Electric drive axle of new energy automobile

Abstract

An electric drive axle of a new energy automobile comprises a drive motor, a speed reducer, a controller and a differential mechanism, the drive motor, the speed reducer, the controller and the differential mechanism are installed in a shared shell, a drive motor installation cavity is formed in the middle of the shared shell, a speed reducer installation cavity is formed in one side of the drive motor, and a controller installation cavity is formed in the other side of the drive motor. A differential mounting cavity is formed in the front side of the speed reducer, axle tube connecting parts are arranged on the left side and the right side of the differential mounting cavity respectively, the two ends of a motor shaft of the driving motor are supported on the shared shell through bearings respectively, and one end of the motor shaft extends into the speed reducer mounting cavity to form a cantilever end; the cantilever end is provided with a driving bevel gear which is meshed with a driven bevel gear on the intermediate shaft of the speed reducer.

Description

Technical Field

[0001] This utility model relates to the field of electric drive axles, specifically to an electric drive axle for new energy vehicles. Background Technology

[0002] With the continuous development of new energy vehicles, miniaturization, high speed, and lightweighting of electric drive systems have become major research directions. The following problems still exist in the integration of electric drive bridges in existing technologies: 1. The housings of the motor, reducer, and controller are separate, resulting in high manufacturing costs; 2. The motor shaft and the input shaft of the reducer are connected by splines. For example, in the utility model patent with authorization announcement number CN211335443U, the motor shaft of the drive motor and the input shaft of the reducer transmit power through a spline connection. This structure requires extremely high spline precision, thus increasing the manufacturing cost of the spline shaft and also causing problems such as spline wear and shaft frequency; 3. The motor rotor has axial forces at an angle, which increases the load on the bearings, leading to reduced bearing life and increased noise. Summary of the Invention

[0003] To address the aforementioned problems, this utility model provides an electric drive axle for new energy vehicles. It features a shared housing design for the motor, controller, and reducer, and a coaxial design between the reducer input shaft and the motor shaft. This design ensures a compact rear axle structure, small size, and low cost, achieving a highly integrated power layout for new energy vehicle models.

[0004] The technical solution of this utility model is as follows: an electric drive axle for a new energy vehicle, comprising a drive motor, a reducer, a controller, and a differential. The drive motor, reducer, controller, and differential are installed in a common housing. The middle part of the common housing is the drive motor mounting cavity, one side of the drive motor is the reducer mounting cavity, the other side of the drive motor is the controller mounting cavity, and the front side of the reducer is the differential mounting cavity. The left and right sides of the differential mounting cavity are respectively provided with axle tube connection parts. The two ends of the drive motor shaft are supported on the common housing by bearings. One end of the motor shaft extends into the reducer mounting cavity to form a cantilever end. A driving helical gear is provided on the cantilever end to mesh with a driven helical gear on the intermediate shaft of the reducer.

[0005] Preferably, the active helical gear is integrally formed on the cantilever end of the motor shaft.

[0006] Preferably, the helix angle of the driving helical gear and the driven helical gear is in the range of 8° to 30°.

[0007] Preferably, the common housing includes a housing body, a controller end cover, a reducer end cover, and a differential cover. The housing body has a drive motor mounting cavity, a reducer mounting cavity, a controller mounting cavity, and a differential mounting cavity. The controller end cover is located on one side of the controller mounting cavity of the housing body, the reducer end cover is located on one side of the reducer mounting cavity of the housing body, and the differential cover is located on one side of the differential mounting cavity of the housing body.

[0008] Preferably, the controller end cover, reducer end cover, and differential cover are all connected to the housing body by bolts.

[0009] The advantages of this utility model are:

[0010] 1. The input shaft of the reducer and the motor shaft of the motor are integrally formed, and the driving helical gear is integrally formed on the motor shaft. This eliminates the spline connection between the input shaft of the reducer and the motor shaft, avoiding many problems caused by the spline connection. At the same time, it reduces the two bearings required for the input shaft of the reducer, reduces one assembly process between the reducer and the motor, improves the sealing performance, and reduces the manufacturing cost.

[0011] 2. The motor, controller and reducer of this utility model are all set in a common housing, which is compact, small in size and low in cost, and realizes a highly integrated power layout for new energy vehicles.

