An electric drive assembly and vehicle

Abstract

This utility model provides an electric drive assembly and vehicle for achieving high-voltage filtering, wiring separation, passive load protection, and detachable maintenance functions without occupying more X-axis and Z-axis space. The electric drive assembly includes: a motor, a motor controller, and a filter assembly; the motor controller is fixed to the motor and arranged parallel to the motor in the horizontal direction; the filter assembly is disposed in the empty gap area formed between the motor controller and the motor; the vertex position of the filter assembly in the longitudinal direction of the vehicle is lower than or flush with the vertex position of the motor controller.

Description

Technical Field

[0001] This application relates to the field of electric drive systems for vehicles, specifically an electric drive system and a vehicle. Background Technology

[0002] With the rapid development of new energy vehicles, electric drive system assemblies are gradually becoming smaller and lighter, with increasingly higher integration levels. The more integrated multi-in-one electric drive structure is a key development direction for major new energy vehicle manufacturers. In multi-in-one electric drive system assemblies, the filter module connecting the battery pack input and the thin-film capacitor plays a crucial role. Generally, in the current mainstream multi-in-one electric drive system assembly structure, the motor controller is positioned as a separate assembly above the motor, and the filter responsible for filtering within the motor controller is planarly arranged on the upper surface of the motor controller, following its shape (e.g., ...). Figure 5 As shown in the figure, while integrating more functions, the motor controller will occupy a larger area, resulting in excessive Z-axis space occupation. This is not conducive to the pursuit of miniaturization and high volumetric power density of the motor controller. Summary of the Invention

[0003] This utility model provides an electric drive assembly and vehicle that can achieve high-voltage filtering, wiring, passive load protection, and detachable maintenance functions without occupying more X-axis and Z-axis space.

[0004] The technical solution of this utility model is as follows: This application provides an electric drive assembly, including: a motor, a motor controller, and a filter assembly; The motor controller is fixed to the motor, and the motor controller and the motor are arranged parallel to each other along the length of the vehicle. The filter component is disposed in the empty gap area formed between the motor controller and the motor; The bottom position of the motor in the longitudinal direction of the vehicle is flush with the bottom position of the motor controller; The vertex position of the filter component in the longitudinal direction of the vehicle is lower than the vertex position of the motor controller or is flush with the vertex position of the motor controller.

[0005] Preferably, the motor controller and the motor are arranged parallel to each other along the length of the vehicle, and the bottom position of the motor in the longitudinal direction of the vehicle is flush with the bottom position of the motor controller.

[0006] Preferably, the filtering component includes: A branch mounting bracket for fixed connection with the motor of the electric drive assembly; The main circuit is set on the branch mounting base and electrically connects the battery pack DC bus connector and the motor controller high-voltage DC input copper bus. The first fuse is mounted on the branch mounting base and electrically connects the main circuit and the high-voltage junction box connector; The second fuse is installed on the branch mounting base and electrically connects the main circuit and the high-voltage DC harness of the power supply device. A Y capacitor is mounted on the branch mounting base, with one end electrically connected to the main circuit and the other end grounded. A magnetic ring is disposed on the branch mounting base; The magnetic ring is arranged around the high-voltage DC input copper busbar interface of the motor controller on the main circuit, and the Y capacitor is arranged inside the magnetic ring.

[0007] Preferably, one end of the first fuse is connected to the main circuit, and the other end is electrically connected to the high-voltage junction box connector through the first connecting bar; One end of the second fuse is connected to the main circuit, and the other end is electrically connected to the high-voltage DC harness of the power supply device through the second connecting bar.

[0008] Preferably, the branch mounting base is provided with a first mounting groove, and the magnetic core is encapsulated in the first mounting groove with potting compound to form the magnetic ring.

[0009] Preferably, the branch mounting base is provided with a second mounting groove, and the Y capacitor is bonded and fixed in the second mounting groove.

[0010] Preferably, the junction box mounting base is provided with a plurality of first mounting holes, which are used to fix the high voltage junction box connector, the battery pack DC bus connector, the motor controller high voltage DC input copper busbar, and the power supply device high voltage DC harness on the junction box mounting base.

