All-in-one electric drive assembly and vehicle
By integrating the drive motor, reducer, motor controller, and power supply system into a single electric drive housing and using interconnected cooling water channels, the high hardware cost of the electric drive assembly is solved, resulting in reduced costs, increased power density, and improved cooling system reliability.
Patent Information
- Application Number
- CN202520129431.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-20
- Publication Date
- 2026-01-23
- Estimated Expiration
- 2035-01-20
AI Technical Summary
Existing electric drive assemblies have high hardware and assembly costs, making it difficult to achieve high integration, miniaturization, lightweight design, high power density, and high efficiency.
Design an all-in-one electric drive assembly that integrates the drive motor, reducer, motor controller, power supply system, and wiring harness assembly through an all-in-one electric drive housing. Cooling is achieved through interconnected cooling water channels, and the module layout is optimized to reduce the number of parts used and connecting parts.
It reduces the hardware and assembly costs of the electric drive assembly, increases power density and modularity, simplifies the structure, and enhances the reliability and heat dissipation efficiency of the cooling system.
Smart Images
Figure CN223821448U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The application relates to the field of electric drive assemblies, in particular to a multi-in-one electric drive assembly and a vehicle. BACKGROUND
[0002] With the intensification of market competition, higher requirements are put forward for the performance indexes of electric drive assemblies. At present, the performance improvement direction of electric drive assemblies for new energy vehicles mainly includes high integration, small size and light weight, high power density, high efficiency, modularity, high reliability and low cost.
[0003] It is necessary to provide an integrated electric drive capable of reducing the hardware cost and assembly cost of the electric drive assembly. SUMMARY
[0004] The utility model provides a multi-in-one electric drive assembly and a vehicle for reducing the hardware cost and assembly cost of the electric drive assembly.
[0005] The technical scheme of the utility model is as follows:
[0006] The application provides a multi-in-one electric drive assembly, which comprises a multi-in-one electric drive shell, a speed reducer, a driving motor, a motor controller, a power supply system and a wire distribution mounting seat assembly.
[0007] The speed reducer, the driving motor, the motor controller, the power supply system and the wire distribution mounting seat assembly are integrated into one through the multi-in-one electric drive shell.
[0008] A first cooling water channel is arranged on the power supply system, a second cooling water channel is arranged on the multi-in-one electric drive shell, and a third cooling water channel is arranged on the motor controller.
[0009] The outlet of the first cooling water channel is in communication with the inlet of the second cooling water channel, and the outlet of the second cooling water channel and the inlet of the third cooling water channel are in communication in sequence.
[0010] Preferably, a fourth cooling water channel for cooling the driving motor is further arranged on the multi-in-one electric drive shell, and the inlet of the fourth cooling water channel is in communication with the outlet of the third cooling water channel.
[0011] Preferably, a heat insulation material is coated on the side surface of a target shell of the multi-in-one electric drive shell facing the driving motor; the target shell is a part of the shell of the multi-in-one electric drive shell for being used by the driving motor and the motor controller.
[0012] Preferably, the driving motor and the speed reducer are placed inside the multi-in-one electric drive shell, and the driving motor and the speed reducer are connected through a motor transmission shaft.
[0013] The motor controller, the power supply system and the distribution mounting base assembly are detachably mounted on the all-in-one electric drive shell.
[0014] Preferably, the motor controller takes the all-in-one electric drive shell as a cover.
[0015] Preferably, the power supply system and the reducer are side-mounted on the side of the all-in-one electric drive shell.
[0016] Preferably, the power supply system comprises a power supply system cover plate, a power supply system internal function module and a power supply system shell.
[0017] The power supply system cover plate is connected with the power supply system shell, so that the power supply system internal function module is sealed inside the power supply system shell.
[0018] The power supply system internal function module integrates the on-board charger, the DC / DC conversion and the DC / AC conversion functions on the same PCB board.
[0019] Preferably, the motor controller comprises a motor controller shell, an inverter brick assembly and a three-phase copper bar assembly; the inverter brick assembly is used for converting direct current of a battery into three-phase alternating current, and the three-phase copper bar assembly is used for connecting the inverter brick assembly and stator lead wires of the driving motor.
[0020] Preferably, the third cooling water channel arranged on the motor controller comprises a cooling sub-water channel arranged on the motor controller shell and a heat dissipation sub-water channel arranged on the inverter brick assembly, and the cooling sub-water channel and the heat dissipation sub-water channel are communicated.
