Electric motorcycle power system and potting process therefor

Abstract

Provided in the present invention are an electric motorcycle power system and a potting process therefor. The system comprises an electric motor shell and a controller shell arranged on one side of the electric motor shell; the controller shell comprises a front controller shell end portion, a rear controller shell end portion and a controller shell edge portion connecting the front controller shell end portion and the rear controller shell end portion; and a controller assembly is provided between the front controller shell end portion and the rear controller shell end portion, a potting port and a cable exit are provided in the rear controller shell end portion; the potting port is located at one end, in a radial direction, of a surface of the rear controller shell end portion, and the cable exit is located at the other end, in the radial direction, of the surface of the rear controller rear shell end portion; and an anti-overflow plate is provided on an outer side surface of the rear controller shell end portion that corresponds to the cable exit, and a cable entry facing the potting port is formed between the anti-overflow baffle and the rear controller shell end portion. Interference of a circuit board with the filling of a thermally conductive adhesive is avoided, and the thermally conductive adhesive can fully fill a gap between the controller shell and the controller assembly and tightly wrap the controller assembly, such that heat is better transferred, and the heat dissipation performance of the controller is improved.

Description

An electric motorcycle power system and its glue filling process Technical Field

[0001] The present invention relates to the technical field of drive assemblies, and in particular to an electric motorcycle power system and a glue pouring process thereof. Background Art

[0002] When the electric motorcycle power system is working, the components of its controller part will generate a lot of heat. In order to avoid excessive concentration of heat, the existing controller housing is usually filled with insulating thermal conductive glue to evenly disperse the heat generated by the components in the controller housing.

[0003] Currently, the glue filling process for controller housings is as follows: first, place the controller housing horizontally, then fill the controller housing with glue from the wire outlet on the upper cover until the thermal conductive glue gradually fills the inner cavity along the thickness direction of the controller housing. This glue filling method has the following problems: 1. Because the circuit board inside the controller housing is horizontally located between the upper and lower covers of the controller housing, the thermal conductive glue poured from the wire outlet will be blocked by the circuit board, resulting in poor filling effect between the circuit board and the bottom cover; 2. Due to the viscosity and tension of the thermal conductive glue itself, it is difficult to ensure that the gap between the upper cover of the controller housing and the circuit board is fully filled when filling along the thickness direction of the controller housing. As a result, the above two problems lead to poor heat transfer efficiency of the thermal conductive glue, and therefore need to be improved.

[0004] Summary of the Invention

[0005] Based on this, the purpose of the present invention is to provide an electric motorcycle power system and a glue filling process thereof, so as to solve the technical problems mentioned in the above background technology.

[0006] On the one hand, the present invention proposes an electric motorcycle power system, including a motor housing and a controller housing arranged on one side of the motor housing, the controller housing including a controller front housing end, a controller rear housing end and a controller housing edge portion connecting the two, a controller assembly is provided between the controller front housing end and the controller rear housing end, a glue filling port and a wire outlet are provided on the controller rear housing end, the glue filling port is located at one end of the radial direction of the surface of the controller rear housing end, and the wire outlet is located at the other end of the radial direction of the surface of the controller rear housing end, an anti-overflow plate is provided on the outer side of the controller rear housing end corresponding to the wire outlet, and a lead-in port facing the glue filling port is formed between the anti-overflow plate and the controller rear housing end.

[0007] Furthermore, in the electric motorcycle power system, the two ends of the controller component in the radial direction are respectively spaced apart from the controller housing to form a glue filling channel opposite to the glue filling port, and a lead-in channel opposite to the wire outlet.

[0008] Furthermore, the electric motorcycle power system, wherein the controller assembly includes a controller body, a circuit board provided on the controller body, and a second wiring harness connected to the circuit board, the second wiring harness passes through the controller housing from the lead port of the anti-overflow plate along the lead channel.

[0009] Furthermore, the electric motorcycle power system, wherein the anti-overflow plate includes a top cover and a left-side limiting portion, a rear-side limiting portion and a right-side limiting portion continuously arranged along the periphery of the top cover, and the end between the left-side limiting portion and the right-side limiting portion away from the rear-side limiting portion forms the lead-in port toward the glue filling port.