[0011] Preferably, the branch mounting base is provided with a plurality of second mounting holes, and the branch mounting base is connected to the motor housing by bolts passing through the second mounting holes.

[0012] Preferably, the main circuit is a copper busbar.

[0013] Preferably, the magnetic core is a nanocrystalline magnetic core.

[0014] This application also provides a vehicle including the aforementioned electric drive assembly.

[0015] The beneficial effects of this utility model are as follows: After separating the filter component from the motor controller to form an independent assembly, the X and Z dimensions of the motor controller are reduced, thus decreasing the overall area of ​​the motor controller and achieving miniaturization and high volumetric power density. Simultaneously, by arranging the motor controller horizontally parallel to the motor and placing the filter component in the empty gap area between the motor controller and the motor, the Z-axis space occupied by the electric drive assembly can be reduced. Furthermore, since the existing motor controller's length in the vehicle's overall length direction is greater than the motor's length in the vehicle's X direction, the overall size of the existing electric drive assembly in the vehicle's overall length direction is equal to the X-axis length of the motor controller. However, by removing the filter component and reducing the overall size of the motor controller, and by changing the motor controller's current horizontal arrangement above the motor to a longitudinal arrangement beside the motor, the overall X-axis size of the electric drive assembly does not increase. This allows the electric drive assembly to achieve high-voltage filtering, branching, passive load protection, and detachable maintenance functions without occupying more X and Z-axis space. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the filtering component in the embodiments of this application; Figure 2 This is a top view of the filtering component in the embodiments of this application; Figure 3 This is a schematic diagram of the branch mounting base according to an embodiment of this application; Figure 4 This is an electrical schematic diagram of the filter component in the embodiments of this application; Figure 5 This is a schematic diagram of an existing electric drive assembly; Figure 6 This is a schematic diagram of the electric drive assembly in the embodiments of this application; Explanation of reference numerals in the attached drawings: 1-Motor; 2-Motor controller; 3-Filter assembly; 31-Branch mounting base; 3101-First mounting slot; 3102-Second mounting slot; 3103-First mounting hole; 3104-Second mounting hole; 32-Main circuit; 311-First connecting busbar; 312-Second connecting busbar; 33-Battery pack DC busbar connector; 34-Motor controller high-voltage DC input copper busbar; 35-First fuse; 36-High-voltage junction box connector; 37-Second fuse; 38-High-voltage DC wiring harness of power supply device; 39-Y capacitor; 310-Magnetic ring. Detailed Implementation

[0017] The method of this utility model will be further described below with reference to the embodiments and accompanying drawings. This embodiment is implemented based on the technical solution of this utility model, and provides detailed implementation methods and specific operation processes, but the protection scope of this utility model is not limited to the following embodiments.

[0018] Reference Figure 6 This application provides an electric drive assembly, including: a motor 1, a motor controller 2, and a filter assembly 3; The motor controller 2 is fixed on the motor 1, and the motor controller 2 and the motor 1 are arranged parallel to each other in the horizontal direction; The filter component 3 is disposed in the empty gap area formed between the motor controller 2 and the motor 1; The vertex position of the filter component 3 in the longitudinal direction of the vehicle is lower than or flush with the vertex position of the motor controller 2.

[0019] Specifically, in this embodiment of the application, the filter component 3 is designed in the top arc-shaped triangular area of ​​the electric drive assembly.

[0020] After the filter component 3 is removed from the motor controller 2 to form an independent component, the X and Z dimensions of the motor controller 2 are reduced, which can reduce the overall area of ​​the motor controller 2 and achieve miniaturization and high volumetric power density of the motor controller 2. At the same time, by arranging the motor controller 2 parallel to the motor 1 in the horizontal direction and placing the filter component 3 in the empty gap area formed between the motor controller 2 and the motor 1, the Z-axis space occupation of the electric drive assembly can be reduced.