[0021] In another aspect, the application further provides a vehicle comprising the all-in-one electric drive assembly.
[0022] The application has the following beneficial effects:
[0023] By designing the second cooling water channel connecting the third cooling water channel of the motor controller and the first cooling water channel of the power supply system on the surface of the all-in-one electric drive shell, the interconnection of the cooling water channels of the two function modules is realized, the use of connecting parts is reduced, and the cost of the electric drive assembly is reduced. BRIEF DESCRIPTION OF DRAWINGS
[0024] Figure 1 is a schematic diagram of the all-in-one electric drive assembly provided by the embodiment of the application;
[0025] Figure 2 is an exploded schematic diagram of the all-in-one electric drive assembly provided by the embodiment of the application;
[0026] Figure 3 is an exploded schematic view of a power supply system provided by an embodiment of the present application;
[0027] Figure 4 is an exploded schematic view of a motor controller provided by an embodiment of the present application;
[0028] Figure 5 is a structural schematic view of an inverter brick assembly inside a motor controller provided by an embodiment of the present application;
[0029] Figure 6 is a left view of an inverter brick assembly inside a motor controller provided by an embodiment of the present application;
[0030] Figure 7 is a first cooling water channel schematic view of a power supply system provided by an embodiment of the present application;
[0031] Figure 8 is a first cooling water channel schematic view of a power supply system provided by an embodiment of the present application;
[0032] Figure 9 is a cooling water channel position schematic view on a multi-in-one electric drive shell provided by an embodiment of the present application;
[0033] Figure 10 is a common shell schematic view in an embodiment of the present application;
[0034] Figure 11 is a cooling sub-water channel schematic view of a motor controller shell provided by an embodiment of the present application;
[0035] Legend of reference signs: 1-multi-in-one electric drive shell; 11-second inlet; 12-second cooling water channel; 13-second outlet; 14-target shell; 141-thermal insulation material; 15-fourth cooling water channel; 101-first arc-shaped space; 102-second arc-shaped space;
[0036] 2-motor controller; 201-third cooling water channel; 21-motor controller shell; 211-third inlet; 212-cooling sub-water channel; 213-third outlet; 22-inverter brick assembly; 23-three-phase copper bar; 221-direct current support thin film capacitor integrated filter assembly; 222-inverter brick assembly communication port; 223-power module water cooling plate; 224-fourth outlet; 225-inverter brick assembly drive and control integrated board; 226-power module; 227-power module three-phase output end; 228-fourth inlet; 229-inverter brick assembly direct current output terminal;
[0037] 3-power supply system; 31-power supply system shell; 32-power supply system internal function module; 33-power supply system cover plate; 311-first inlet; 312-first cooling water channel; 313-first outlet;
[0038] 4 - junction block assembly; 41 - cover plate. DETAILED DESCRIPTION
[0039] The technical solutions in the embodiments of the present application will be described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the scope of the present application.
[0040] With reference to Figure 1 and Figure 2 The embodiments of the present application provide a multi-in-one electric drive assembly, which comprises a power supply system 3, a motor controller 2, a multi-in-one electric drive shell 1, a drive motor, a reducer and a junction block assembly 4.
[0041] The multi-in-one electric drive shell 1 is the main frame of the multi-in-one electric drive assembly, and other functional modules are detachably fixed to the multi-in-one electric drive shell 1 to form a whole. The motor controller 2, the power supply system 3 and the high-voltage power battery are electrically connected through a wire harness after being matched through the junction block assembly 4; the motor controller 2 is electrically connected with the drive motor through an internal three-phase copper bar 23.
[0042] By integrating the drive motor, the reducer, the motor controller 2, the power supply system 3 and the junction block assembly 4 through the multi-in-one electric drive shell 1, the structure is simplified, the use of parts is reduced, and the hardware cost and the assembly cost of the electric drive assembly are reduced.
[0043] Specifically, with reference to Figure 2 In the embodiments of the present application, other functional modules are fixed to the multi-in-one electric drive shell 1 to form a whole through screws, the screw heads are designed to the outside of the multi-in-one electric drive shell 1, so that the disassembly of the other functional modules can be conveniently realized, thereby reducing the maintenance difficulty. Since the motor controller 2 and the power supply system 3 can be independently disassembled from the multi-in-one electric drive shell 1 for maintenance without affecting each other, the maintenance and replacement of the fault part can be conveniently realized after the fault point of the electric drive assembly is determined.