[0010] Furthermore, the electric motorcycle power system, wherein the motor housing includes a motor front housing end, a motor rear housing end and a motor housing edge portion, the motor front housing end is integrally connected to one side of the controller front housing end in the horizontal direction to form an overall front housing structure, the motor rear housing end is integrally connected to one side of the controller rear housing end in the horizontal direction to form an overall rear housing structure, the motor housing edge portion is integrally connected to one side of the controller housing edge portion in the horizontal direction to form an overall housing edge structure for connecting the overall front housing structure and the overall rear housing structure, a motor assembly is provided between the motor front housing end and the motor rear housing end, and the motor assembly and the controller assembly are horizontally spaced apart.

[0011] Furthermore, in the electric motorcycle power system, the end of the motor rear shell and the end of the controller rear shell are coplanar and form an air-cooled external plate.

[0012] Furthermore, the electric motorcycle power system, wherein the motor assembly includes an output shaft, a stator structure and a rotor structure, the output shaft is rotatably arranged in the motor housing, and one end extends from the end of the front housing of the motor, the stator structure includes a first stator arranged at the end of the rear housing of the motor, and a second stator arranged at the end of the front housing of the motor, the rotor structure is arranged between the first stator and the second stator and is fixedly connected to the output shaft.

[0013] Furthermore, in the electric motorcycle power system, the stator structure, the rotor structure and the output shaft constitute an axial flux motor, and the fastening direction of the integral front shell structure and the integral rear shell structure is the same as the axial direction of the axial flux motor.

[0014] Furthermore, in the electric motorcycle power system, a sensor installation cavity is formed inwardly at the end of the rear shell of the motor corresponding to the position of the output shaft, and a sensor component is arranged in the sensor installation cavity and is closed by a cover plate.

[0015] Furthermore, in the electric motorcycle power system, the end of the motor rear shell protrudes outward at the position corresponding to the output shaft to form an annular enclosure surrounding the sensor installation cavity, the cover plate is fixed on the end face of the annular enclosure, and the inner wall of the sensor installation cavity protrudes inward to form a limiting step, and the supporting surface of the limiting step is flush with the cover plate and is spaced apart.

[0016] Furthermore, the electric motorcycle power system, wherein the sensor assembly includes a control circuit board, a magnetic head and a sensor chip, the control circuit board is horizontally arranged on the limiting step, the magnetic head is embedded in one end of the output shaft facing the control circuit board, and the sensor chip is arranged on the control circuit board and opposite to the magnetic head.

[0017] Furthermore, the electric motorcycle power system, wherein the inner side surface of the end of the motor rear shell is provided with a wire passing bottom groove, one end of the wire passing bottom groove extends into the sensor installation cavity, and the other end extends to the edge of the end of the motor rear shell, and the side of the control circuit board facing away from the sensor chip is connected to the signal line, and the signal line passes through the side wall of the sensor installation cavity and is routed into the controller housing through the wire passing bottom groove.

[0018] Furthermore, in the electric motorcycle power system, the outer side surfaces of the rear shell end of the motor and the rear shell end of the controller are provided with a heat dissipation structure, and the projection of part of the heat dissipation structure in the axial direction of the motor housing coincides with the bottom groove of the wire.

[0019] Furthermore, the electric motorcycle power system further includes:

[0020] A reducer, the reducer is located on one side of the end of the front housing of the motor and is connected to the output shaft;

[0021] The wheel is located on a side of the reducer away from the end of the front housing of the motor, and the reducer is driven and connected to the wheel.

[0022] Furthermore, the electric motorcycle power system, wherein a first power lead is provided on the first stator, a second power lead is provided on the second stator, a wire passing channel is provided between the motor assembly and the controller assembly, the first power lead and the second power lead are electrically connected to the controller assembly through the wire passing channel, and the projections of the parts of the first power lead and the second power lead in the axial direction of the shell do not overlap.

[0023] Furthermore, the electric motorcycle power system also includes a separator provided on the controller assembly, the separator is provided with a plurality of first limit buckles, the first limit buckles are used to fix the first power lead, and the end of the front shell of the controller is provided with a plurality of second limit buckles, the second limit buckles are used to fix the second power lead.

[0024] Furthermore, in the electric motorcycle power system, the orthographic projection of the second limit buckle on the separator plate does not overlap with that of the first limit buckle.

[0025] Furthermore, in the electric motorcycle power system, a wiring floating plate is detachably connected to the wiring channel, and a plurality of wire threading holes are provided on the wiring floating plate, and the wire threading holes are configured to be suitable for the first power lead wire and the second power lead wire to pass through.

