Cover assembly, electric machine, electric drive system and vehicle

Abstract

The utility model relates to vehicle technical field discloses a cover assembly, electric drive system and vehicle. The cover assembly includes the rotation change cover plate, sensor, connector with sensor connection, wherein, sensor and connector nest are equipped in rotation change cover plate. The utility model adopts the depth integration scheme, has saved the wire harness and the buckle and the like spare parts, has reduced the mould quantity, has saved the mould cost, transportation cost, maintenance cost and part cost, has simplified the installation step, the operability in transportation, circulation and assembly etc. has been promoted, shortens the development period through modularization integration, and integrated circuit board can integrate multiple sensors, can select and match integrated multiple functions, improves the reliability, stability, security, driving comfort, intelligent level and work efficiency of electric drive system, improves the configuration flexibility and product competitiveness of vehicle.

Description

Technical Field

[0001] This utility model relates to the field of vehicle technology, and in particular to a cover plate assembly, a motor, an electric drive system, and a vehicle. Background Technology

[0002] In new energy vehicles, precise control of the electric motor is directly related to the vehicle's driving safety and stability. The electric drive system of a new energy vehicle mainly consists of the drive motor and the motor controller. The drive motor is one of the core components of a new energy vehicle, responsible for converting electrical energy into mechanical energy to drive the vehicle. The motor controller is the core control unit of an electric vehicle, responsible for managing and optimizing the operation of the drive motor. The motor controller needs to interact with various sensors (such as eddy current sensors and oil temperature sensors) to exchange information and transmit commands. The main functions of the motor controller include: collecting acceleration, deceleration, and braking signals; interpreting the driver's intentions and controlling the drive motor's operation; monitoring battery status to ensure safe operation; and controlling the forward and reverse rotation of the drive motor to protect it.

[0003] In existing electric drive systems, the cover plate used for sealing and protection, the circuit board used for connecting sensors, and the connectors are all independent components. The sensors and connectors need to be connected by a wiring harness, which needs to be secured with clips. There are many components, the integration is low, and the installation process is complicated. Utility Model Content

[0004] Based on the above problems, the purpose of this utility model is to provide a cover plate assembly, a motor, an electric drive system, and a vehicle, which reduces the number of parts, improves integration, and simplifies the installation steps.

[0005] To achieve the above objectives, the following technical solution is provided:

[0006] In a first aspect, the present invention provides a cover plate assembly, comprising: a resolver cover plate; a sensor; and a connector connected to the sensor; wherein the sensor and the connector are embedded in the resolver cover plate.

[0007] As an optional solution for the cover plate assembly provided by this utility model, the resolver cover plate is provided with an integrated circuit board, and the resolver cover plate is integrally formed with connectors.

[0008] As an optional solution for the cover plate assembly provided by this utility model, the connector and the rotary cover plate are integrally injection molded.

[0009] As an optional solution to the cover plate assembly provided by this utility model, the resolver cover plate is provided with a receiving groove, and the integrated circuit board is potted in the receiving groove with potting adhesive.

[0010] As an optional solution to the cover plate assembly provided by this utility model, the integrated circuit board is provided with a connecting part, which is electrically connected to the pins in the connector.

[0011] As an optional solution for the cover plate assembly provided by this utility model, the integrated circuit board is provided with a concentric part, the concentric part is located at the center of the resolver cover plate, the sensor is an eddy current sensor, and the coil of the eddy current sensor and the concentric part are concentric circles.

[0012] As an optional solution to the cover plate assembly provided by this utility model, the integrated circuit board is provided with an extension section, and the extension section is provided with a filter circuit.

[0013] As an optional solution for the cover plate assembly provided by this utility model, the integrated circuit board integrates an oil temperature sensor, the resolver cover plate is integrally formed with an oil channel, and the detection probe of the oil temperature sensor extends into the oil channel.

[0014] As an optional solution to the cover plate assembly provided by this utility model, the integrated circuit board integrates an oil detection sensor; and / or, the integrated circuit board integrates a motion parameter detection sensor.

[0015] Secondly, this utility model also provides a motor, including the cover plate assembly as described above.

[0016] Thirdly, this utility model also provides an electric drive system, including the cover plate assembly as described above or the motor as described above.

