Motor assembly and vehicle powertrain

Abstract

The application provides a motor assembly and a vehicle power system. The motor assembly comprises a housing, a motor and a controller assembled together. The housing comprises a first housing body, a second housing body and an intermediate cover. The intermediate cover is located between the first housing body and the second housing body, and is detachably fixed to the first housing body and the second housing body to close the openings of the two housing bodies. Thus, the first housing body, the second housing body and the intermediate cover surround the first cavity and the second cavity arranged side by side in the axial direction of the motor, the motor is installed in the first cavity, and the controller is installed in the second cavity. In this way, the motor and the controller can be integrated together to be modularly constructed into the motor assembly, facilitating transportation and disassembly, and the radial space occupied by the motor assembly can be reduced, which is beneficial to improving the structural layout of the vehicle using the vehicle power system.

Description

Technical Field

[0001] This application relates to the field of electric motors, and more particularly to electric motor assemblies and vehicle power systems including such electric motor assemblies. Background Technology

[0002] Today, electric motors are widely used in pure electric vehicles and hybrid vehicles. They can serve as a power source to drive the vehicle or be driven by an engine to generate electricity. Furthermore, to control the operation of the motor, a controller is also installed in conjunction with it. Typically, for ease of assembly and transportation, the motor and controller can be integrated to create a modular motor assembly. However, in existing motor assemblies, the controller is usually positioned radially outward from the motor, resulting in an excessively large radial dimension of the motor assembly. This leads to an excessively large vertical space occupied after the motor assembly is assembled. Utility Model Content

[0003] To overcome or mitigate the shortcomings of the prior art, one objective of this application is to provide a novel motor assembly that is not only easy to assemble and disassemble, but also has a smaller overall size in the radial direction of the motor. Another objective of this application is to provide a vehicle powertrain system including the aforementioned motor assembly, enabling the vehicle powertrain system to reduce the vertical space it occupies.

[0004] To achieve the above objectives, this application adopts the following technical solution.

[0005] This application provides a motor assembly for a vehicle powertrain system, comprising a housing, a motor, and a controller assembled together.

[0006] The housing includes a first housing body, a second housing body, and an intermediate cover. The first housing body has a first opening facing one axial direction, and the second housing body has a second opening facing the other axial direction. The intermediate cover is located between the first housing body and the second housing body along the axial direction of the motor. The intermediate cover is detachably fixed to the first housing body and the second housing body to close the first opening and the second opening.

[0007] The first housing body and the intermediate cover surround to form a first chamber, and the second housing body and the intermediate cover surround to form a second chamber. The first chamber and the second chamber are arranged side by side in the axial direction. The motor is housed and installed in the first chamber and the controller is housed and installed in the second chamber.

[0008] In one alternative embodiment, the first housing body has a first flange portion with a first mounting hole, the second housing body has a second flange portion with a second mounting hole, the intermediate cover has a through hole, and the grouped first mounting hole, second mounting hole, and through hole are interconnected.

[0009] The motor assembly also includes connectors, each of which is inserted into a corresponding set of the first mounting holes, the second mounting holes, and the through holes, such that the first housing body, the second housing body, and the intermediate cover are fixed to each other via the connectors.

[0010] In another alternative embodiment, the connector is formed with an external thread, and one of the first mounting hole and the second mounting hole is formed with an internal thread that mates with the external thread, and the connector is threadedly connected to the one of the first mounting hole and the second mounting hole.

[0011] In another alternative, the plurality of the connectors are arranged spaced apart from each other over the entire circumference of the housing.

[0012] In another alternative embodiment, the motor assembly further includes a first water passage disposed in the first housing body and a second water passage disposed in the second housing body, the first water passage and the second water passage being directly connected to each other, such that water flowing through the second water passage can flow into the first water passage.

[0013] In another alternative embodiment, the first water passage is formed with a receiving portion extending along the axial direction, and the second water passage is formed with an insert portion extending along the axial direction, the insert portion being inserted into the receiving portion such that the first water passage and the second water passage are in direct communication with each other.

