Integrated electric drive system and electric vehicle

Abstract

To provide an integrated electric drive system and an electric vehicle.SOLUTION: An integrated electric drive system includes: a motor (1); a speed reducer (2); a controller (3); and a single-piece enclosure (4). A first enclosure space is formed on the single-piece enclosure (4), and a second enclosure space and a third enclosure space configured for the speed reducer (2) to be mounted are arranged on the single-piece enclosure (4). The controller (3) is connected with the motor (1). The output shaft of the motor (1) is connected with the speed reducer (2). An absolute value of a difference between a preset mounting width value and the width value of the first enclosure space is less than or equal to a first difference threshold. The absolute value of the difference between the length value of the first enclosure space and the length value of the third enclosure space is less than or equal to a second difference threshold.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present application relates to the technical field of electric vehicles, and more particularly to integrated electric drive systems and electric vehicles. [Background technology]

[0002] The electric drive system is a core component of electric vehicles. With the continuous development of new energy vehicles, the requirements for the layout of vehicle drive systems are becoming increasingly stringent. An electric drive system combines components such as a drive motor, a motor controller, a transmission, an air compressor, a water pump, a vehicle overall controller, an on-board charger, and a DC converter. In conventional technologies, the integrated control housing of an electric drive system is typically mounted on top of the stator housing of the drive motor, the transmission is mounted on the end of the drive motor's output shaft, and the air compressor is attached to the transmission by a support frame. However, such an integrated electric drive system has drawbacks, such as a heavy overall weight, low integration, a large housing space, and high mold and material costs. Summary of the Invention [Problem to be solved by the invention]

[0003] The present application solves the technical problems of electric drive systems in the prior art, such as low integration and large housing space, and provides an integrated electric drive system and electric vehicle. [Means for solving the problem]

[0004] In view of the above problems, an integrated electric drive system according to an embodiment of the present application includes a motor, a reducer, a controller, and an integrated housing, the integrated housing having a first opening and a recessed first housing space for mounting the controller, a second housing space for mounting the motor and a third housing space for mounting the reducer provided in a direction away from the first opening of the integrated housing, the controller is connected to the motor, and an output shaft of the motor is connected to the reducer, an absolute value of a difference between a preset mounting width value and a width value of a first housing space in a direction parallel to an output shaft of the motor is equal to or less than a first difference threshold, and the preset mounting width value is a sum of the width value of the second housing space and the width value of the third housing space; In a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane, the absolute value of the difference between the length value of the first housing space and the length value of the third housing space is less than or equal to a second difference threshold value.

[0005] In some examples of the present application, in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane, the absolute value of the difference between half the length value of the first housing space and the length value of the second housing space is less than or equal to a third difference threshold.

[0006] In some examples herein, the first difference threshold is zero.

[0007] In some examples herein, the second difference threshold is zero.

[0008] In some examples herein, the third difference threshold is zero.

[0009] In some examples of the present application, the integrated electric drive system further includes a support frame attached to an end face of the air conditioner compressor and the reducer remote from the second housing space, and the air conditioner compressor is attached to the support frame and connected to the controller.

[0010] In some examples herein, the integrated electric drive system further includes a water pump mounted to the support frame and connected to the controller.

[0011] In some examples of the present application, the support frame includes a vertical plate and a horizontal plate connected to the upper end of the vertical plate, the vertical plate is attached to the end face of the reducer farther from the motor, the water pump is attached above the horizontal plate, and the air conditioner compressor is attached to one side of the vertical plate farther from the reducer and located below the horizontal plate.

[0012] In some examples of the present application, the controller includes a capacitor module, an IGBT module, a three-phase copper bar, a DC bus bar, an on-board charger, and a DC converter, the on-board charger and the DC converter are all connected to a vehicle power battery, the capacitor module, the IGBT module, the three-phase copper bar, the on-board charger, and the DC converter are all mounted within the first housing space, the capacitor module is connected to the vehicle power battery via the DC bus bar mounted on the integrated housing, and the three-phase copper bar is connected to three-phase terminals of the motor, The automobile power battery drives the rotation of the motor through the DC bus bar, the capacitor module, the IGBT module and the three-phase copper bar connected in sequence.

[0013] In some examples of the present application, the on-board charger and DC converter include a heat dissipation module, an electronic control element driving module, and a heat-generating element driving module, the heat-generating element driving module being attached to the heat dissipation module, and the electronic control element driving module being attached to one end of the heat-generating element driving module far from the heat dissipation module.

[0014] In some examples of the present application, the first housing space includes a first internal space and a second internal space that are both rectangular and adjacent to each other; The capacitor module, IGBT module, and three-phase copper bar are all installed in the first internal space, the on-board charger and DC converter are installed in the second internal space, and the DC bus bar is located on one side of the first internal space away from the second internal space.