[0017] Fourthly, this utility model also provides a vehicle, including the cover assembly as described above, the motor as described above, or the electric drive system as described above.

[0018] The beneficial effects of this utility model are as follows:

[0019] The cover plate assembly, electric drive system, and vehicle provided by this utility model adopt a deeply integrated solution. Sensors and connectors are embedded in the resolver cover plate, and the connectors are connected to the sensors. This eliminates the need for wiring harnesses and clips, reduces the number of parts, and saves on mold costs, transportation costs, maintenance costs, and parts costs. It also improves the integration level, simplifies the installation steps, and enhances operability in transportation, circulation, and assembly. Modular integration shortens the development cycle, improves the reliability, stability, safety, driving comfort, intelligence level, and work efficiency of the electric drive system, and enhances the vehicle's configuration flexibility and product competitiveness. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments of this utility model will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of this utility model and these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the structure of the refractive cover plate in the cover plate assembly provided in a specific embodiment of this utility model;

[0022] Figure 2 This is a schematic diagram of the structure of the rotary cover plate and the integrated circuit board in the cover plate assembly provided in a specific embodiment of this utility model;

[0023] Figure 3 This is a half-sectional schematic diagram of the cover plate assembly provided in a specific embodiment of the present utility model;

[0024] Figure 4 This is a schematic diagram of the structure of the rotary cover plate and the integrated circuit board in the cover plate assembly provided by a specific embodiment of the present utility model. The integrated circuit board integrates an oil detection sensor and a motion parameter detection sensor.

[0025] In the picture:

[0026] 1. Resolver cover plate; 2. Integrated circuit board; 3. Connector; 4. Oil temperature sensor; 5. Oil detection sensor; 6. Motion parameter detection sensor; 11. Receiving groove; 12. Oil channel; 13. Connecting lug; 14. Sealing flange; 15. Reinforcing flange; 16. Oil passage housing; 121. Oil inlet; 122. First oil outlet; 123. Second oil outlet; 21. Connecting part; 22. Concentric part; 23. Extension part. Detailed Implementation

[0027] To make the technical problems solved by this utility model, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of this utility model will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0028] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Specifically, the terms "first position" and "second position" refer to two different positions.

[0029] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0030] like Figures 1 to 4 As shown, this embodiment provides a cover plate assembly, which includes a resolver cover plate 1, a sensor, and a connector 3. Both the sensor and the connector 3 are embedded in the resolver cover plate 1. This design eliminates the need for wiring harnesses and clips, reducing the number of components and saving on mold costs, transportation costs, maintenance costs, and parts costs. It also improves integration, simplifies installation steps, and enhances operability in transportation, distribution, and assembly.

[0031] In some embodiments, an integrated circuit board 2 is disposed on the resolver cover 1, the integrated circuit board 2 being located on the inner side of the resolver cover 1, and a connector 3 is integrally formed on the resolver cover 1, the connector 3 being located on the outer side of the resolver cover 1. The resolver cover 1 is typically used to seal a housing with an opening, the inner side of the resolver cover 1 being the side facing the inner cavity of the housing, and the outer side of the resolver cover 1 being the side facing away from the inner cavity of the housing. For example, when the resolver cover 1 is used to seal a motor housing, the inner side of the resolver cover 1 refers to the side facing the motor, and the outer side of the resolver cover 1 refers to the side facing away from the motor. The connector 3 may include a hollow sleeve and a limiting block disposed on the sleeve, the sleeve being used to pass through a wire harness connector, and the limiting block ensuring a stable connection between the connector 3 and the corresponding wire harness connector.

[0032] The cover assembly adopts a deeply integrated solution, with an integrated circuit board 2 set on the inner side of the resolver cover 1 and a connector 3 integrally formed on the outer side of the resolver cover 1. Modular integration shortens the development cycle. The integrated circuit board 2 can integrate multiple sensors and can be optionally equipped with multiple functions, improving the reliability, stability, safety, driving comfort, intelligence level and working efficiency of the electric drive system, and enhancing the vehicle's configuration flexibility and product competitiveness.

[0033] Optionally, connector 3 and the resolver cover 1 are integrally injection molded. The principle of integral injection molding is to heat and melt the plastic raw material in an injection molding machine, and then inject the molten plastic into a closed mold through the pushing force of a screw or plunger. After cooling and solidification, the desired product is formed. Integral injection molding can significantly shorten the development cycle and also allows for better quality control. From material selection to surface treatment, mold trials, and mold repair, everything can be carried out under unified quality standards, ensuring the overall quality of the mold.

