Motor and controller integrated system, range extender assembly and vehicle

Abstract

The utility model discloses a motor and controller integrated system, range extender assembly and vehicle, the motor and controller integrated system comprises an integrated housing, a controller main body and a motor main body, the controller main body and the motor main body are successively arranged in the integrated housing along the axial direction, a motor water jacket is arranged outside the motor main body, a water channel for cooling liquid to circulate is formed between the integrated shell and the motor water jacket, a sealing assembly is arranged between the integrated shell and the motor water jacket, and the motor water jacket is connected with the integrated shell through a plurality of mounting support lugs. According to the range extender assembly, the integration level and the rigidity of the range extender assembly can be improved. Moreover, the sealing assembly is arranged between the integrated shell and the motor water jacket, the integrated shell and the motor water jacket are connected through the mounting support lugs, the contact area of the two parts is small, the vibration transmission path is small, the NVH performance can be improved, meanwhile, compared with a traditional structure, the number of the parts is reduced, and the assembly efficiency is improved.

Description

Technical Field

[0001] This utility model relates to new energy vehicles, specifically to an integrated system of motor and controller, a range extender assembly, and a vehicle. Background Technology

[0002] The range extender assembly is a crucial power component of new energy vehicles, primarily consisting of an engine, an electric motor (or ISG motor, generator), and a controller. The engine provides the power for the range extender assembly, the electric motor converts the mechanical energy generated by the engine into electrical energy, and the controller monitors and controls the operation of the range extender assembly in real time. To improve ride comfort, the requirements for NVH (Noise, Vibration, and Harshness) performance in automotive range extender assemblies are becoming increasingly stringent. Simultaneously, with the optimization of vehicle space layout and the advancement of lightweight design, the axial dimensions of automotive range extender assemblies are continuously decreasing, rendering existing assemblies inadequate for these needs.

[0003] CN115991105A discloses an integrated structure for a generator system in a range-extended electric vehicle, including a motor controller, a housing assembly, and a rotor assembly. The motor controller includes a housing and a cover, as well as supporting capacitors, power components, and filter components housed within the housing. The housing is a disc-shaped cavity structure with a ring-shaped resolver boss at the center of its outer surface. The housing assembly includes a housing, a stator assembly, a resolver bracket, a resolver, and a resolver pressure plate. The stator assembly is heat-fitted into the housing with an interference fit. The resolver bracket is fixed to the resolver boss in the housing, and the resolver is fixed to the rear end face of the resolver bracket via the resolver pressure plate. The housing and the rear end face of the housing are fixedly connected. Undoubtedly, the technical solution disclosed in the above patent document represents a beneficial attempt in the relevant technical field. However, the motor and controller housings in this solution are separate, and there is still room for improvement in terms of housing rigidity, motor cost, and integration. Utility Model Content

[0004] In view of this, the purpose of this utility model is to provide an integrated system of motor and controller, a range extender assembly and a vehicle, which can improve the integration and rigidity of the range extender assembly, improve NVH performance, increase assembly efficiency and reduce manufacturing and labor costs.

[0005] This utility model discloses an integrated system for a motor and controller, comprising an integrated housing, a controller body, and a motor body. The controller body and the motor body are sequentially arranged axially inside the integrated housing. A motor water jacket is provided on the outside of the motor body. A water channel for coolant flow is formed between the integrated housing and the motor water jacket. A sealing assembly is provided between the integrated housing and the motor water jacket. The motor water jacket is connected to the integrated housing through multiple mounting lugs.

[0006] Furthermore, the motor water jacket is provided with a flow channel groove on its exterior, and the flow channel groove forms the water channel between the inner wall of the integrated housing.

[0007] Furthermore, the front end of the integrated housing is provided with a front flange, and a plurality of mounting grooves are provided on the front flange at intervals. The plurality of mounting lugs are located at the front end of the motor water jacket, and each mounting lug corresponds to the position of each mounting groove.

[0008] Furthermore, the mounting lug is embedded in the mounting groove of the front flange, and the mounting lug is connected to the front flange by bolts.

[0009] Furthermore, the motor water jacket is provided with two annular grooves, which are located on different sides of the water channel; the sealing assembly includes two sealing rings, which are respectively installed on the two annular grooves.

[0010] Furthermore, the integrated housing is a one-piece die-cast aluminum alloy structure.