[0026] Another aspect of the present invention provides a glue pouring process for an electric motorcycle power system, which is applied to the electric motorcycle power system described in the above technical solution. The glue pouring process for the electric motorcycle power system includes:

[0027] Place the controller housing vertically on the ground so that the glue filling port on the end of the controller rear shell is located directly above the wire outlet;

[0028] Filling thermal conductive glue from the glue filling port at the end of the controller rear shell until the liquid level of the thermal conductive glue closes the lead-in port of the anti-overflow plate and then stops filling;

[0029] After the thermal conductive glue poured into the controller housing for the first time is solidified, the glue is poured a second time through the glue pouring port until the liquid level of the thermal conductive glue is consistent with the height of the glue pouring port, and then the glue pouring is stopped;

[0030] After the thermal conductive glue poured into the controller housing for the second time is solidified, the glue pouring process of the controller housing is completed.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. Since the lead-in port of the anti-overflow plate is arranged toward the glue filling port, the controller housing can be glued in a vertical state, because the anti-overflow plate can collect a portion of the thermal conductive glue overflowing from the outlet. The thermal conductive glue injected from the glue filling port can flow smoothly from the gap between the controller component and the end of the controller front shell or the end of the controller rear shell to the bottom under the action of gravity. Compared with the existing solution of glue filling the controller housing in a horizontal state, the interference of the circuit board on the filling of the thermal conductive glue is avoided. The thermal conductive glue can fully fill the gap between the controller housing and the controller component and tightly wrap the controller component, thereby better transferring heat and improving the heat dissipation performance of the controller.

[0033] 2. Since the controller housing is potted in a vertical state, the liquid level of the thermal conductive adhesive gradually rises along the radial direction of the controller housing. Compared with the existing solution of potting the controller housing in a horizontal state, this avoids the influence of the viscosity and tension of the thermal conductive adhesive, which may cause insufficient filling of the gap between the end of the controller front shell and the controller component. This design helps to ensure that the thermal conductive adhesive can fully fill the entire controller housing, including the gap between the controller and the circuit board, thereby better ensuring the efficiency of heat transfer and further improving the heat dissipation performance and service life of the controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG1 is a schematic diagram of the overall housing of the present invention being assembled on a wheel;

[0035] FIG2 is a perspective view of the overall housing of the present invention;

[0036] FIG3 is a schematic diagram of a controller housing in the present invention;

[0037] FIG4 is a cross-sectional view of the controller housing and the motor housing in the present invention;

[0038] FIG5 is a perspective view of the overall rear shell structure of the present invention;

[0039] FIG6 is a wiring diagram of the first wiring harness and the second wiring harness in the second installation position according to the present invention;

[0040] FIG7 is a perspective view of the anti-overflow plate of the present invention;

[0041] FIG8 is a schematic diagram of the specific structure of the heat dissipation structure of the present invention;

[0042] FIG9 is a distribution diagram of the second limit buckle on the end of the front shell of the controller in the present invention;

[0043] FIG10 is a cross-sectional view of the motor housing of the present invention;

[0044] FIG11 is a schematic diagram of the bottom trough of the wire in the present invention;

[0045] FIG12 is a cross-sectional view of the reducer and the motor housing of the present invention;

[0046] Key component symbol description: 10, controller housing; 11, controller rear housing end; 12, controller front housing end; 13, controller housing edge; 101, first baffle; 102, second baffle; 103, wire trough; 104, wiring float; 105, wire hole; 106, wire plug; 20, motor housing; 21, motor rear housing end; 22, motor front housing end; 23, motor housing edge; 201, first mounting position; 202, second mounting position; 203, wire channel; 204, positive power line; 205, negative power line; 206, signal line; 207, wiring harness buckle; 31. Glue filling port; 32. Wire outlet; 33. Anti-overflow plate; 331. Top cover; 332. Left side limiter; 333. Rear side limiter; 334. Right side limiter; 335. Mounting portion; 336. Mounting hole; 301. First heat dissipation rib; 302. Second heat dissipation rib; 3021. Arc-shaped heat dissipation rib; 3022. Straight-shaped heat dissipation rib; 3023. Annular heat dissipation rib; 40. First power lead wire; 41. U1 phase wire; 42. V1 phase wire; 43. W1 phase wire; 50. Second power lead wire; 51. U2 phase wire; 52. V2 phase wire; 53. W2 phase wire; 61. Glue filling channel; 62. Lead wire channel; 63. Thermal conductive layer; 71. First stator; 72. Second stator; 73. Rotor structure; 74. Output shaft; 75. Sensor mounting cavity; 76. Cover plate; 77. Annular enclosure; 78. Limiting step; 791. Control circuit board; 792. Magnetic head; 793. Sensor chip; 794. Wire groove; 795. Inner bushing; 796. Reinforcement rib; 797. Avoidance step; 798. First bearing chamber; 799. First bearing; 7910. Second bearing chamber; 7911. Second bearing; 81. Controller body; 82. Circuit board; 83. First wiring port; 84. Second wiring port; 85. Third wiring port; 86. Wire separator; 87. First limiting buckle; 88. Second limiting buckle; 91. Reducer; 92. Wheel; 93. Suspension link; 94. Fixed link; 95. Connecting bracket; 96. Screw hole; 97. Through hole.