[0034] In some embodiments, the integral molding of the connector 3 and the resolver cover 1 can also be achieved through riveting, adhesive bonding, mechanical locking, and ultrasonic welding, etc. Riveting involves inserting a rivet into the parts to be connected, utilizing the deformation of the rivet to achieve the connection. Riveting connections are strong and suitable for components subjected to impact and vibration. The riveting process does not require heating and has minimal impact on material properties, but it requires pre-drilling holes in the parts to be connected, increasing processing difficulty and cost. Adhesive bonding is a method of connecting two or more components together using adhesives. Adhesive bonding has advantages such as light weight, good sealing, and uniform stress distribution, and is suitable for connecting different materials, such as metal and plastic, glass and metal. However, the strength of adhesive bonding is affected by various factors such as adhesive properties and the cleanliness of the connecting surfaces, requiring strict control of adhesive bonding quality. Mechanical locking is a connection method that uses mechanical means to lock components, suitable for applications requiring rapid assembly and disassembly. Mechanical locking has a simple structure and is easy to operate, but the connection strength is relatively low. Ultrasonic welding uses high-frequency vibration to fuse two plastic components together. This method is suitable for heat-sensitive materials, provides high bonding strength and speed, but requires specialized equipment and skills.

[0035] Optionally, the resolver cover 1 is provided with a receiving groove 11, and the integrated circuit board 2 is encapsulated in the receiving groove 11 with potting compound. By providing the receiving groove 11, the integrated circuit board 2 is prevented from protruding significantly from the resolver cover 1, reducing the installation space requirements. The integrated circuit adopts an overall potting process, which improves the reliability of the circuit system. The potting process is relatively simple, the operation time is flexible, and it can be cured at room temperature or under heating conditions. The heat released during the curing process is small, and the shrinkage is small. The potting compound can be epoxy resin potting compound. Epoxy resin potting compound has excellent performance and is suitable for long-term use. Epoxy resin potting compound has low viscosity and strong penetration, which can penetrate into deeper gaps to ensure good filling effect. Epoxy resin potting compound has good high temperature resistance and electrical insulation ability, and can maintain stable performance in high temperature environments. Its cured surface is smooth, has good gloss, and has good electrical and physical properties.

[0036] In some embodiments, the integrated circuit board 2 can also be connected to the resolver cover plate 1 by other connection methods. For example, the integrated circuit board 2 and the resolver cover plate 1 can be connected by bolts, or the integrated circuit board 2 and the resolver cover plate 1 can be connected by welding, plugging, or other methods.

[0037] To facilitate the connection between the resolver cover 1 and the motor housing, the outer periphery of the resolver cover 1 can be integrally formed with connecting lugs 13. Bolts are inserted through the lug holes of the connecting lugs 13 and then fixedly connected to the motor housing. To ensure the sealing between the resolver cover 1 and the motor housing, the resolver cover 1 can be integrally formed with a sealing flange 14. The slotted design of the receiving groove 11 results in insufficient overall structural strength of the resolver cover 1. Therefore, a reinforcing flange 15 can be integrally formed on the resolver cover 1, and the reinforcing flange 15 can surround the outer periphery of the receiving groove 11.

[0038] In some embodiments, the integrated circuit board 2 is provided with a connecting part 21, which is electrically connected to the pins in the connector 3. This simplifies the connection method between the integrated circuit board 2 and the connector 3, eliminates the need for wire harnesses and clips, and reduces the number of components. The connecting part 21 and the pins of the connector 3 can be directly connected by plugging in, or they can be connected by a shorter busbar of wires.

[0039] To facilitate the detection of the relative position between the motor rotor and stator, the integrated circuit board 2 may optionally include a concentric section 22 located at the center of the resolver cover plate 1. An eddy current sensor is embedded in the resolver cover plate 1, with its coil concentric with the concentric section 22. The eddy current sensor utilizes the principle of electromagnetic induction to transmit and receive induced AC signals using corresponding coils at the transmitting and receiving ends, thereby calculating the position of the target wheel. The target wheel is fixed on the shaft and rotates with the rotor; by detecting the position of the target wheel, the relative position between the motor rotor and stator can be measured. When the eddy current sensor is powered on, the sensor's transmitting coil generates an excitation magnetic field. The target plate rotates with the motor, cutting the excitation magnetic field, thus generating a coil voltage in the receiving coil. The sensor module demodulates and processes the coil voltage to obtain the voltage signal at the corresponding position.