[0014] In another alternative embodiment, the motor assembly further includes a heat exchanger mounted on the outer peripheral wall of the first housing body.

[0015] The motor assembly also includes an oil passage disposed in the first housing body. Both the oil passage and the first water passage extend through the heat exchanger, so that the water in the first water passage and the oil in the oil passage exchange heat in the heat exchanger.

[0016] In another alternative embodiment, the first water path includes multiple water pipes fixed to the outer peripheral wall of the main body of the first housing body, with adjacent water pipes directly connected to each other or connected via the heat exchanger.

[0017] This application also provides a vehicle powertrain system including the motor assembly described in any of the above technical solutions.

[0018] In one alternative embodiment, the vehicle powertrain includes a range extender system, which includes the motor assembly.

[0019] By adopting the above technical solution, this application provides a motor assembly for use in a vehicle powertrain system. The motor assembly includes a housing, a motor, and a controller assembled together. Specifically, the housing includes a first housing body, a second housing body, and an intermediate cover that are detachably fixed together. The first housing body forms a first opening facing one axial direction, and the second housing body forms a second opening facing the other axial direction. The intermediate cover is located between the first and second housing bodies and is detachably fixed to the first and second housing bodies to close the first and second openings. Thus, the first housing body and the intermediate cover surround to form a first chamber, and the second housing body and the intermediate cover surround to form a second chamber. The first and second chambers are arranged side-by-side along the axial direction of the motor, with the motor housed in the first chamber and the controller housed in the second chamber. This application also provides a vehicle powertrain system including the above-described motor assembly.

[0020] In this way, by using a housing consisting of a first housing body, a second housing body, and an intermediate cover that can be detachably fixed together, the motor and controller can be integrated into a modular motor assembly. This not only facilitates transportation and installation but also simplifies the housing structure for easy assembly and disassembly. Furthermore, since the first chamber for mounting the motor and the second chamber for mounting the controller, defined by the housing, are arranged side-by-side along the motor's axial direction, the radial space occupied by the motor assembly can be reduced compared to a motor assembly where the controller is located radially outward from the motor. Therefore, in a vehicle powertrain system including the aforementioned motor assembly, when the motor assembly is mounted in the vehicle with the motor's axial direction parallel to the vehicle's length or width direction, the vehicle powertrain system can reduce its height space, which is beneficial for improving the structural layout of vehicles using this powertrain system. Attached Figure Description

[0021] Figure 1A This is a schematic diagram showing a three-dimensional structure of a motor assembly according to an embodiment of this application.

[0022] Figure 1B It shows Figure 1A A side view of the motor assembly.

[0023] Figure 2A It is shown in sectional view. Figure 1A A three-dimensional schematic diagram of the housing of the motor assembly, in which cross-sectional lines are omitted.

[0024] Figure 2B It shows Figure 2A A side view of the casing.

[0025] Figure 3A It shows Figure 1A A three-dimensional schematic diagram of the first housing body of the motor assembly housing.

[0026] Figure 3B It shows Figure 3A Another three-dimensional schematic diagram of the first shell body in the diagram.

[0027] Figure 4A It shows Figure 1A A three-dimensional schematic diagram of the second housing body of the motor assembly housing.

[0028] Figure 4B It shows Figure 4A Another three-dimensional schematic diagram of the second shell body.

[0029] Figure 5A It shows Figure 1A A three-dimensional schematic diagram of the middle cover of the housing of the motor assembly.

[0030] Figure 5B It shows Figure 5A Another three-dimensional diagram of the middle cover.

[0031] Explanation of reference numerals in the attached figures

[0032] 1 First housing body; 1o First opening; 1c First chamber; 11 First main body part; 12 First flange part; 12h First mounting hole; 13 First water passage; 131 Receiving part; 132 Water pipe; 14 Oil passage;

[0033] 2 Second housing body; 2o Second opening; 2c Second chamber; 21 Second main body part; 22 Second flange part; 22h Second mounting hole; 23 Second water channel; 231 Insertion part;

[0034] 3. Middle cover; 3h through hole;

[0035] 4. Connectors;

[0036] 5. Heat exchanger;

[0037] A is axial; R is radial. Detailed Implementation

[0038] Exemplary embodiments of this application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are for teaching those skilled in the art how to implement this application only, and are not intended to exhaust all possible methods of this application, nor to limit the scope of this application.