[0015] In some examples of the present application, the integrated housing includes a first cooling water passage, a second cooling water passage, a water passage inlet, and a water passage outlet, the first cooling water passage being provided at a position facing the IGBT module within the integrated housing, and the second cooling water passage being provided at a position facing the on-board charger and the DC converter within the integrated housing; A preset water supply device is connected to one end of the water channel inlet, the first cooling water channel and the second cooling water channel are connected to the other end of the water channel inlet, and the water channel outlet is connected to one end of the first cooling water channel and the second cooling water channel that is far from the water channel inlet.

[0016] In some examples of the present application, the motor includes an external housing connected to the reducer and an internal housing inserted into the external housing, a cooling space is formed between the inner wall of the external housing and the outer wall of the internal housing, the external housing is provided with a water inlet and a water outlet both of which communicate with the cooling space, and one end of the water channel outlet remote from the first cooling water channel communicates with the water inlet.

[0017] In some examples herein, an outer wall of the inner housing is provided with a plurality of guide rib plates arranged circumferentially along the output shaft of the motor.

[0018] In some examples of the present application, the reducer includes a main shaft, an intermediate shaft, an output shaft, a drive gear, an output gear, an intermediate drive gear, and an intermediate driven gear, the main shaft is connected to the output shaft of the motor, the drive gear is attached to the main shaft, the intermediate drive gear and the intermediate driven gear are both attached to the intermediate shaft, the output gear is attached to the output shaft, the intermediate drive gear meshes with the drive gear, and the intermediate driven gear meshes with the output gear, The axis of the intermediate shaft is higher than the axes of the main shaft and the output shaft, and in a plane perpendicular to the axis of the main shaft, the angle between a line connecting the center point of the main shaft and the center point of the output shaft and a horizontal plane is equal to or smaller than a predetermined angle.

[0019] In some examples of the present application, a battery mounting space for mounting a battery is provided on an end surface of the integrated housing that is away from the first opening.

[0020] In some examples herein, the integrated electric drive system further comprises a housing cover that fits into the opening.

[0021] In the present application, the integrated electric drive system is configured such that the controller, the motor, and the reducer are integrated, the controller is mounted in a first housing space within the integrated housing, and the motor and the reducer are mounted in a second housing space and a third housing space below the integrated housing, respectively, and the absolute value of the difference between the sum of the width value of the second housing space and the width value of the third housing space and the width value of the first housing space is less than or equal to a first difference threshold, and the absolute value of the difference between the length value of the first housing space and the length value of the third housing space in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane is less than or equal to a second difference threshold. With the above layout, the integrated electric drive system has a relatively balanced installation space in all directions, and does not leave a large amount of suspension space in any direction, thereby improving the modality of the integrated housing and improving the vehicle's NVH (Noise, Vibration, Harshness). Furthermore, the integrated electric drive system is highly integrated, reducing the installation space required in the vehicle, thereby providing space for an increased motor. The highly integrated integrated electric drive system also eliminates the need for complex harness connections between components.

[0022] An embodiment of the present application further provides an electric vehicle including the integrated electric drive system described above.

[0023] Additional aspects and advantages of the present application will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the present application. [Brief explanation of the drawings]

[0024] [Figure 1] 1 is an exploded structural schematic diagram of an integrated electric drive system according to an embodiment of the present application; [Figure 2] 1 is a schematic assembly diagram of an integrated electric drive system according to an embodiment of the present application; [Figure 3] 1 is a schematic diagram illustrating the layout of a first housing space, a second housing space, and a third housing space of an integrated electric drive system according to an embodiment of the present application. [Figure 4] 1 is a structural schematic diagram of an integrated electric drive system according to an embodiment of the present application; [Figure 5] 1 is a structural schematic diagram of a controller of an integrated electric drive system according to an embodiment of the present application; [Figure 6] 1 is a structural schematic diagram of an on-board charger and a DC converter of an integrated electric drive system according to an embodiment of the present application; [Figure 7] FIG. 2 is a schematic diagram of a first cooling water passage and a second cooling water passage of an integrated electric drive system according to one embodiment of the present application. [Figure 8] 1 is a structural schematic diagram of a reducer of an integrated electric drive system according to an embodiment of the present application; DETAILED DESCRIPTION OF THE INVENTION

[0025] In order to make the technical problems, technical means and advantageous effects that the present application aims to solve clearer, the present application will be described in more detail below with reference to the drawings and examples. It should be understood that the specific examples described herein are only used to interpret the present application, and are not intended to limit the present application.