[0021] Considering that the vehicle's wheelbase is much smaller than the vehicle's X-axis dimension, arranging the motor controller 2 and the motor 1 parallel to each other along the vehicle's Y-axis might result in the length of the motor controller 2 exceeding the wheelbase limit. Therefore, in this embodiment, the motor controller 2 and the motor 1 are specifically arranged parallel to each other along the vehicle's length direction (i.e., the vehicle's X-axis). Since the existing motor controller's length along the vehicle's length direction is greater than the motor's length along the vehicle's X-axis, the overall size of the existing electric drive assembly along the vehicle's length direction is equal to the motor controller's X-axis length. However, removing the filter assembly 3 reduces the overall size of the motor controller 2. By changing the motor controller 2 from its current horizontal arrangement above the motor 1 to a longitudinal arrangement beside the motor 1, the X-axis dimension of the electric drive assembly does not increase. This allows the electric drive assembly to achieve high-voltage filtering, branching, passive load protection, and detachable maintenance functions without occupying more X-axis and Z-axis space.

[0022] Furthermore, in this embodiment, the bottom position of the motor 1 in the longitudinal direction of the vehicle is flush with the bottom position of the motor controller 2. This allows for more space above the motor 1 for the installation of the filter assembly 3.

[0023] Reference Figures 1-4 The filtering component 3 in this embodiment includes: Branch mounting bracket 31 for fixed connection with motor 1; The main circuit 32 is mounted on the branch mounting base 31 and electrically connects the battery pack DC bus connector 33 and the motor controller high voltage DC input copper bus 34. The first fuse 35 is mounted on the branch mounting base 31 and electrically connects the main circuit 32 and the high-voltage junction box connector 36. The second fuse 37 is mounted on the branch mounting base 31 and electrically connects the main circuit 32 and the high-voltage DC harness 38 of the power supply device. Y capacitor 39 is mounted on the branch mounting base 31, with one end electrically connected to the main circuit 32 and the other end grounded; A magnetic ring 310 is disposed on the branch mounting base 31; The magnetic ring 310 is arranged around the high voltage DC input copper busbar interface of the motor controller on the main circuit 32, and the Y capacitor 39 is arranged inside the magnetic ring 310.

[0024] The main circuit 32 is the core electrical connection part of the filter component 3. For example, the main circuit 32 is formed by copper busbars. By designing a reasonable circuit layout, the DC bus connector 33 of the battery pack is connected to the high voltage DC input copper busbar 34 of the motor controller. In this embodiment, for example, high-quality conductive materials (such as copper busbars) are used as the conductive part of the main circuit to ensure high efficiency and low resistance of current transmission.

[0025] In the main circuit 32, there are DC bus connector positive interface for connecting the positive terminal of the battery pack DC bus connector 33 and DC bus connector negative interface for connecting the negative terminal of the battery pack DC bus connector 33; there are also high voltage DC input copper bus positive interface for connecting the positive terminal of the motor controller high voltage DC input copper bus 34 and high voltage DC input copper bus negative interface for connecting the negative terminal of the motor controller high voltage DC input copper bus 34.

[0026] The first fuse 35 is used to monitor and protect the current of the branch where the high-voltage junction box connector 36 is located; the second fuse 37 is used to monitor and protect the current of the branch where the high-voltage DC harness 38 of the power supply device is located; the first fuse 35 and the second fuse 37 provide overload and short-circuit protection for their respective branches, preventing equipment damage and safety accidents caused by overload or short circuit.

[0027] In this embodiment, the first fuse 35 is connected to the high-voltage junction box connector 36 via a first connecting bus 311. The first connecting bus 311 has a positive terminal interface and a negative terminal interface for the high-voltage junction box connector 36, both for connection to the high-voltage junction box connector 36.

[0028] The selection of Y capacitor 39 should be optimized according to the system voltage level and filtering requirements to ensure that it can effectively suppress high-frequency noise and electromagnetic interference, thereby suppressing high-frequency noise and electromagnetic interference in the main circuit 32 and improving the electromagnetic compatibility of the electric drive assembly. The design of magnetic ring 310 can suppress high-frequency electromagnetic interference from the high-voltage DC input copper busbar 34 of the motor controller, improving the electromagnetic compatibility of the electric drive assembly.

[0029] By placing the Y capacitor 39 inside the magnetic ring 310, a compact filter structure is formed; this layout can effectively reduce the propagation path of high-frequency noise and electromagnetic interference, and improve the filtering effect.