[0047] The following specific embodiments will further illustrate the present invention in conjunction with the above-mentioned drawings. DETAILED DESCRIPTION

[0048] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the accompanying drawings. The drawings illustrate several embodiments of the present invention. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the present invention.

[0049] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may be an intermediate element. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only.

[0050] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used in this specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0051] First embodiment

[0052] Please refer to Figures 1 to 4. The electric motorcycle power system in the present invention includes a motor housing 20 and a controller housing 10 arranged on one side of the motor housing 20. The controller housing 10 includes a controller front housing end 12, a controller rear housing end 11 and a controller housing edge 13 connecting the two. A controller component is provided between the controller front housing end 12 and the controller rear housing end 11. A glue filling port 31 and a wire outlet 32 ​​are provided on the controller rear housing end 11. The glue filling port 31 is located at one end of the radial direction of the surface of the controller rear housing end 11, and the wire outlet 32 ​​is located at the other end of the radial direction of the surface of the controller rear housing end 11. An anti-overflow plate 33 is provided on the outer side of the controller rear housing end 11 corresponding to the wire outlet 32, and a lead-in port facing the glue filling port 31 is formed between the anti-overflow plate 33 and the controller rear housing end 11.

[0053] Since the lead-in port of the anti-overflow plate 33 is arranged toward the glue filling port 31, the controller housing 10 can be glued in a vertical state, because the anti-overflow plate 33 can collect a portion of the thermal conductive glue overflowing from the outlet 32. The thermal conductive glue injected from the glue filling port 31 can flow smoothly from the gap between the controller component and the controller front shell end 12 or the controller rear shell end 11 to the bottom under the action of gravity. Compared with the existing solution of glue filling the controller housing 10 in a horizontal state, the interference of the circuit board 82 in the filling of the thermal conductive glue is avoided. The thermal conductive glue can fully fill the gap between the controller housing 10 and the controller component and tightly wrap the controller component, thereby better transferring heat and improving the heat dissipation performance of the controller.

[0054] In this embodiment, the controller housing 10 can be combined with the motor housing 20 to form an integral shell to improve the compactness of the overall structure. Please refer to Figure 2 for details. The motor housing 20 includes a motor front shell end 22, a motor rear shell end 21 and a motor shell edge 23. The motor front shell end 22 is integrally connected to one side of the controller front shell end 12 in the horizontal direction to form an integral front shell structure. The motor rear shell end 21 is integrally connected to one side of the controller rear shell end 11 in the horizontal direction to form an integral rear shell structure. The motor shell edge 23 is integrally connected to one side of the controller shell edge 13 in the horizontal direction to form an integral shell edge structure for connecting the integral front shell structure and the integral rear shell structure. A motor assembly is provided between the motor front shell end 22 and the motor rear shell end 21, and the motor assembly and the controller assembly are arranged horizontally at intervals.

[0055] Furthermore, the motor rear housing end 21 and the controller rear housing end 11 are coplanar and form an air-cooled external plate. Thus, the motor assembly and the controller assembly can share the air-cooled external plate, which is beneficial for heat dissipation of the entire power system and improves the stability and service life of the system.

[0056] 2 , 4 , and 5 , a first mounting position 201 and a second mounting position 202 are horizontally spaced apart and formed between the integral front shell structure and the integral rear shell structure. The motor assembly is disposed in the first mounting position 201 , and the controller assembly is disposed in the second mounting position 202 . A wiring passage 203 is formed between the first mounting position 201 and the second mounting position 202 . A first wiring harness disposed on the motor assembly can pass through the wiring passage 203 to electrically connect to the controller assembly.