[0026] Furthermore, terms indicating directions and positional relationships, such as "upper," "lower," "left," "right," "front," "rear," and "middle," are based on the directions or positional relationships shown in the drawings and are merely used to facilitate and simplify the description of this application. They do not indicate or imply that the device or element being referred to must have a specific direction, configuration, or operation in a specific direction, and cannot be considered to limit this application.

[0027] In order to better illustrate the structure of the integrated electric drive system and its connection relationships, the term "upper" used herein refers to the direction actually facing the roof (i.e., above the integrated electric drive system shown in FIG. 2), the term "lower" used herein refers to the direction actually facing the bottom of the vehicle (i.e., below the integrated electric drive system shown in FIG. 2), the term "left" used herein refers to the left side of the integrated electric drive system shown in FIG. 2, and the term "right" used herein refers to the right side of the integrated electric drive system shown in FIG. 2.

[0028] As shown in FIGS. 1 to 4 , an integrated electric drive system according to one embodiment of the present application includes a motor 1, a reducer 2, a controller 3, and an integrated housing 4. The integrated housing 4 has a first opening and a recessed first housing space 41 for mounting the controller 3. A second housing space 42 for mounting the motor 1 and a third housing space 43 for mounting the reducer 2 are provided in the integrated housing 4 in a direction away from the first opening. The controller 3 is connected to the motor 1, and the output shaft 23 of the motor 1 is connected to the reducer 2. As can be seen, the first housing space 41 is located within the integrated housing 4, and the second housing space 42 and the third housing space 43 are located on the left and right sides below the integrated housing 4, respectively. The controller 3 includes a motor controller, an automobile power battery controller, an automobile power battery charging / discharging device, etc.

[0029] As shown in FIGS. 3 and 4, in a direction parallel to the output shaft 23 of the motor 1, the absolute value of the difference between the preset mounting width value and the width value of the first housing space 41 is equal to or less than a first difference threshold, and the preset mounting width value is the sum of the width value of the second housing space 42 and the width value of the third housing space 43. In some embodiments of the present application, The preset mounting width value and the width value of the first housing space 41 are the same.That is, the width value of the first housing space 41 is the sum of the width value of the second housing space 42 and the width value of the third housing space 43, that is, in the width direction of the integrated housing 4 (i.e., in the direction parallel to the output shaft 23 of the motor 1), the motor 1 and the reducer 2 are spaced below the integrated housing 4. As can be understood, the first difference threshold value can be set according to actual needs, for example, the value range of the first difference threshold value is 0 to 10 mm (e.g., 3 mm, 6 mm, 9 mm, etc.).

[0030] In a direction perpendicular to the output shaft 23 of the motor 1 and parallel to a horizontal plane, the absolute value of the difference between the length value of the first housing space 41 and the length value of the third housing space 43 is equal to or less than a second difference threshold value. The length value of the first housing space 41 and the length value of the third housing space 43 are the same. That is, the length value of the first housing space 41 is equal to the length value of the third housing space 43, that is, in the long side direction of the integrated housing 4, the reducer 2 closes one side of the lower part of the integrated housing 4. As can be understood, the second difference threshold value can be set according to actual needs, for example, the value range of the second difference threshold value may be 0 to 10 mm (e.g., 3 mm, 6 mm, 9 mm, etc.).

[0031] In the present application, the integrated electric drive system integrates the controller 3, the motor 1, and the reducer 2, the controller 3 is mounted in a first housing space 41 within the integrated housing 4, the motor 1 and the reducer 2 are mounted in a second housing space 42 and a third housing space 43 below the integrated housing 4, respectively, and the absolute value of the difference between the sum of the width value of the second housing space 42 and the width value of the third housing space 43 and the width value of the first housing space 41 is less than or equal to a first difference threshold, and the absolute value of the difference between the length value of the first housing space 41 and the length value of the third housing space 43 in a direction perpendicular to the output shaft 23 of the motor 1 and parallel to the horizontal plane is less than or equal to a second difference threshold. With the above arrangement, the integrated electric drive system has a relatively balanced installation space in all directions, and does not leave a large amount of suspension space in any direction, thereby improving the modality of the integrated housing 4 and improving the vehicle's NVH (Noise, Vibration, Harshness). Furthermore, the integrated electric drive system is highly integrated, reducing the installation space in the vehicle, thereby providing space for an increased motor 1. The highly integrated integrated electric drive system also eliminates the need for complex harness connections between the various components.