[0012] 3. In this utility model, the axial force generated when the driving helical gear meshes with the driven helical gear offsets part of the axial force of the motor rotor helical stage, thereby improving bearing life, reducing noise, and enhancing NVH performance. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the internal structure of the present invention;

[0014] Figure 2 This is a schematic diagram of the first external structure of the present invention;

[0015] Figure 3 This is a schematic diagram of the second external structure of the present invention. Detailed Implementation

[0016] See Figures 1 to 3An electric drive axle for a new energy vehicle includes a drive motor 4, a reducer 3, a controller 2, and a differential 6. The drive motor 4, reducer 3, controller 2, and differential 6 are installed in a common housing 1. The common housing 1 includes a housing body 11, a controller end cover 12, a reducer end cover 13, and a differential cover 14. The middle part of the common housing 1 is the drive motor mounting cavity, one side of the drive motor 4 is the reducer mounting cavity, the other side of the drive motor 4 is the controller mounting cavity, and the front side of the reducer 3 is the differential mounting cavity. The controller end cover 12 is located on one side of the controller mounting cavity, the reducer end cover 13 is located on one side of the reducer mounting cavity, and the differential cover 14 is located on one side of the differential mounting cavity of the housing body 11. Axle tube connection parts 7 are respectively provided on the left and right sides of the differential mounting cavity. The controller end cover 12, the reducer end cover 13, and the differential cover 14 are all connected to the housing body 11 by bolts. This design makes the electric drive bridge compact and small in size, reducing production costs. Furthermore, the inclusion of the controller end cover 12, reducer end cover 13, and differential cover 14 facilitates the assembly of the controller 2, reducer 3, and differential 6 within the common housing 1. The motor shaft 41 of the drive motor 4 is supported at both ends by bearings 5 ​​on the common housing 1. One end of the motor shaft 41 extends into the reducer mounting cavity, forming a cantilever end. A driving helical gear 411 is mounted on this cantilever end, meshing with a driven helical gear 31 on the intermediate shaft of the reducer 3. The driving helical gear 411 is integrally formed on the cantilever end of the motor shaft 41. The helix angle between the driving helical gear 411 and the driven helical gear 31 ranges from 8° to 30°. Within this angle range, the axial force generated when the driving helical gear 411 meshes with the driven helical gear 31 can offset part of the axial force of the motor rotor's slant gear, improving bearing life, reducing noise, and enhancing NVH performance.

[0017] This invention is applied to electric vehicles by integrating the controller 2, motor 4, and reducer 3 into a three-in-one electric drive assembly. The motor shaft 41 is integrated with the reducer input shaft, and the driving helical gear 411 is integrally machined onto the motor shaft 41, eliminating the spline connection. This achieves a shared housing design for the motor 4, controller 2, and reducer 3, resulting in a compact structure, small size, and low cost. Furthermore, it avoids the shaft sidefrequency problems, spline wear problems, and spline knocking problems caused by the misalignment of the motor 4 and reducer input shaft spline connection. It also reduces the number of bearings required for reducer input shaft assembly, eliminates one assembly step between reducer 3 and motor 4, and improves sealing performance.

[0018] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of this utility model. Any modifications made to this utility model by those skilled in the art without departing from its spirit shall fall within the protection scope of this utility model.

Claims

1. A new energy vehicle electric drive axle, comprising a drive motor (4), a reducer (3), a controller (2), and a differential (6), characterized in that: The driving motor (4), the reducer (3), the controller (2) and the differential (6) are installed in a common housing (1), the middle part of the common housing (1) is a driving motor installation cavity, the side of the driving motor (4) is a reducer installation cavity, the other side of the driving motor (4) is a controller installation cavity, the front side of the reducer (3) is a differential installation cavity, the left and right sides of the differential installation cavity are respectively provided with bridge pipe connecting parts (7), the motor shaft (41) of the driving motor (4) is supported on the common housing (1) through bearings (5) at both ends, one end of the motor shaft (41) extends into the reducer installation cavity to form a cantilever end, a driving helical gear (411) is arranged on the cantilever end and meshes with a driven helical gear (31) on the intermediate shaft of the reducer (3).

2. The electric drive axle of a new energy vehicle according to claim 1, characterized in that: The driving helical gear (411) is integrally formed on the cantilever end of the motor shaft (41).

3. The electric drive axle of a new energy vehicle according to claim 1, characterized in that: The helix angle of the driving helical gear (411) and the driven helical gear (31) ranges from 8° to 30°.

4. The electric drive axle of a new energy vehicle according to claim 1, characterized in that: The common housing (1) comprises a housing body (11), a controller end cover (12), a reducer end cover (13) and a differential cover (14), the inner cavity of the housing body (11) is provided with a driving motor installation cavity, a reducer installation cavity, a controller installation cavity and a differential installation cavity, the controller end cover (12) is arranged on one side of the controller installation cavity of the housing body (11), the reducer end cover (13) is arranged on one side of the reducer installation cavity of the housing body (11), and the differential cover (14) is arranged on one side of the differential installation cavity of the housing body (11).

5. The electric drive axle of a new energy vehicle according to claim 4, characterized in that: The controller end cover (12), the reducer end cover (13) and the differential cover (14) are connected with the housing body (11) through bolts.

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