[0057] The second wiring harness 200 provided on the controller assembly can be led out of the controller housing 10 from the lead-in port of the anti-overflow plate 33 for external connection to a battery.

[0058] It should be noted that since the lead-in port of the anti-overflow plate 33 is set toward the glue filling port 31, the portion of the second wiring harness 200 located outside the controller housing 10 can fit in the surface of the controller rear shell end to output the wires. Therefore, in some embodiments, a wiring harness buckle 207 can be used to fix the second wiring harness 200 directly on the controller rear shell end 11 to prevent it from vibrating back and forth during vehicle transportation and causing wear. See Figure 3 for details.

[0059] Because the motor assembly and controller assembly are spaced horizontally apart, the first wiring harness connecting the two assemblies can be designed to be shorter, reducing the complexity of the first wiring harness routing and improving its transmission efficiency and system response speed. Furthermore, by arranging the first wiring harness within the overall housing, the housing itself also protects the first wiring harness.

[0060] In this embodiment, the second wiring harness 200 for the external battery is bent when it is led out of the controller housing 10. By increasing the bending angle of the second wiring harness 200, the stress of the second wiring harness 200 at the bend is reduced, thereby avoiding excessive damage to the wiring harness at the bend.

[0061] Specifically, after the second wiring harness 200 passes through the integral housing at the outlet 32, it is guided by the anti-overflow plate 33 toward the glue injection port 31 and then bends in the opposite direction at a certain angle. It will be appreciated that the second wiring harness 200 exiting toward the glue injection port 31 and bending in the opposite direction is intended to maximize the surface area of ​​the controller rear housing end 11, thereby creating a large overlap area between the second wiring harness 200 and the controller rear housing end 11, thereby achieving optimal support for the bent portion of the second wiring harness 200 by the controller rear housing end 11.

[0062] As shown in Figures 3, 4, and 6, the second wiring harness 200 includes a positive power line 204, a negative power line 205, and a signal line 206. The positive power line 204, negative power line 205, and signal line 206 are bent side by side and in opposite directions at the portion fixed to the controller rear housing end 11, and secured to the surface of the controller rear housing end 11 via a wiring harness clip 207. The curvature of the bends is obtuse. As will be appreciated, the most obtuse bend angles are chosen here, as the smaller the sharp angle, the greater the damage to the second wiring harness 200. Therefore, an obtuse bend angle is chosen throughout the wiring harness. By increasing the bend angle, the second wiring harness 200 is protected and its bending life is extended. The securing of the wiring harness clip 207 ensures close contact between the positive power line 204, negative power line 205, and signal line 206 and the controller rear housing end 11. This close contact provides mechanical stability, reducing shaking and vibration of the wiring harness, thereby reducing the risk of damage to the wiring harness when subjected to external impact or collision.

[0063] As shown in Figure 3, the glue filling port 31 is located at the center line position of the length direction of the controller rear shell end 11. It can be understood that by setting the glue filling port 31 at the center line position of the controller rear shell end 11, it can be ensured that the thermal conductive glue diffuses from the center to the surroundings, thereby more evenly filling the entire controller housing 10 and avoiding uneven filling. In addition, in this embodiment, the wire outlet 32 ​​is aligned with the glue filling port 31 and is also located at the center line position of the controller rear shell end 11. The purpose is to facilitate the arrangement of the second wiring harness 200 and ensure that there is sufficient contact area between the second wiring harness 200 and the controller rear shell end 11. Regardless of whether the second wiring harness 200 is bent in the opposite direction to the left or the right, it can be fixed to the controller rear shell end 11 by the wiring harness buckle 207.