[0032] In one embodiment, as shown in Figure 2, in a direction perpendicular to the output shaft 23 of the motor 1 and parallel to a horizontal plane, the absolute value of the difference between half the length value of the first housing space 41 and the length value of the second housing space 42 is equal to or less than a third difference threshold value. Half the length of the first housing space 41 and the length of the second housing space 42 are the same.That is, in the longitudinal direction of the integrated housing 4, the mounting length of the motor 1 occupies half the length of the integrated housing 4, and the length of the second housing space 42 occupies only half the length of the first housing space 41, because these are designed according to the shape of the motor 1. It can be understood that the third difference threshold can be set according to actual needs, for example, the value range of the third difference threshold is 0 to 10 mm (e.g., 3 mm, 6 mm, 9 mm, etc.). The layout manner of the second housing space 42 further increases the integration degree of the integrated electric drive system and further improves the NVH of the automobile.

[0033] 1 and 2, the integrated electric drive system further includes an air conditioner compressor 8 and a support frame 5 attached to the end face of the reducer 2 far from the second housing space 42, and the air conditioner compressor 8 is attached to the support frame 5 and connected to the controller 3. In some embodiments of the present application, the support frame 5 and the housing of the reducer 2 are an integrally molded structure, and as can be understood, the support frame 5 and the air conditioner compressor 8 are located on the side of the integrated housing 4, and the support frame 5 allows the air conditioner compressor 8 to be integrated into the integrated electric drive system, further improving the integration degree of the integrated electric drive system.

[0034] 1 and 2, the integrated electric drive system further includes a water pump 6 mounted on the support frame 5 and connected to the controller 3. As can be seen, the water pump 6 can provide a water source for the windshield wipers of a vehicle, and the design of the water pump 6 further improves the integration degree of the integrated electric drive system.

[0035] 1 and 2, the support frame 5 includes a vertical plate and a horizontal plate connected to the upper end of the vertical plate, the vertical plate being attached to the end face of the reducer 2 farther from the motor 1, the water pump 6 being attached to the upper side of the horizontal plate, and the air conditioner compressor 8 being attached to the side of the vertical plate farther from the reducer 2 and located below the horizontal plate. As can be seen, locating the water pump 6 above the support frame 5 helps to reduce the length of the connection pipeline between the water pump 6 and the automobile windshield wipers, and mounting the air conditioner compressor 8 below the support frame 5 ensures sufficient space for connecting the air conditioner compressor 8 to other components of the automobile air conditioner. Furthermore, the support frame 5 allows the water pump 6 and the air conditioner compressor 8 to be integrated into the integrated electric drive system, thereby improving the integration degree of the integrated electric drive system.

[0036] In one embodiment, as shown in FIG. 5, the controller 3 includes a capacitor module 31, an IGBT (Insulated Gate Bipolar Transistor), The vehicle battery 1 includes an IGBT (insulated gate bipolar transistor) module 32, a three-phase copper bar 33, a DC bus bar 34, an on-board charger, and a DC converter 35, with the on-board charger and DC converter 35 connected to the vehicle power battery. The capacitor module 31, the IGBT module 32, the three-phase copper bar 33, the on-board charger, and the DC converter 35 are all installed in the first housing space 41, with the capacitor module 31 connected to the vehicle power battery by the DC bus bar 34 installed in the integrated housing 4, and the three-phase copper bar 33 connected to the three-phase terminals of the motor 1. It can be understood that the on-board charger and DC converter 35 is a device integrating an on-board charger and a DC converter, where the on-board charger has the ability to safely and automatically fully charge the vehicle power battery, the on-board charger dynamically adjusts the charging current and charging voltage, and performs corresponding operations to complete the charging process of the vehicle power battery, and the DC converter can convert the high voltage of the vehicle power battery to the low voltage required for the storage battery of the vehicle. The design of the on-board charger and DC converter 35 further improves the integration of the controller 33 .

[0037] The automobile power battery drives the rotation of the motor 1 through the sequentially connected DC bus bar 34, the capacitor module 31, the IGBT module 32, and the three-phase copper bar 33. As can be seen, the automobile power battery drives the rotation of the motor 1 through the above path, and the motor 1 couples the rotation of the automobile wheels through the reducer 2, and further, the automobile power battery achieves the technical effect of driving the rotation of the automobile wheels.

[0038] In one embodiment, as shown in FIG. 6 , the on-board charger and DC converter 35 comprises a heat dissipation module 351, an electronic control element driving module 352 and a heat-generating element driving module 353, the heat-generating element driving module 353 is attached to the heat dissipation module 351, and the electronic control element driving module 352 is attached to one end of the heat-generating element driving module 353 far from the heat dissipation module 351. As can be seen, the heat dissipation module 351 integrates heat dissipation components such as a straight cold plate, the electronic control element driving module 352 mainly integrates electronic control elements of the on-board charger and DC converter 35 (for example, the electronic control element driving module 352 integrates electronic control elements with low heat generation such as an overall vehicle controller, a controller for the air conditioner compressor 8, a controller for the water pump 6, and a controller for the automobile power battery), and the heat-generating element driving module 353 mainly integrates heat-generating elements of the on-board charger and DC converter 35 (for example, the heat-generating element driving module 353 integrates heat-generating elements with high heat generation such as an overall vehicle controller, a controller for the air conditioner compressor 8, a controller for the water pump 6, and a controller for the automobile power battery). That is, the on-board charger and DC converter 35 is divided into three layers, the middle layer is the heat-generating element driving module 353, the lower layer is the electronic control element driving module 352, and the upper layer is the heat dissipation module 351. The heat dissipation module 351 is in contact with the cooling water channel inside the integrated housing 4, so the on-board charger and DC converter 35 is designed in layers, which improves the heat dissipation efficiency of the on-board charger and DC converter 35.