[0040] In some embodiments, the integrated circuit board 2 is provided with an extension section 23, which includes a filter circuit. The filter circuit filters electromagnetic signals from the motor system cavity, reducing interference signals transmitted from the motor system cavity to the motor controller cavity and enhancing electromagnetic interference resistance. The filter circuit can be an oil temperature sensor filter circuit or a stator temperature sensor filter circuit. The filter circuit typically includes components such as capacitors and resistors; through the combination of these components, high-frequency noise and interference signals can be effectively filtered out. For example, capacitors can smooth voltage signals, reducing spikes and glitches. Resistors can limit the rate of change of current, further stabilizing the signal. The filter circuit can reduce signal fluctuations caused by environmental interference (such as electromagnetic interference, mechanical vibration, etc.), thereby improving signal stability and accuracy. The connection section 21 is used for connection with the pins of the connector 3, the concentric section 22 is circular for easy installation and positioning, the extension section 23 is used for expanding functionality, and the entire integrated circuit board 2 is clearly divided into sections, making it easy to manufacture.

[0041] Optionally, the integrated circuit board 2 integrates an oil temperature sensor 4, and the resolver cover plate 1 is integrally formed with an oil channel 12. The detection probe of the oil temperature sensor 4 extends into the oil channel 12 to detect the temperature of the oil within the oil channel 12. When the cross-section of the oil channel 12 is large, the resolver cover plate 1 can be provided with a raised oil passage housing 16, the inner cavity of which forms the oil channel 12. When the cross-section of the oil channel 12 is small, the oil channel 12 can also be directly formed in the resolver cover plate 1. The thermistor material of the oil temperature sensor 4 can be an NTC thermistor, which is a resistor with a negative temperature coefficient. Its resistance decreases as the temperature increases and vice versa. This characteristic allows the NTC thermistor to sense temperature changes and convert them into changes in resistance.

[0042] Optionally, the oil channel 12 is provided with an oil inlet 121, a first oil outlet 122, and a second oil outlet 123. The first oil outlet 122 is connected to the oil passage of the motor rotor and is located between the oil inlet 121 and the second oil outlet 123. Oil enters the oil channel 12 through the oil inlet 121. The oil temperature sensor 4 is used to detect the oil temperature near the oil inlet 121. Part of the oil enters the oil passage of the motor rotor through the first oil outlet 122, and the other part enters the second oil outlet 123. Based on the stator water cooling scheme, a rotor cooling oil path is added. The cooling oil flows from the front cover into the housing, forms a ring-shaped oil path in the stator core, collects from the rear cover into the rotor, and reaches the outlet of the front cover from the rotor.

[0043] In some embodiments, the integrated circuit board 2 integrates an oil detection sensor 5; and / or, the integrated circuit board 2 integrates a motion parameter detection sensor 6. The oil detection sensor 5, which detects oil-related parameters, includes, but is not limited to, pressure sensors, temperature sensors, flow sensors, density sensors, and contamination sensors. The motion parameter detection sensor 6, which detects motion-related parameters of the electric drive system, includes, but is not limited to, accelerometers, gyroscopes, and vibration sensors. The pressure sensor monitors the oil pressure in the electric drive system's oil passages to ensure the system operates within specified ranges. The temperature sensor measures the oil temperature to further estimate the temperature of the motor system and components, preventing system overheating and optimizing performance to improve system efficiency. The flow sensor monitors the oil flow rate entering the target section, such as critical components like bearings and motor rotors, to ensure normal and effective oil supply. The density sensor or contamination sensor detects the particulate matter content in the oil to prevent wear or insulation-related faults in the electric drive system. The accelerometer measures the acceleration and tilt angle of the entire vehicle or electric drive system. The gyroscope measures angular velocity and directional changes. The vibration sensor detects the vibration state of the electric drive system and predicts the health status of mechanical components such as motors and shafts.