[0064] As shown in FIG. 4 , both ends of the controller assembly in the radial direction are spaced apart from the controller housing 10 to form a glue pouring channel 61 opposite to the glue pouring port 31 and a wire lead channel 62 opposite to the wire outlet 32 ​​. It can be understood that the formation of the glue filling channel 61 ensures that the thermal conductive glue injected from the glue filling port 31 will not be directly sprayed on the controller component, but will first enter the glue filling channel 61 and then settle downward under the action of gravity, avoiding the interference of the controller component on the injection of the thermal conductive glue, making the filling of the thermal conductive glue smoother; and the formation of the lead channel 62 is to leave enough wiring space for the second wiring harness 200 to pass through the outlet 32. Please refer to Figure 4 for details. The controller component includes a controller body 81, a circuit board 82 provided on the controller body 81, and a second wiring harness 200 connected to the circuit board 82, wherein the controller body 81 is fixed on the controller rear shell end 11, and the second wiring harness 200 is vertically led downward from the gap between the circuit board 82 and the controller front shell end 12 to the position of the controller shell edge 13, and then bent horizontally and passed through the lead channel 62 from the outlet 32, and finally, under the guidance of the anti-overflow plate 33, it is attached to the surface of the controller rear shell end 11.

[0065] It is worth mentioning that since a part of the second wiring harness 200 is located between the anti-overflow plate 33 and the end 11 of the controller rear shell, the thermal conductive glue can also seal and fix the second wiring harness 200 when closing the lead-in port of the anti-overflow plate 33, thereby further strengthening the fixation of the second wiring harness 200 and preventing it from vibrating back and forth when the vehicle is running and causing breakage.

[0066] Furthermore, referring to FIG4 , a heat-conducting layer 63 is provided between the controller body 81 and the controller rear housing end 11. The heat-conducting layer 63 has a greater thermal conductivity than the controller rear housing end 11, thereby accelerating the conduction of heat generated by the controller components to the controller rear housing end 11, reducing thermal stress and thereby extending the life of the controller.

[0067] As shown in Figures 3, 4 and 7, the anti-overflow plate 33 is fixed to the position of the outer side of the end portion 11 of the controller rear shell corresponding to the wire outlet 32. The anti-overflow plate 33 includes a top cover 331 and a left limiting portion 332, a rear limiting portion 333 and a right limiting portion 334 continuously arranged along the periphery of the top cover 331. The end between the left limiting portion 332 and the right limiting portion 334 away from the rear limiting portion 333 forms the lead-in port toward the glue filling port 31.

[0068] It can be understood that since the lead-in port of the anti-overflow plate 33 is set toward the glue filling port 31, when the controller housing 10 is in a vertical state for the glue filling process, the lead-in port of the anti-overflow plate 33 can be set upward, thereby being able to store a portion of the thermal conductive glue overflowing from the outlet 32.

[0069] It should be noted that in this embodiment, the glue filling process of the controller housing 10 needs to be carried out in two steps, as follows: first, a fixed amount of thermal conductive glue is poured in for the first time until the glue liquid level reaches the lead opening of the anti-overflow plate 33, and the thermal conductive glue is allowed to solidify to close the lead opening of the anti-overflow plate 33. Then, a second glue filling is carried out until the thermal conductive glue fully fills the interior of the controller housing 10, and the thermal conductive glue is allowed to solidify to complete the glue filling process of the controller housing 10. The advantage of this glue filling process is that it fully utilizes the structural characteristics of the controller housing 10, allowing the thermal conductive glue to fully fill the gap between the controller component and the controller housing 10 under the action of gravity. It is divided into two glue fillings. The first glue filling is to use the adhesion of the glue itself after curing to seal and fix the second wiring harness 200. The second glue filling is to fully wrap the controller component with thermal conductive glue, which can not only play a role in fixing and supporting its own components, but also play a role in sealing and enhancing heat conduction, and can better dissipate the heat of the controller component.

[0070] In addition, the cross-section of the lead-in port is equivalent to the sum of the cross-sections of the positive power line 204, the negative power line 205 and the signal line 206. It can be understood that the anti-overflow plate 33 is provided at the outlet 32, which can protect the second wiring harness 200 on the one hand and prevent its bent part from being damaged or worn in the external environment. On the other hand, the cross-section of the lead-in port is equivalent to the sum of the cross-sections of the positive power line 204, the negative power line 205 and the signal line 206, so that the positive power line 204, the negative power line 205 and the signal line 206 remain close together when passing through the lead-in port, avoiding crossing or interference between the wiring harnesses.

[0071] Furthermore, in this embodiment, a mounting portion 335 is horizontally extended outward from the left limiting portion 332 and the right limiting portion 334. The mounting portion 335 is provided with a mounting hole 336. The screw is passed through the mounting hole 336 and fixed to the end portion 11 of the controller rear shell, thereby realizing the installation of the anti-overflow plate 33 on the controller shell 10. Please refer to Figures 3 and 7 for details.