[0039] In one embodiment, as shown in FIG. 5, the first housing space 41 is rectangular and includes adjacent first and second internal spaces, and it can be seen that the first and second internal spaces are located on the left and right sides of the integrated housing 4, respectively.

[0040] The capacitor module 31, the IGBT module 32, and the three-phase copper bars 33 are installed in the first internal space, the on-board charger and DC converter 35 is installed in the second internal space, and the DC bus bar 34 is located on one side of the first internal space away from the second internal space. In some embodiments of the present application, the capacitor module 31, the IGBT module 32, and the three-phase copper bars 33 are sequentially arranged in the first internal space. As can be seen, the capacitor module 31, the IGBT module 32, the three-phase copper bars 33, and the on-board charger and DC converter 35 are neatly installed in the first housing space 41, thereby eliminating complex harness connections between each component in the controller 3, improving the compactness and reliability of the integrated electric drive system, and improving the modality of the controller 3.

[0041] 7 , the integrated housing 4 includes a first cooling water channel 44, a second cooling water channel 45, a water channel inlet, and a water channel outlet 47. The first cooling water channel 44 is located opposite the IGBT module 32 within the integrated housing 4, and the second cooling water channel 45 is located opposite the on-board charger and DC converter 35 within the integrated housing 4. As can be seen, the first cooling water channel 44 is primarily used to absorb heat from the IGBT module 32, and the second cooling water channel 45 is primarily used to absorb heat from the on-board charger and DC converter 35. Specifically, a plurality of protrusions are provided on a lower portion of the heat dissipation module 351 of the on-board charger and DC converter 35, and the protrusions are located opposite the second cooling water channel 45. The protrusions increase the contact area between the heat dissipation module 351 and the second cooling water channel 45, thereby improving the heat dissipation efficiency of the heat dissipation module 351.

[0042] One end of the water channel inlet is connected to a predetermined water supply device, the other end of the water channel inlet is connected to the first cooling water channel 44 and the second cooling water channel 45, and the water channel outlet 47 is connected to one end of the first cooling water channel 44 and the second cooling water channel 45 that is far from the water channel inlet. As can be seen, the first cooling water channel 44 and the second cooling water channel 45 are connected in parallel between the water channel inlet 46 and the water channel outlet 47. In the present application, the design of the first cooling water channel 44 and the second cooling water channel 45 improves the heat dissipation efficiency of the controller 3 and further extends the service life of the integrated electric drive system.

[0043] 1 and 2, the motor 1 includes an outer housing 11 connected to the reducer 2 and an inner housing 12 inserted into the outer housing 11, a cooling space is formed between the inner wall of the outer housing 11 and the outer wall of the inner housing 12, the outer housing 11 is provided with a water inlet and a water outlet 111 both connected to the cooling space, and one end of the water channel outlet 47 remote from the first cooling water channel 44 communicates with the water inlet. As can be seen, the design of the cooling space can improve the heat dissipation efficiency of the motor 1 and extend the service life of the motor 1.

[0044] Specifically, the coolant flowing in from the water supply port is divided into two paths, one path absorbing heat from the IGBT module 32 through the first cooling water channel 44, and the other path absorbing heat from the on-board charger and DC converter 35 through the second cooling water channel 45. The coolant from the two paths join at the water channel outlet 47 and then flows into the cooling space from the water supply port. After absorbing heat from the motor 1 in the cooling space, the coolant flows out from the water outlet 111. In the present application, the coolant can lower the temperatures of the IGBT module 32, the on-board charger and DC converter 35, and the motor 1, improving the utilization rate of the coolant.

[0045] 1 and 2, a plurality of guide rib plates are provided on the outer wall of the inner housing 12, which are arranged along the circumferential direction of the output shaft 23 of the motor 1. As can be seen, the guide rib plates allow the coolant in the cooling space to flow in the circumferential direction of the inner housing 12, thereby improving the cooling efficiency of the motor 1.