[0039] In this application, unless otherwise specified, "axial," "radial," and "circumferential" refer to the axial, radial, and circumferential directions of the motor, respectively. Further, "one side of the axial direction" refers to... Figure 1B , Figure 2B The left side of the axis, "the other side of the axis" refers to Figure 1B , Figure 2B The right side of the motor; "radial outer side" refers to the side that is radially away from the central axis of the motor, and "radial inner side" refers to the side that is radially closer to the central axis of the motor.

[0040] The following description, in conjunction with the accompanying drawings, illustrates an embodiment of a motor assembly according to this application.

[0041] In this application, the motor assembly integrates the motor and controller to form a modular construction. For example... Figure 1A and Figure 1B As shown, a motor assembly according to an embodiment of this application includes a housing, a motor, and a controller assembled together. The motor and controller are housed and installed within the housing. The motor is used to generate torque or receive torque from an external source for power generation, and the controller is mainly used to control the operating state of the motor.

[0042] In this embodiment, as Figure 2A and Figure 2B As shown, the housing includes a first housing body 1, a second housing body 2, and an intermediate cover 3, which are detachably fixed together. The first housing body 1 has a first opening 1o that opens toward one axial side (see...). Figure 3A The second housing body 2 has a second opening 2o that opens toward the other side of the axial direction (see...). Figure 4B The first housing body 1 and the second housing body 2 are arranged facing each other along axis A. Along axis A, an intermediate cover 3 is located between the first housing body 1 and the second housing body 2, and is detachably fixed to the first housing body 1 and the second housing body 2 to close the first opening 1o and the second opening 2o. The first housing body 1 and the intermediate cover 3 enclose a first chamber 1c, and the second housing body 2 and the intermediate cover 3 enclose a second chamber 2c, such that the first chamber 1c and the second chamber 2c are arranged side-by-side along axis A. The motor is housed and installed within the first chamber 1c, and the controller is housed and installed within the second chamber 2c.

[0043] It is understandable that the intermediate cover 3 does not completely isolate the first chamber 1c and the second chamber 2c, such as Figure 5A and Figure 5B As shown, the intermediate cover 3 may be formed with a through hole as needed, so that structures such as connection structures for realizing electrical connections can extend from the first chamber 1c through the through hole into the second chamber 2c.

[0044] like Figure 2A , Figure 2B , Figure 3A and Figure 3B As shown, the first housing body 1 includes a first main body portion 11, a first flange portion 12, a first water passage 13, and an oil passage 14. The first main body portion 11 is integrally formed as a cylindrical structure with an open axial side end and a bottom at the other axial side end. The aforementioned first opening 1o of the first housing body 1 is formed at the axial side end of the first main body portion 11, while the bottom is located at the other axial side end of the first main body portion 11, and a through hole through which the motor shaft of the power supply extends is provided at the central portion of the bottom. The first flange portion 12 is located at the axial side end of the first main body portion 11 and extends radially outward from the outer peripheral wall of the first main body portion 11 in a predetermined shape. A plurality of first mounting holes 12h are formed on the first flange portion 12 at circumferential intervals, each first mounting hole 12h penetrating the first flange portion 12 along the axial direction A, and each first mounting hole 12h is used to insert and install the connector 4 of the power supply assembly.