[0030] Reference Figure 2 In this embodiment, the splitter mounting base 31 is provided with a first mounting groove 3101, and the magnetic core is encapsulated in the first mounting groove 3101 with potting compound to form the magnetic ring 310. The magnetic core in this embodiment is a nanocrystalline magnetic core. By encapsulating the magnetic core in the first mounting groove 3101 of the splitter mounting base 31 to form a magnetic ring, the internal space of the splitter mounting base 31 is effectively utilized, avoiding additional space occupation; and no extra magnetic ring protective shell is required, reducing weight.

[0031] Reference Figure 2 In this embodiment of the application, the branch mounting base 31 is provided with a second mounting groove 3102, and the Y capacitor 39 is bonded and fixed in the second mounting groove 3102.

[0032] In this embodiment, the Y capacitors 39 are a pair. One end of each Y capacitor 39 is connected to the positive and negative terminals of the main circuit 32 via a connecting bar, and the other end is grounded via the connecting bar.

[0033] The Y-capacitor 39 is fixed in the second mounting slot 3102 by adhesive bonding. Its main function is to suppress high-frequency noise and electromagnetic interference. One end of the Y-capacitor 39 is electrically connected to the main circuit 32 through a connector, and the other end is grounded through the connector, forming a high-frequency bypass path to guide high-frequency noise to ground, thereby reducing the impact of noise on other circuits. The integrated design of the Y-capacitor 39 and the branch mounting bracket 31 makes the structure of the entire filter module more compact.

[0034] In actual use, the high-voltage junction box connector 36, the battery pack DC bus connector 33, the motor controller high-voltage DC input copper busbar 34, and the power supply device high-voltage DC harness 38 are respectively fixed in the first mounting hole 3103 of the junction box mounting base 31 by bolts.

[0035] Reference Figure 2 and Figure 3 The branch mounting base 31 is provided with multiple second mounting holes 3104 for connecting to the motor housing. The branch mounting base 31 is fixedly connected to the motor housing by bolts or other means, realizing integration on the electric drive assembly.

[0036] In this embodiment, all connecting busbars and connecting busbars are supported by copper busbars. The copper busbars are bent and sized to meet the requirements through a stamping process, and are integrally injection molded with the branch mounting base 31.

[0037] By rationally arranging the copper busbar, magnetic core, Y capacitor 39, and fuse into a single CL architecture filtering component, and separately installing it in the "triangular cavity" at the top of the electric drive assembly, the circuit connection between the battery pack inlet and the "inverted" motor controller, as well as the high-voltage circuit filtering function, are achieved. In this configuration of the electric drive assembly, the filtering component of this invention has high-voltage filtering, branching, passive load protection, and the ability to be disassembled and repaired independently. The magnetic core is arranged at the port position of the motor controller, and a first mounting slot 3101 is reserved on the branch mounting base 31, reducing weight while achieving better filtering function. Two fuses are installed in the branches where the first and second connecting busbars are located, which can realize the passive protection function of the load and facilitate disassembly and repair.

[0038] In the electric drive assembly of this application embodiment, the filter component 3 is fixed on the motor housing; The battery pack DC bus connector 33, the motor controller high-voltage DC input copper busbar 34, the high-voltage junction box connector 36, and the power supply device high-voltage DC wiring harness 38 are all fixed on the junction mounting base. The battery pack DC bus connector 33 and the motor controller high voltage DC input copper bus 34 are electrically connected to the main circuit 32. The high-voltage junction box connector 36 is electrically connected to the first fuse 35 via the first connecting bar 311. The high-voltage DC harness 38 of the power supply device is electrically connected to the second fuse 37 via the second connector 312.

[0039] The low Z-axis height requirement of the electric drive assembly is achieved by reducing the Z-axis height difference between the mounting surface of the battery pack DC bus connector and the mounting surface of the high-voltage DC input copper busbar of the motor controller.

[0040] This application also provides a vehicle including the above-described electric drive assembly.

[0041] Among them, vehicles can be, but are not limited to, pure electric vehicles (PEV / BEV), hybrid electric vehicles (HEV), range-extended electric vehicles (REEV), plug-in hybrid electric vehicles (PHEV), new energy vehicles, and fuel vehicles.