[0046] 8, the reducer 2 includes a main shaft 21, an intermediate shaft 22, an output shaft 23, a drive gear 24, an output gear 25, an intermediate drive gear 26, and an intermediate driven gear 27, the main shaft 21 is connected to the output shaft of the motor 1, the drive gear 24 is attached to the main shaft 21, the intermediate drive gear 26 and the intermediate driven gear 27 are both attached to the intermediate shaft 22, the output gear 25 is attached to the output shaft 23, the intermediate drive gear 26 meshes with the drive gear 24, and the intermediate driven gear 27 meshes with the output gear 25. As can be seen, the output shaft 23 of the motor 1 passes through the main shaft 21, the drive gear 24, the intermediate drive gear 26, the intermediate shaft 22, the intermediate driven gear 27, the output gear 25, and the output shaft 23 in sequence to rotate the wheels of the automobile.

[0047] The axis of the intermediate shaft 22 is higher than the axes of the main shaft 21 and the output shaft 23, and in a plane perpendicular to the axis of the main shaft 21, an angle between a line connecting the center point of the main shaft 21 and the center point of the output shaft 23 and a horizontal plane is less than or equal to a predetermined angle. The predetermined angle can be set according to design needs, for example, a value range of the predetermined angle is -10 to 10 degrees. In some embodiments of the present application, the angle between a line connecting the center point of the main shaft 21 and the center point of the output shaft 23 and a horizontal plane is 0 degrees. As can be seen, the intermediate shaft 22 is located above the main shaft 21 and the output shaft 23, and the intermediate drive gear 26 and the intermediate driven gear 27 are both located above the drive gear 24 and the output gear 25. The design of the reducer 2 lowers the center of gravity of the integrated electric drive system and the vehicle, improving the running stability of the vehicle and enhancing the driving enjoyment of the vehicle.

[0048] In one embodiment, as shown in FIGS. 1 and 2, a battery mounting space 48 for mounting a battery is provided on the end face of the integrated housing 4 away from the first opening. It can be understood that the integrated electric drive system further includes a battery mounted in the battery mounting space 48. In one embodiment, as shown in FIG. 2, the battery mounting space 48 has a second opening, and the direction of the second opening is perpendicular to the direction of the second opening. It can be understood that the battery mounting space 48 is integrated below the integrated housing 4, so that the battery can be mounted in the battery mounting space 48. The battery is a 12V small battery, which is typically used for low-power subsystems in automobiles, such as car door opening / closing, car starting, and lights. The design of the battery further improves the integration of the integrated electric drive system.

[0049] 1 and 2, the integrated electric drive system further includes a housing cover 7 that fits into the first opening. As can be seen, the housing cover 7 is connected to the integrated housing 4, thereby protecting the controller 3 inside the integrated housing 4.

[0050] The above is only a preferred embodiment of the present application, and is not intended to limit the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application are all included in the protection scope of the present application.

[0051] This application claims priority from a Chinese patent application filed on September 30, 2020 by BYD Co., Ltd., entitled "Integrated Electric Drive System and Electric Vehicle," with Chinese patent application number "202011063762.8."

[0052] (Addendum) (Appendix 1) An integrated electric drive system comprising a motor, a reducer, a controller, and an integrated housing, the integrated housing having a first opening and a recessed first housing space for mounting the controller, a second housing space for mounting the motor in a direction away from the first opening of the integrated housing, and a third housing space for mounting the reducer, the controller being connected to the motor, and an output shaft of the motor being connected to the reducer, an absolute value of a difference between a preset mounting width value and a width value of a first housing space in a direction parallel to an output shaft of the motor is equal to or less than a first difference threshold, and the preset mounting width value is a sum of the width value of the second housing space and the width value of the third housing space; an absolute value of a difference between a length value of the first housing space and a length value of the third housing space in a direction perpendicular to an output shaft of the motor and parallel to a horizontal plane is less than or equal to a second difference threshold value.

[0053] (Appendix 2) 2. The integrated electric drive system of claim 1, wherein the absolute value of the difference between half the length value of the first housing space and the length value of the second housing space in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane is less than or equal to a third difference threshold.

[0054] (Appendix 3) 3. The integrated electric drive system of claim 2, wherein the first difference threshold is zero.

[0055] (Appendix 4) 3. The integrated electric drive system of claim 2, wherein the second difference threshold is zero.

[0056] (Appendix 5) 3. The integrated electric drive system of claim 2, wherein the third difference threshold is zero.

[0057] (Appendix 6) The integrated electric drive system described in any one of Supplementary Notes 1 to 5, further comprising a support frame attached to an end face of the air conditioner compressor and the reducer remote from the second housing space, the air conditioner compressor being attached to the support frame and connected to the controller.