[0044] With reference to Figure 2In the embodiment of the present application, the motor controller 2 uses the all-in-one electric drive shell 1 as a cover plate; the wire distribution mounting seat assembly 4 uses the all-in-one electric drive shell 1 as a shell and uses a separate cover plate 41. Specifically, the first arc-shaped space 101 on the all-in-one electric drive shell 1 is used as a space for accommodating internal devices of the motor controller 2, and the second arc-shaped space 102 on the all-in-one electric drive shell 1 is used as a placement space for the wire distribution mounting seat assembly 4, thereby improving the power density of the all-in-one electric drive assembly, optimizing the module layout, and reducing the use of the motor controller cover plate, thereby reducing the cost.
[0045] As shown in Figure 2 , the drive motor and the speed reducer are placed inside the all-in-one electric drive shell 1 and are connected through a motor transmission shaft; the cover plate 41 of the wire distribution mounting seat assembly 4 and the all-in-one electric drive shell 1 are fixed by screws, and the cover plate 41 of the wire distribution mounting seat assembly 4 is sealed around by materials including but not limited to sealing rings and sealing glue. Similarly, the motor controller 2 and the all-in-one electric drive shell 1 also include but are not limited to sealing rings and sealing glue to achieve the sealing effect.
[0046] Referring to Figure 10 , in order to avoid the influence of high temperature generated by the drive motor on the internal devices of the motor controller 2 when the drive motor is running, a portion of the all-in-one electric drive shell 1 serving as a motor controller cover plate is coated with a heat insulation material 141. Specifically, referring to Figure 9 and Figure 10 , the target shell 14 of the all-in-one electric drive shell 1 is coated with a heat insulation material 141 on the side surface facing the drive motor; the target shell 14 is a portion of the shell of the all-in-one electric drive shell 1 for common use of the drive motor and the motor controller 2.
[0047] Referring to Figure 2 , in the embodiment of the present application, the motor controller 2 and the power supply system 3 are hung side by side on the front end side or the rear end side of the all-in-one electric drive shell 1, thereby reducing the Z-direction height of the all-in-one electric drive assembly and avoiding the occupation of the Z-direction space of the passenger compartment by the all-in-one electric drive assembly, thereby providing a more comfortable riding experience for passengers.
[0048] As shown in Figure 4As shown, the power supply system 3 includes a power supply system cover plate 33, a power supply system internal function module 32, and a power supply system shell 31. The power supply system shell 31 is designed with a first cooling water channel 312 for heat dissipation during operation of the power supply system. The power supply system internal function module 32 integrates the on-board charger, DC / DC conversion, and DC / AC conversion functions onto the same PCB board, reducing the use of material costs and improving the power density of the power supply system 3. Similarly, the power supply system cover plate 33 and the power supply system shell 31 use materials such as but not limited to sealing rings, sealing glue, etc. to achieve a sealing effect, and use bolts to achieve integrated fixation of the power supply system cover plate 33 and the power supply system shell 31.
[0049] As shown in Figure 3 , Figure 5 and Figure 6 , the motor controller 2 includes a motor controller shell 21, an inverter brick assembly 22, and a three-phase copper bar assembly 23. The inverter brick assembly 22 is used to convert the direct current of the battery into three-phase alternating current. The three-phase copper bar assembly 23 is used to connect the inverter brick assembly and the stator lead wire of the driving motor. The inverter brick assembly 22 includes a direct current support thin film capacitor integrated filter assembly 221 (including a magnetic ring and a filter capacitor), an inverter brick assembly communication port 222, a power module water cooling plate 223, a power module 226, a power module three-phase output end 227, an inverter brick assembly drive control integrated board 225, and an inverter brick assembly direct current output terminal 229. The bus side of the direct current support thin film capacitor integrated filter assembly 221 and the power module 226 are integrated together through a common copper bar, reducing the use of copper bars and bolts at the stacking place, abandoning the bolt fixation method to reduce the parasitic inductance of the power module loop and the internal volume occupied by the above-mentioned components, and improving the power density and reliability of the motor controller 2 through the integrated method of the above-mentioned function modules.
[0050] The inverter brick function module 22 also includes a thin film capacitor and a power module heat dissipation sub-water channel. The inverter brick function module 22 realizes the common use of the 400V voltage platform and the 800V voltage platform through the unified 400V and 800V platform external enclosure size structure, water channel connection method, and electrical connection method interface to realize the common use of the 400V voltage platform and the 800V voltage platform, reducing the cost of the mold.