[0045] Furthermore, such as Figure 3A and Figure 3B As shown, the first water passage 13 is formed by connecting multiple water pipes 132 disposed in the first main body 11. These water pipes 132 are fixed to the outer peripheral wall of the first main body 11 with predetermined dimensions and structure. Each pair of adjacent water pipes 132 is directly connected to each other or connected via other structures such as a heat exchanger 5. The first water passage 13 has a receiving portion 131 extending along the axial direction A of the motor. In this embodiment, one of the water pipes 132 constituting the first water passage 13 can serve as the receiving portion 131, which is used as the inlet of the first water passage 13. The receiving portion 131 is connected to the insertion portion 231 of the second water passage 23 of the second housing body 2, so that the first water passage 13 and the second water passage 23 are directly connected to each other, thereby allowing water flowing through the second water passage 23 to enter the first water passage 13. Furthermore, in this embodiment, another water pipe 132 extending from the heat exchanger 5 and constituting the first water passage 13 can serve as the outlet of the first water passage 13. The outlet can be connected to the circuit of the vehicle's thermal management system, allowing water flowing through the first water passage 13 to circulate within the vehicle's thermal management system circuit. The first oil passage 14 can be composed of multiple oil pipes disposed in the first main body 11. These oil pipes are fixed to the outer peripheral wall of the first main body 11 with predetermined dimensions and construction. One of the oil pipes can be connected to the first chamber 1c and the heat exchanger 5, allowing oil from the first chamber 1c to enter the heat exchanger 5 via this oil pipe. Another oil pipe extending from the heat exchanger 5 can be connected to the circuit of the vehicle's thermal management system, allowing oil flowing through the heat exchanger 5 to circulate within the vehicle's thermal management system circuit; alternatively, another oil pipe extending from the heat exchanger 5 can be connected to the first chamber 1c, allowing oil flowing through the heat exchanger 5 to directly return to the first chamber 1c.

[0046] It is understood that the specific structure of the first water passage 13 and the oil passage 14 is not limited to the specific structure shown in the above figures, but can be changed as needed, as long as the first water passage 13 and the oil passage 14 can achieve the functions described above.

[0047] like Figure 2A , Figure 2B , Figure 4A and Figure 4B As shown, the second housing body 2 includes a second main body portion 21, a second flange portion 22, and a second water passage 23. The second main body portion 21 is integrally formed as a square cylindrical structure with an open end on one axial side and a bottom on one axial side. The aforementioned second opening 2o of the second housing body 2 is formed at the other axial side of the second main body portion 21, and the bottom is located at the other axial side of the second main body portion 21. The second flange portion 22 is located at the other axial side of the second main body portion 21 and extends radially outward from the outer peripheral wall of the second main body portion 21 in a predetermined shape. A plurality of second mounting holes 22h are formed on the second flange portion 22 at circumferential intervals, each second mounting hole 22h penetrating the second flange portion 22 along the axial direction A, and each second mounting hole 22h allows the connector 4 of the power supply assembly to be inserted and installed.

[0048] Furthermore, such as Figure 4A and Figure 4B As shown, the second water passage 23 is composed of multiple water pipes disposed in the second main body 21 and connected to a cavity formed within the second main body 21. The second water passage 23 has an insertion portion 231 extending along the axial direction A of the motor toward the first housing body 1. In this embodiment, one water pipe constituting the second water passage 23 can serve as this insertion portion 231, which acts as the outlet of the second water passage 23. As described above, the insertion portion 231 is connected to the receiving portion 131 of the first water passage 13 of the first housing body 1, allowing direct communication between the first water passage 13 and the second water passage 23. Furthermore, in this embodiment, another water pipe constituting the second water passage 23 can serve as the inlet of the second water passage 23. This inlet can be connected to the circuit of the vehicle's thermal management system, allowing water from the vehicle's thermal management system circuit to enter the second water passage 23.

[0049] It is understood that the second water channel 23 can be used to dissipate heat from the controller. The specific structure of the second water channel 23 is not limited to the specific structure shown in the above figure, but can be changed as needed, as long as the second water channel 23 can achieve the functions described above.