[0058] (Appendix 7) 7. The integrated electric drive system of claim 6, further comprising a water pump mounted to the support frame and connected to the controller.

[0059] (Appendix 8) The integrated electric drive system of claim 7, wherein the support frame includes a vertical plate and a horizontal plate connected to an upper end of the vertical plate, the vertical plate being attached to an end face of the reducer farther from the motor, the water pump being attached above the horizontal plate, and the air conditioner compressor being attached to one side of the vertical plate farther from the reducer and located below the horizontal plate.

[0060] (Appendix 9) the controller comprises a capacitor module, an IGBT module, a three-phase copper bar, a DC bus bar, an on-board charger, and a DC converter, the on-board charger and the DC converter are all connected to a vehicle power battery, the capacitor module, the IGBT module, the three-phase copper bar, the on-board charger, and the DC converter are all installed in the first housing space, the capacitor module is connected to the vehicle power battery via the DC bus bar installed in the integrated housing, and the three-phase copper bar is connected to three-phase terminals of the motor; The integrated electric drive system according to any one of Supplementary Notes 1 to 8, wherein the automobile power battery drives the rotation of the motor through the DC bus bar, the capacitor module, the IGBT module, and the three-phase copper bar, which are connected in sequence.

[0061] (Appendix 10) The integrated electric drive system described in Appendix 9, characterized in that the on-board charger and DC converter comprise a heat dissipation module, an electronic control element driving module, and a heat-generating element driving module, the heat-generating element driving module is attached to the heat dissipation module, and the electronic control element driving module is attached to one end of the heat-generating element driving module far from the heat dissipation module.

[0062] (Appendix 11) the first housing space includes a first internal space and a second internal space, both of which are rectangular and adjacent to each other; 10. The integrated electric drive system of claim 9, wherein the capacitor module, the IGBT module, and the three-phase copper bar are all mounted in the first internal space, the on-board charger and the DC converter are mounted in the second internal space, and the DC bus bar is located on one side of the first internal space away from the second internal space.

[0063] (Appendix 12) the integrated housing includes a first cooling water passage, a second cooling water passage, a water passage inlet, and a water passage outlet, the first cooling water passage being provided at a position facing the IGBT module within the integrated housing, and the second cooling water passage being provided at a position facing the on-board charger and the DC converter within the integrated housing; 10. An integrated electric drive system as described in Appendix 9, characterized in that a preset water supply device is connected to one end of the water channel inlet, the first cooling water channel and the second cooling water channel are connected to the other end of the water channel inlet, and the water channel outlet is connected to one end of the first cooling water channel and the second cooling water channel that is far from the water channel inlet.

[0064] (Appendix 13) 13. The integrated electric drive system of claim 12, wherein the motor includes an outer housing connected to the reducer and an inner housing inserted into the outer housing, a cooling space is formed between an inner wall of the outer housing and an outer wall of the inner housing, the outer housing is provided with a water inlet and a water outlet both communicating with the cooling space, and one end of the water channel outlet remote from the first cooling water channel communicates with the water inlet.

[0065] (Appendix 14) 14. The integrated electric drive system of claim 13, wherein the outer wall of the inner housing is provided with a plurality of guide rib plates arranged circumferentially along the output shaft of the motor.

[0066] (Appendix 15) the reducer comprises a main shaft, an intermediate shaft, an output shaft, a drive gear, an output gear, an intermediate drive gear, and an intermediate driven gear, the main shaft is connected to the output shaft of the motor, the drive gear is attached to the main shaft, the intermediate drive gear and the intermediate driven gear are both attached to the intermediate shaft, the output gear is attached to the output shaft, the intermediate drive gear meshes with the drive gear, and the intermediate driven gear meshes with the output gear; An integrated electric drive system according to any one of appendixes 1 to 14, characterized in that the axis of the intermediate shaft is higher than the axes of the main shaft and the output shaft, and in a plane perpendicular to the axis of the main shaft, an angle between a line connecting the center point of the main shaft and the center point of the output shaft and a horizontal plane is equal to or smaller than a predetermined angle.

[0067] (Appendix 16) An integrated electric drive system as described in any one of appendices 1-15, characterized in that a battery mounting space for mounting a battery is provided on an end surface of the integrated housing away from the first opening.

[0068] (Appendix 17) An integrated electric drive system according to any one of claims 1 to 16, further comprising a housing cover that fits and connects to the opening.

[0069] (Appendix 18) 18. An electric vehicle comprising an integrated electric drive system according to any one of claims 1-17.