[0051] In the embodiments of the present application, the materials constituting the all-in-one electric drive shell 1, the motor controller shell 21, and the power supply system shell 31 include but are not limited to aluminum alloy, magnesium alloy, cast iron, etc.
[0052] Specifically, cooling channels are designed on the surfaces of the motor controller housing 21, the power supply system housing 31, and the multi-function electric drive housing 11. Specifically, the power supply system housing 31 is provided with a first cooling channel 312, the multi-function electric drive housing 1 is provided with a second cooling channel 12, and the motor controller housing 21 is provided with a third cooling channel 201. The first cooling channel 312, the second cooling channel 12, and the third cooling channel 201 are connected in sequence.
[0053] By designing a connection channel between the third cooling channel 201 of the motor controller 2 and the first cooling channel 312 of the power supply system 3 on the surface of the all-in-one electric drive housing 1, the cooling channels of the two functional modules are interconnected, which reduces the use of connecting parts and lowers the cost of the electric drive assembly.
[0054] The sealing rings and covers of the third cooling water channel 201 and the first cooling water channel 312 are located on the outside of the corresponding housings to avoid cooling water leakage caused by accidental failure or aging of the sealing rings, which could ultimately lead to the burnout of the control circuit board. The third cooling water channel 201 and the first cooling water channel 312 are not on the same plane. Therefore, a second cooling water channel 12 is designed on the surface of the multi-in-one electric drive housing 1 to connect the inlet of the third cooling water channel 201 with the outlet 313 of the first cooling water channel 312.
[0055] like Figures 3 to 5 , Figures 7 to 11 As shown, the cooling water for this all-in-one electric drive assembly enters from the first inlet 311 of the first cooling water channel 312, passes through the first cooling water channel 312, and exits at the first outlet 313. The first outlet 313 of the first cooling water channel 312 is sealed to the second inlet 11 of the second cooling water channel 12, and passes through the second cooling water channel 12 to the second outlet 13. By using the second cooling water channel 12, the first cooling water channel 212 of the power supply system 3 and the third cooling water channel 201 of the motor controller 2 are connected, which reduces the number of cooling water pipe components used while improving the reliability of the cooling system. The second outlet 13 of the second cooling water channel 12 is sealed to the third inlet 211 of the cooling sub-channel 212. After passing through the cooling sub-channel 212, the water is sealed to the fourth inlet 228 of the heat dissipation sub-channel of the inverter brick assembly 22 through the third outlet 213 of the cooling sub-channel 212. Finally, cooling water is delivered from the fourth outlet 224 of the heat dissipation sub-channel of the inverter brick assembly 22 to the fifth inlet of the fourth cooling water channel 15 on the multi-in-one electric drive housing 1 for cooling the drive motor. The heat dissipation sub-channel of the inverter brick assembly achieves double-sided heat dissipation. The first heat dissipation surface dissipates heat from the power module 226, and the second heat dissipation surface dissipates heat from the DC support thin film capacitor integrated filter assembly 221. The heat dissipation efficiency of the electric drive assembly is improved by shortening the stroke of the heat dissipation sub-channel in the motor controller.
[0056] ReferenceFigure 8 The first cooling water channel 312 of the power supply system 3 is in the shape of a Chinese character'' to ensure that the power components used by the on-board charger, the DC / DC converter, the DC / AC converter and other heat-generating elements can be closely attached to the water channel to achieve high-efficiency heat dissipation.
[0057] The power density of the motor controller 2 is improved by designing the DC support thin film capacitor integrated filter assembly 221, the power module 226 and the power module drive control integrated board 225 in an integrated manner.
[0058] The third cooling water channel 201 of the motor controller 2 and the first cooling water channel 312 of the power supply system 3 are both designed to the surface of the shell, and the cover plates of the first cooling water channel 312 and the third cooling water channel 201 are both designed to the outer surface of the shell and sealed by a sealing ring to avoid the insulation damage of the electrical elements in the shell caused by the leakage of water vapor due to poor sealing.
[0059] It should be noted that each of the embodiments in the specification is described in a progressive manner, and each embodiment focuses on the difference from other embodiments.
[0060] Although the preferred embodiments of the utility model embodiments have been described, those skilled in the art can make other changes and modifications to the embodiments once they know the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications falling within the scope of the utility model embodiments.