[0011] Furthermore, the integrated housing has a controller mounting cavity and a motor mounting cavity arranged sequentially along the axial direction inside.

[0012] Furthermore, it also includes a housing cover plate, which is connected to the rear end of the integrated housing by threaded fasteners.

[0013] One type of range extender assembly of this utility model includes the motor and controller integrated system described above.

[0014] One type of vehicle according to this utility model includes the above-mentioned range extender assembly.

[0015] The beneficial effects of this utility model are:

[0016] (1) By setting up an integrated housing to accommodate the controller body and the motor body, this utility model can improve the integration and rigidity of the range extender assembly. In addition, a sealing component is provided between the integrated housing and the motor water jacket. The integrated housing and the motor water jacket are connected by mounting lugs. The contact area between the two parts is small, the vibration transmission path is small, which can improve NVH performance. At the same time, compared with the traditional structure, the number of parts is reduced, the assembly efficiency is improved, and the labor cost is reduced.

[0017] (2) The integrated housing of this utility model reduces the number of parts, improves assembly efficiency, and reduces manufacturing and labor costs.

[0018] (3) The sealing component of this utility model can prevent coolant leakage.

[0019] (4) The mounting ears of this utility model fit the mounting groove in a conformal manner, which can play a positioning role during assembly and reduce the assembly difficulty. Attached Figure Description

[0020] To make the objectives, technical solutions, and beneficial effects of this utility model clearer, the following drawings are provided for illustration:

[0021] Figure 1 This is a cross-sectional schematic diagram of the present invention;

[0022] Figure 2 This is a schematic diagram of the structure of this utility model;

[0023] Figure 3 This is a schematic diagram of the structure of the motor body of this utility model;

[0024] Figure 4 This is a schematic diagram of the integrated housing of this utility model;

[0025] Figure 5 This is an exploded structural diagram of the integrated housing and motor water jacket of this utility model.

[0026] The following labels are used in the attached diagram: 1-Integrated housing, 101-Front flange, 102-Mounting groove, 103-Controller mounting cavity, 104-Motor mounting cavity, 2-Controller body, 3-Motor body, 301-Motor water jacket, 302-Mounting lug, 303-Flow channel groove, 304-Annular groove, 4-Water channel, 5-Sealing assembly, 6-Housing cover plate, 7-Bolt. Detailed Implementation

[0027] The technical solution of this utility model will be described in detail below with reference to the accompanying drawings and embodiments.

[0028] like Figures 1-5As shown, an integrated system for a motor and controller in this embodiment includes an integrated housing 1, a controller body 2, and a motor body 3. The controller body 2 and the motor body 3 are sequentially arranged axially inside the integrated housing 1. A motor water jacket 301 is provided on the outside of the motor body 3. A water channel 4 for coolant flow is formed between the integrated housing 1 and the motor water jacket 301. A sealing assembly 5 is provided between the integrated housing 1 and the motor water jacket 301. The motor water jacket 301 is connected to the integrated housing 1 through multiple mounting lugs 302.

[0029] By integrating the controller body 2 and the motor body 3 into a single, unified housing 1, the integration and rigidity of the range extender assembly can be improved. Furthermore, a sealing assembly 5 is provided between the integrated housing 1 and the motor water jacket 301. The integrated housing 1 and the motor water jacket 301 are connected by mounting lugs 302. This results in a small contact area between the two parts, shortening the vibration transmission path and improving NVH performance. Compared to traditional structures, this reduces the number of parts, increases assembly efficiency, and lowers labor costs. In addition, the sealing assembly 5 prevents coolant leakage.

[0030] In this embodiment, a flow channel groove 303 is provided on the outside of the motor water jacket 301, and the water channel 4 is formed between the flow channel groove 303 and the inner wall of the integrated housing 1. By setting the complex shape structure of the flow channel groove 303 used to form the water channel 4 on the outside of the motor water jacket 301, the inner wall of the integrated housing 1 does not need to be provided with a groove structure, which can reduce the manufacturing difficulty of the integrated housing 1, thereby reducing the difficulty of the die casting process of the integrated housing 1.

[0031] In this embodiment, a front flange 101 is provided at the front end of the integrated housing 1. Multiple mounting slots 102 are spaced apart on the front flange 101. Multiple mounting lugs 302 are located at the front end of the motor water jacket 301, and each mounting lug 302 corresponds to a specific mounting slot 102. In this embodiment, the mounting lugs 302 are embedded in the mounting slots 102 of the front flange 101, and the mounting lugs 302 are connected to the front flange 101 by bolts 7.