Claims

1. An integrated electric drive system comprising a motor, a reducer, a controller, and an integrated housing, the integrated housing having a first opening and a recessed first housing space for mounting the controller, a second housing space for mounting the motor in a direction away from the first opening of the integrated housing, and a third housing space for mounting the reducer, the controller being connected to the motor, and an output shaft of the motor being connected to the reducer, When projected onto a horizontal plane, the projection of the first housing space and the projection of the second housing space at least partially overlap in both a direction parallel to the output shaft of the motor and a direction perpendicular to the output shaft of the motor, and the projection of the first housing space and the projection of the third housing space at least partially overlap in both a direction parallel to the output shaft of the motor and a direction perpendicular to the output shaft of the motor; an absolute value of a difference between a preset mounting width value and a width value of a first housing space in a direction parallel to an output shaft of the motor is equal to or less than a first difference threshold, and the preset mounting width value is a sum of the width value of the second housing space and the width value of the third housing space; an absolute value of a difference between the length value of the first housing space and the length value of the third housing space in a direction perpendicular to an output shaft of the motor and parallel to a horizontal plane is less than or equal to a second difference threshold value; the reducer comprises a main shaft, an intermediate shaft, an output shaft, a drive gear, an output gear, an intermediate drive gear, and an intermediate driven gear, the main shaft is connected to the output shaft of the motor, the drive gear is attached to the main shaft, the intermediate drive gear and the intermediate driven gear are both attached to the intermediate shaft, the output gear is attached to the output shaft, the intermediate drive gear meshes with the drive gear, and the intermediate driven gear meshes with the output gear; an axis of the intermediate shaft being higher than axes of the main shaft and the output shaft; and an angle between a line connecting a center point of the main shaft and a center point of the output shaft and a horizontal plane in a plane perpendicular to the axis of the main shaft being equal to or smaller than a predetermined angle.

2. 2. The integrated electric drive system according to claim 1, wherein the range of values ​​of the preset angle is from -10 to 10 degrees.

3. 3. The integrated electric drive system according to claim 1, wherein the predetermined mounting width value and the width value of the first housing space are the same in a direction parallel to the output shaft of the motor, and the predetermined mounting width value is the sum of the width values ​​of the second housing space and the third housing space.

4. 3. The integrated electric drive system according to claim 1, wherein the length values ​​of the first housing space and the third housing space are the same in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane.

5. In a direction parallel to an output shaft of the motor, the preset mounting width value and a width value of the first housing space are equal, and the preset mounting width value is the sum of the width values ​​of the second housing space and the third housing space, 3. The integrated electric drive system according to claim 1, wherein the length values ​​of the first housing space and the third housing space are the same in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane.

6. In a direction parallel to an output shaft of the motor, an absolute value of a difference between the preset mounting width value and a width value of the first housing space is equal to or less than a first difference threshold, and the preset mounting width value is a sum of a width value of the second housing space and a width value of the third housing space; 3. The integrated electric drive system according to claim 1, wherein an absolute value of a difference between the length value of the first housing space and the length value of the third housing space in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane is less than or equal to a second difference threshold value.

7. 7. The integrated electric drive system of claim 6, wherein the first difference threshold value is between 0 and 1 cm.

8. 7. The integrated electric drive system of claim 6, wherein the second difference threshold value is between 0 and 1 cm.

9. 9. An integrated electric drive system according to claim 1, wherein half the length of the first housing space is equal to the length of the second housing space in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane.

10. 9. An integrated electric drive system according to claim 1, wherein an absolute value of a difference between half the length value of the first housing space and the length value of the second housing space in a direction perpendicular to the output shaft of the motor and parallel to a horizontal plane is less than or equal to a third difference threshold value.

11. 11. The integrated electric drive system of claim 10, wherein the third difference threshold value is between 0 and 1 cm.

12. the controller comprises a capacitor module, an IGBT module, a three-phase copper bar and a DC bus bar, the capacitor module, the IGBT module and the three-phase copper bar are all mounted in the first housing space, the capacitor module is connected to an automobile power battery via the DC bus bar mounted in the integrated housing, and the three-phase copper bar is connected to three-phase terminals of the motor; The integrated electric drive system according to any one of claims 1 to 11, wherein the automobile power battery drives the rotation of the motor through the DC bus bar, the capacitor module, the IGBT module, and the three-phase copper bar, which are connected in sequence.

13. the integrated housing includes a first cooling water passage, a water passage inlet, and a water passage outlet; An integrated electric drive system according to any one of claims 1 to 12, characterized in that one end of the water channel inlet is connected to a predetermined water supply device, the other end of the water channel inlet is connected to the first cooling water channel, and the water channel outlet is connected to one end of the first cooling water channel that is far from the water channel inlet.

14. 14. The integrated electric drive system of claim 1, further comprising a housing cover that fits and connects to the first opening.

15. An electric vehicle comprising an integrated electric drive system according to any one of claims 1 to 14.

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