[0050] like Figure 2A , Figure 2B , Figure 5A and Figure 5BAs shown, the intermediate cover 3 is formed as a plate-like structure, and its shape mates with the first housing body 1 and the second housing body 2. Multiple through holes 3h are formed on the outer periphery of the intermediate cover 3, and these through holes 3h are spaced apart along the entire circumference of the intermediate cover 3. Each through hole 3h mates with a corresponding first mounting hole 12h on the first housing body 1 and a corresponding second mounting hole 22h on the second housing body 2 to form a group. The group of first mounting holes 12h, second mounting holes 22h, and through holes 3h are interconnected, thereby allowing each connector 4 to be inserted into a corresponding group of first mounting holes 12h, second mounting holes 22h, and through holes 3h to fix the first housing body 1, the second housing body 2, and the intermediate cover 3 together.

[0051] In this embodiment, the motor includes a stator, a rotor, and a motor shaft. Both the stator and rotor are housed and installed inside the first chamber 1c. The stator can be fixed to the first housing body 1, and the rotor is coaxially arranged with the stator and rotatable relative to the stator. The motor shaft is drively connected to the rotor to transmit torque generated by the rotor to the outside of the motor assembly or to receive torque from the outside of the motor assembly and transmit it to the rotor. The motor shaft extends from the first housing body 1 along axial direction A towards the other side of the axial direction. The controller may include a control module, which may include a circuit board and devices such as chips disposed on the circuit board. The control module can be housed and installed inside the second chamber 2c.

[0052] In this embodiment, as Figure 1A , Figure 1B , Figure 2A and Figure 2B As shown, the motor assembly also includes multiple connectors 4, which are threaded connectors with external threads. The connectors 4 are inserted into a group of first mounting holes 12h, second mounting holes 22h, and through holes 3h to fix the first housing body 1, the second housing body 2, and the intermediate cover 3 together. In this embodiment, the connectors 4 are inserted from one axial side through the second mounting holes 22h and 3h into the first mounting holes 12h, and each first mounting hole 12h has an internal thread that mates with the external thread of the connector 4. Thus, the threaded connection between the connectors 4 and the first housing body 1 achieves stable assembly and secure fixation of the entire housing assembly, and connecting the various parts of the housing together through the common connectors 4 simplifies the assembly and disassembly process.

[0053] In this embodiment, as Figure 1A and Figure 1B As shown, the motor assembly also includes a heat exchanger 5, which is mounted on the outer peripheral wall of the first housing body 1. Both the oil passage 14 and the first water passage 13 extend through the heat exchanger 5, so that the water in the first water passage 13 and the oil in the oil passage 14 exchange heat in the heat exchanger 5, thereby reducing the temperature of the oil in the oil passage 14.

[0054] By adopting the above-described scheme, the motor and controller can be modularly integrated into a motor assembly by means of a housing consisting of a first housing body 1, a second housing body 2, and an intermediate cover 3, which can be detachably fixed together. This facilitates transportation, installation, and disassembly. Furthermore, since the first chamber 1c for mounting the motor and the second chamber 2c for mounting the controller, defined by the housing, are arranged side-by-side along the motor axis A, the radial space occupied by the motor assembly can be reduced compared to a motor assembly where the controller is located radially outward from the motor. Moreover, integrating the first water passage 13, the oil passage 14, and the second water passage 23 into the housing makes the entire motor assembly structure more compact. In addition, in a vehicle powertrain system including the above-described motor assembly, when the motor assembly is mounted in the vehicle with the motor axis A parallel to the length or width direction of the vehicle, the vehicle powertrain system can reduce the height space it occupies, which is beneficial for improving the structural layout of vehicles using this powertrain system.

[0055] It should be understood that the above embodiments are merely exemplary and are not intended to limit this application. Those skilled in the art can make various modifications and changes to the above embodiments under the teachings of this application without departing from the scope of this application. The technical solutions of this application are further described below.

[0056] i. The motor assembly of this application is used in a vehicle powertrain system, which can be a pure electric system or a hybrid powertrain system. In the case of a hybrid powertrain system, the motor assembly according to this application can be used to construct a range extender system. This motor assembly can be connected to the engine drive system, thereby utilizing the engine to drive the motor of the motor assembly to generate electricity.