[0061] It also needs to be explained that in this paper, the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, which is for the convenience of describing the utility model and simplifying the description, and does not indicate or imply that the device or component referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the utility model. In addition, relationship terms such as "first" and "second" are used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between the entities or operations, nor can it be understood as indicating or implying relative importance. Moreover, the terms "include", "contain" or any other variants thereof are intended to cover non-exclusive inclusion, so that the process, method, article or terminal device including a series of elements does not include those elements, but also includes other elements not explicitly listed, or includes elements inherent to such process, method, article or terminal device. Without more limitations, the element defined by the statement "including a…" does not exclude the presence of another identical element in the process, method, article or terminal device including the element.
[0062] The above describes the technical solutions provided by the utility model in detail, and the principles and implementation modes of the utility model are described by applying specific examples. The above example is only used to help understand the utility model, and the content of the specification should not be understood as a limitation on the utility model. At the same time, for those skilled in the art, according to the utility model, there will be different forms of changes in specific implementation modes and application ranges, which do not need to be enumerated here, and the obvious changes or changes derived therefrom are still within the protection scope of the utility model.
Claims
1. An all-in-one electric drive assembly, characterized in that, include: All-in-one electric drive housing (1), reducer, drive motor, motor controller (2), power supply system (3) and branch mounting bracket assembly (4); The reducer, the drive motor, the motor controller (2), the power supply system (3) and the branch mounting bracket assembly (4) are integrated into one unit through the multi-in-one electric drive housing (1); The power supply system (3) is provided with a first cooling water channel (312), the multi-in-one electric drive housing (1) is provided with a second cooling water channel (12), and the motor controller (2) is provided with a third cooling water channel (201). The outlet of the first cooling water channel (312) is connected to the inlet of the second cooling water channel (12), and the outlet of the second cooling water channel (12) and the inlet of the third cooling water channel (201) are connected in sequence.
2. The all-in-one electric drive assembly according to claim 1, characterized in that, The multi-functional electric drive housing (1) is also provided with a fourth cooling water channel (15) for cooling the drive motor. The inlet of the fourth cooling water channel (15) is connected to the outlet of the third cooling water channel (201).
3. The all-in-one electric drive assembly according to claim 1, characterized in that, The target housing of the all-in-one electric drive housing (1) is coated with a heat-insulating material (141) on the side facing the drive motor; the target housing is the part of the housing of the all-in-one electric drive housing (1) that is used by the drive motor and the motor controller (2).
4. The all-in-one electric drive assembly according to claim 1, characterized in that, The drive motor and the reducer are placed inside the multi-in-one electric drive housing (1), and the drive motor and the reducer are connected by a motor drive shaft; The motor controller, the power supply system (3), and the branch mounting bracket assembly (4) are detachably mounted on the all-in-one electric drive housing (1).
5. The all-in-one electric drive assembly according to claim 1, characterized in that, The motor controller (2) uses the all-in-one electric drive housing (1) as its cover.
6. The all-in-one electric drive assembly according to claim 1, characterized in that, The power supply system (3) and the reducer are mounted side by side on the side of the all-in-one electric drive housing (1).
7. The all-in-one electric drive assembly according to claim 1, characterized in that, The power supply system (3) includes: a power supply system cover plate (33), an internal functional module (32) of the power supply system, and a power supply system housing (31). The power supply system cover plate (33) is connected to the power supply system housing (31), so that the internal functional module (32) of the power supply system is sealed inside the power supply system housing (31); The internal functional module (32) of the power supply system integrates the on-board charger, DC / DC conversion and DC / AC conversion functions onto the same PCB board.
8. The all-in-one electric drive assembly according to claim 1, characterized in that, The motor controller (2) includes: a motor controller housing (21), an inverter brick assembly (22), and a three-phase copper busbar assembly (23); the inverter brick assembly (22) is used to convert the DC power of the battery into three-phase AC power, and the three-phase copper busbar assembly (23) is used to connect the inverter brick assembly (22) and the stator wires of the drive motor.
9. The all-in-one electric drive assembly according to claim 8, characterized in that, The third cooling channel (201) provided on the motor controller (2) includes: a cooling sub-channel (212) provided on the motor controller housing (21) and a heat dissipation sub-channel provided on the inverter brick assembly (22), wherein the cooling sub-channel (212) and the heat dissipation sub-channel are connected.
10. A vehicle, characterized in that, Includes the all-in-one electric drive assembly as described in any one of claims 1-9.