[0042] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0043] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0044] It should also be noted that, in this document, the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are used for ease of description and simplification of the present invention, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, relational terms such as "first" and "second" are used to distinguish one entity or operation from another entity or operation, without necessarily requiring or implying any such actual relationship or order between these entities or operations, nor should they be construed as indicating or implying relative importance. Moreover, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements does not include those elements, but also includes other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes the element.

[0045] The technical solution provided by this utility model has been described in detail above. Specific examples have been used to illustrate the principle and implementation of this utility model. The descriptions of the above embodiments are only for the purpose of helping to understand this utility model, and the content of this specification should not be construed as a limitation of this utility model. Furthermore, for those skilled in the art, there will be different forms of changes in the specific implementation methods and application scope based on this utility model. It is neither necessary nor possible to exhaustively list all implementation methods here, and obvious changes or modifications derived therefrom are still within the protection scope of this utility model.

Claims

1. An electric drive assembly, characterized by include: Motor (1), motor controller (2) and filter assembly (3); The motor controller (2) is fixed on the motor (1), and the motor controller (2) and the motor (1) are arranged parallel to each other in the horizontal direction; The filter component (3) is disposed in the empty gap area formed between the motor controller (2) and the motor (1); The vertex position of the filter component (3) in the longitudinal direction of the vehicle is lower than the vertex position of the motor controller (2) or is flush with the vertex position of the motor controller (2).

2. The electric drive assembly of claim 1, wherein, The motor controller (2) and the motor (1) are arranged parallel to each other along the length of the vehicle. The bottom position of the motor (1) in the longitudinal direction of the vehicle is flush with the bottom position of the motor controller (2).

3. The electric drive assembly of claim 1, wherein, The filtering component includes: Branch mounting bracket (31) for fixed connection with the motor (1); The main circuit (32) is set on the branch mounting base (31) and electrically connects the battery pack DC bus connector (33) and the motor controller high voltage DC input copper bus (34); The first fuse (35) is disposed on the junction box (31) and electrically connects the main circuit (32) and the high voltage junction box connector (36); The second fuse (37) is installed on the branch mounting base (31) and electrically connects the main circuit (32) and the high voltage DC harness (38) of the power supply device. Y capacitor (39) is mounted on the branch mounting base (31), with one end electrically connected to the main circuit (32) and the other end grounded; A magnetic ring (310) is disposed on the branch mounting base (31); The magnetic ring (310) is arranged around the high voltage DC input copper busbar interface of the motor controller on the main circuit (32), and the Y capacitor (39) is arranged inside the magnetic ring (310).

4. The electric drive assembly of claim 3, wherein, One end of the first fuse (35) is connected to the main circuit (32), and the other end is electrically connected to the high-voltage junction box connector (36) through the first connecting bar (311); One end of the second fuse (37) is connected to the main circuit (32), and the other end is electrically connected to the high voltage DC harness (38) of the power supply device through the second connecting bar (312).

5. The electric drive assembly of claim 3, wherein, The branch mounting base (31) is provided with a first mounting groove (3101), and the magnetic core is encapsulated in the first mounting groove (3101) by potting glue to form the magnetic ring (310).

6. The electric drive assembly of claim 3, wherein, The branch mounting base (31) is provided with a second mounting groove (3102), and the Y capacitor (39) is bonded and fixed in the second mounting groove (3102).

7. The electric drive assembly of claim 3, wherein, The branch mounting base (31) is provided with a plurality of first mounting holes (3103), which are used to fix the high voltage junction box connector (36), the battery pack DC bus connector (33), the motor controller high voltage DC input copper busbar (34) and the power supply device high voltage DC harness (38) on the branch mounting base (31).

8. The electric drive assembly of claim 3, wherein, A plurality of second mounting holes (3104) are arranged on the branch mounting seat (31), and the branch mounting seat (31) is connected with the motor shell through bolts passing through the second mounting holes (3104).

9. The electric drive assembly of claim 3, wherein, The main circuit (32) is a copper bar.

10. A vehicle characterized by comprising: An electric drive assembly comprising the electric drive assembly of any one of claims 1-9.

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