[0057] ii. In the above embodiments, the connector 4 passes through the second mounting hole 22h and the through hole 3h from one axial side and then achieves a threaded connection with the first mounting hole 12h. Correspondingly, the connector 4 has an external thread and the first mounting hole 12h has an internal thread that mates with the external thread. However, this application is not limited to this. In a variation of the above embodiments, the connector 4 can have an external thread and the second mounting hole 22h can have an internal thread that mates with the external thread. Correspondingly, the connector 4 passes through the first mounting hole 12h and the through hole 3h from the other axial side and then achieves a threaded connection with the second mounting hole 22h, which can also achieve the same function. Alternatively, the connector 4 can include a bolt and a nut, in which case the first mounting hole 12h and the second mounting hole 22h can be smooth holes.

[0058] iii. At least a portion of the water pipe or oil pipe may be integrally formed on the first housing body 1 or the second housing body 2, or attached to the first housing body 1 or the second housing body 2 by means of welding or the like.

Claims

1. A motor assembly, characterized in that, The motor assembly is used in the vehicle powertrain and includes a housing, a motor, and a controller assembled together. The housing includes a first housing body, a second housing body, and an intermediate cover. The first housing body has a first opening facing one axial direction, and the second housing body has a second opening facing the other axial direction. The intermediate cover is located between the first housing body and the second housing body along the axial direction of the motor. The intermediate cover is detachably fixed to the first housing body and the second housing body to close the first opening and the second opening. The first housing body and the intermediate cover surround to form a first chamber, and the second housing body and the intermediate cover surround to form a second chamber. The first chamber and the second chamber are arranged side by side in the axial direction. The motor is housed and installed in the first chamber and the controller is housed and installed in the second chamber.

2. The motor assembly according to claim 1, characterized in that, The first housing body has a first flange portion with a first mounting hole, the second housing body has a second flange portion with a second mounting hole, and the intermediate cover has a through hole. The grouped first mounting hole, second mounting hole, and through hole are interconnected. The motor assembly also includes connectors, each of which is inserted into a corresponding set of the first mounting holes, the second mounting holes, and the through holes, such that the first housing body, the second housing body, and the intermediate cover are fixed to each other via the connectors.

3. The motor assembly according to claim 2, characterized in that, The connector has an external thread, and one of the first mounting hole and the second mounting hole has an internal thread that mates with the external thread. The connector is threadedly connected to one of the first mounting hole and the second mounting hole.

4. The motor assembly according to claim 2, characterized in that, The plurality of the connectors are arranged spaced apart from each other over the entire circumference of the housing.

5. The motor assembly according to any one of claims 1 to 4, characterized in that, The motor assembly further includes a first water channel disposed on the first housing body and a second water channel disposed on the second housing body. The first water channel and the second water channel are directly connected to each other, so that water flowing through the second water channel can flow into the first water channel.

6. The motor assembly according to claim 5, characterized in that, The first water passage has a receiving portion extending along the axial direction, and the second water passage has an insertion portion extending along the axial direction. The insertion portion is inserted into the receiving portion so that the first water passage and the second water passage are directly connected to each other.

7. The motor assembly according to claim 5, characterized in that, The motor assembly also includes a heat exchanger, which is mounted on the outer peripheral wall of the first housing body. The motor assembly also includes an oil passage disposed in the first housing body. Both the oil passage and the first water passage extend through the heat exchanger, so that the water in the first water passage and the oil in the oil passage exchange heat in the heat exchanger.

8. The motor assembly according to claim 7, characterized in that, The first water passage includes multiple water pipes, which are fixed to the outer peripheral wall of the main body of the first housing body. Adjacent water pipes are directly connected to each other or connected via the heat exchanger.

9. A vehicle powertrain system, characterized in that, Includes the motor assembly according to any one of claims 1 to 8.

10. The vehicle power system according to claim 9, characterized in that, The vehicle powertrain includes a range extender system, and the range extender system includes the motor assembly.

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