer.
4. The electric drive system according to claim 1, characterized in that: The electric drive system further includes a wiring harness, through which the vibration sensor is communicatively connected to the circuit assembly.
5. The electric drive system according to claim 4, characterized in that: The vibration sensor has a signal plug-in terminal, and the circuit assembly includes a board-end connector, which is arranged at the part of the integrated housing corresponding to the controller; the two ends of the wiring harness are respectively connected to the signal plug-in terminal and the board-end connector in a pluggable manner.
6. The electric drive system according to claim 1, characterized in that: The vibration sensor includes a sensor body, a wireless module and a power module. The wireless module is wirelessly connected to the circuit component, and the power module is used to supply power to the sensor body and the wireless module.
7. The electric drive system according to claim 1, characterized in that: The vibration sensor is of piezoelectric induction type, magnetostrictive type or MEMS type, and the output signal type of the vibration sensor is an analog voltage signal or a sampled digital signal.
8. The electric drive system according to claim 1, characterized in that: The electric drive system further includes at least one of a charger, a DCDC, a VCU, a BMS, a TMS, and a PDU.
9. The electric drive system according to claim 1, characterized in that: The circuit component is configured to count when the vibration signal exceeds a preset threshold, and output a fault signal when the count exceeds a number limit within a predetermined time.
10. A new energy vehicle, characterized in that: It comprises the electric drive system according to any one of claims 1 to 9.