[0032] The mounting lug 302 conforms to the mounting groove 102, providing positioning during assembly and reducing assembly difficulty. The mounting groove 102 of the front flange 101 has threaded holes, and the mounting lug 302 has bolt through holes. By passing a bolt 7 through the bolt through hole and connecting it to the threaded hole, a detachable connection between the mounting lug 302 and the front flange 101 can be achieved.

[0033] In this embodiment, the motor water jacket 301 is provided with two annular grooves 304, which are located on different sides of the water channel 4; the sealing assembly 5 includes two sealing rings, which are respectively installed on the two annular grooves 304. By also providing the annular grooves 304 on the outside of the motor water jacket 301, the inner wall of the integrated housing 1 does not need to be provided with a groove structure, which can reduce the manufacturing difficulty of the integrated housing 1 and thus reduce the difficulty of the die-casting process of the integrated housing 1.

[0034] In this embodiment, the integrated housing 1 is a one-piece die-cast aluminum alloy structure. The one-piece die-casting of the aluminum alloy gives the integrated housing 1 high strength and high dimensional accuracy, and makes it suitable for mass production.

[0035] In this embodiment, the integrated housing 1 has a controller mounting cavity 103 and a motor mounting cavity 104 arranged sequentially along the axial direction inside. The controller mounting cavity 103 is used to install the controller body 2, and the motor mounting cavity 104 is used to install the motor body 3.

[0036] In this embodiment, a housing cover plate 6 is also included, which is connected to the rear end of the integrated housing 1 by threaded fasteners. The housing cover plate 6 is used to cover the controller mounting cavity 103. The threaded fasteners are easy to install, low in cost, and highly efficient.

[0037] One range extender assembly in this embodiment includes the aforementioned integrated system of motor and controller.

[0038] One vehicle in this embodiment includes the range extender assembly described above.

[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the spirit and scope of the technical solutions of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A motor and controller integrated system, characterized in that: The device includes an integrated housing (1), a controller body (2), and a motor body (3). The controller body (2) and the motor body (3) are arranged sequentially along the axial direction inside the integrated housing (1). A motor water jacket (301) is provided on the outside of the motor body (3). A water channel (4) for coolant flow is formed between the integrated housing (1) and the motor water jacket (301). A sealing assembly (5) is provided between the integrated housing (1) and the motor water jacket (301). The motor water jacket (301) is connected to the integrated housing (1) through multiple mounting lugs (302).

2. The integrated system of motor and controller according to claim 1, characterized in that: The motor water jacket (301) is provided with a flow channel groove (303) on the outside, and the flow channel groove (303) and the inner wall of the integrated housing (1) form the water channel (4).

3. The integrated system of motor and controller according to claim 2, characterized in that: The front end of the integrated housing (1) is provided with a front flange (101), and a plurality of mounting grooves (102) are provided on the front flange (101) at intervals. A plurality of mounting lugs (302) are located at the front end of the motor water jacket (301), and each mounting lug (302) corresponds to the position of each mounting groove (102).

4. The integrated system of motor and controller according to claim 3, characterized in that: The mounting lug (302) is embedded in the mounting groove (102) of the front flange (101), and the mounting lug (302) is connected to the front flange (101) by bolts (7).

5. The integrated system of motor and controller according to claim 3, characterized in that: The motor water jacket (301) is provided with two annular grooves (307), the two annular grooves (307) are located on different sides of the water channel (4); the sealing assembly (5) includes two sealing rings, the two sealing rings are respectively installed on the two annular grooves (307).

6. The integrated system of motor and controller according to claim 1, characterized in that: The integrated housing (1) is an integral die-cast structure of aluminum alloy.

7. The integrated system of motor and controller according to claim 1, characterized in that: The integrated housing (1) has a controller mounting cavity (103) and a motor mounting cavity (104) arranged sequentially along the axial direction inside.

8. The integrated system of motor and controller according to claim 1, characterized in that: It also includes a housing cover plate (6), which is connected to the rear end of the integrated housing (1) by threaded fasteners.

9. A range extender assembly, characterized in that: Including the integrated system of motor and controller as described in any one of claims 1-8.

10. A vehicle, characterized in that: Includes the range extender assembly as described in claim 9.

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