[0044] This embodiment also provides a motor, including the cover plate assembly as described above. By using the cover plate assembly, components such as wiring harnesses and clips are eliminated, reducing the number of molds, saving mold costs, transportation costs, maintenance costs and parts costs, simplifying the installation steps, and improving operability in transportation, circulation and assembly.

[0045] This embodiment also provides an electric drive system, including the cover plate assembly as described above or the motor as described above. A deep integration scheme is adopted, with an integrated circuit board 2 disposed on the inner side of the resolver cover plate 1, and a connector 3 integrally formed on the outer side of the resolver cover plate 1. The connector can directly connect to the sensors on the integrated circuit board 2, eliminating the need for wiring harnesses and clips, reducing the number of parts, saving mold costs, transportation costs, maintenance costs, and component costs, improving integration, simplifying installation steps, and enhancing operability in transportation, distribution, and assembly. Modular integration shortens the development cycle. The integrated circuit board 2 can integrate multiple sensors and optionally integrate multiple functions, improving the reliability, stability, safety, driving comfort, intelligence level, and working efficiency of the electric drive system, and enhancing the vehicle's configuration flexibility and product competitiveness.

[0046] This embodiment also provides a vehicle, which includes the above-mentioned cover plate assembly, the above-mentioned motor or the above-mentioned electric drive system. It adopts a deep integration scheme, with an integrated circuit board 2 set on the inner side of the resolver cover plate 1 and a connector 3 integrally formed on the outer side of the resolver cover plate 1. The connector 3 can be directly connected to the sensors on the integrated circuit board 2, eliminating the need for wiring harnesses and clips, reducing the number of parts, saving mold costs, transportation costs, maintenance costs and parts costs, improving integration, simplifying installation steps, and improving operability in transportation, circulation and assembly. Modular integration shortens the development cycle. The integrated circuit board 2 can integrate multiple sensors and can be optionally equipped with multiple functions, improving the reliability, stability, safety, driving comfort, intelligence level and working efficiency of the electric drive system, and improving the vehicle's configuration flexibility and product competitiveness.

[0047] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments. Many other equivalent embodiments may be included without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A cover plate assembly, characterized in that, include: Resolver cover plate (1); sensor; Connector (3) is connected to the sensor; The sensor and the connector (3) are embedded in the resolver cover plate (1).

2. The cover plate assembly according to claim 1, characterized in that, An integrated circuit board (2) is provided on the resolver cover plate (1), and a connector (3) is integrally formed on the resolver cover plate (1).

3. The cover plate assembly according to claim 2, characterized in that, The connector (3) and the rotary cover plate (1) are integrally injection molded.

4. The cover plate assembly according to claim 2, characterized in that, The resolver cover plate (1) is provided with a receiving groove (11), and the integrated circuit board (2) is potted in the receiving groove (11) with potting adhesive.

5. The cover plate assembly according to claim 2, characterized in that, The integrated circuit board (2) is provided with a connecting part (21), which is electrically connected to the pins in the connector (3).

6. The cover plate assembly according to claim 2, characterized in that, The integrated circuit board (2) is provided with a concentric part (22), which is located at the center of the resolver cover plate (1). The sensor is an eddy current sensor, and the coil of the eddy current sensor is concentric with the concentric part (22).

7. The cover plate assembly according to claim 2, characterized in that, The integrated circuit board (2) is provided with an expansion section (23), and the expansion section (23) is provided with a filter circuit.

8. The cover plate assembly according to any one of claims 2-7, characterized in that, The integrated circuit board (2) integrates an oil temperature sensor (4), and the rotary cover plate (1) is integrally formed with an oil channel (12). The detection probe of the oil temperature sensor (4) extends into the oil channel (12).

9. The cover plate assembly according to any one of claims 2-7, characterized in that, The integrated circuit board (2) integrates an oil detection sensor (5); and / or, the integrated circuit board (2) integrates a motion parameter detection sensor (6).

10. An electric motor, characterized in that, Includes the cover plate assembly as described in any one of claims 1-9.

11. An electric drive system, characterized in that, Includes the cover assembly as described in any one of claims 1-9 or the motor as described in claim 10.

12. A vehicle, characterized in that, Includes the cover assembly as described in any one of claims 1-9, the motor as described in claim 10, or the electric drive system as described in claim 11.

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