[0072] Referring to Figure 3, in this embodiment, the wiring harness buckle 207 can be specifically a pressure strip, the two ends of which can be fixed to the end portion 11 of the controller rear shell by screws, thereby pressing the positive power line 204, the negative power line 205 and the signal line 206 tightly against the end portion 11 of the controller rear shell. The number of wiring harness buckles 207 can be adaptively adjusted according to the degree of bending of the second wiring harness 200.

[0073] As shown in Figure 4, a portion of the second wiring harness 200 is located between the end portion 11 of the controller rear shell and the top cover 331. The setting of the top cover 331 not only protects the second wiring harness 200, but also guides the second wiring harness 200 to a certain extent, so that the second wiring harness 200 can be routed along the surface of the end portion 11 of the controller rear shell when passing through the controller shell 10, ensuring that the second wiring harness 200 can run along a predetermined path, making the layout of the second wiring harness 200 outside the overall shell more compact and tidy.

[0074] It can be seen that in this embodiment, the anti-overflow plate 33 is not only used to collect the thermal conductive glue overflowing from the outlet 32, but can also be used to guide the second wire harness 200 to a predetermined path, and the wire harness buckle 207 is used to fix the second wire harness 200 on the end 11 of the controller rear shell, so that the second wire harness 200 follows the preset direction to lead out of the controller shell 10. The two cooperate with each other to effectively reduce the wear and tear of the second wire harness 200 caused by repeated pulling during the operation of the vehicle.

[0075] As shown in FIG4 , the orthographic projection of the top cover 331 on the end portion 11 of the controller rear housing covers the wire outlet 32 ​​, so as to at least ensure that the thermal conductive glue does not overflow from the lead-in opening when sealing the wire outlet 32 ​​.

[0076] Of course, in some embodiments, the size of the top cover 331 can also be increased to increase the horizontal height of the lead-in opening when the controller housing 10 is in a vertical state. In this way, even if the level of the thermal conductive glue injected for the first time is slightly higher than the outlet 32, it can be collected in the space between the anti-overflow plate 33 and the end 11 of the controller rear shell, and will not flow to the outside of the controller housing 10. It has a higher fault tolerance rate and avoids overflow caused by excessive thermal conductive glue injected during the first injection.

[0077] Referring to Figure 10, the motor assembly includes an output shaft 74, a stator structure and a rotor structure 73. The output shaft 74 is rotatably disposed in the motor housing 20, and one end extends out from the front housing end 22 of the motor. The stator structure includes a first stator 71 disposed at the rear housing end 21 of the motor, and a second stator 72 disposed at the front housing end 22 of the motor. The rotor structure 73 is disposed between the first stator 71 and the second stator 72 and is fixedly connected to the output shaft 74.

[0078] Specifically, in combination with Figures 5, 6 and 10, the first wiring harness connected to the motor assembly includes a first power lead 40 and a second power lead 50. The first power lead 40 is set on the first stator 71, and the second power lead 50 is set on the second stator 72. A wire channel 203 is provided between the motor assembly and the controller assembly. The first power lead 40 and the second power lead 50 are electrically connected to the controller assembly through the wire channel 203. The projections of the parts of the first power lead 40 and the second power lead 50 in the axial direction of the shell do not overlap.

[0079] It can be understood that since the first power lead-in wire 40 and the second power lead-in wire 50 are radially offset from each other along the overall shell, when they are electrically connected to the controller component, the power lines can be prevented from crossing at the connection point of the controller component, effectively solving the problem of assembly and maintenance difficulties caused by crossing power lines.

[0080] The stator structure, the rotor structure 73 and the output shaft 74 constitute an axial flux motor, and the fastening direction of the integral front shell structure and the integral rear shell structure is the same as the axis direction of the axial flux motor.

[0081] Regarding the axial flux motor, it's important to note that during operation, the first and second stators 71 and 72 generate an axial magnetic field force, which drives the rotor structure 73 to rotate and achieve power output. Compared to traditional radial permanent magnet motors, axial flux motors have a shorter axial dimension, smaller size, and lighter weight. This overall shorter axial dimension improves the integration of the drive unit. At the same output power, it is approximately 25% lighter than a conventional radial permanent magnet motor. The motor assembly and controller assembly share a single housing, making the overall structure more compact, lighter, and smaller, improving the integration of the electric drive assembly.

[0082] Specifically, as shown in Figure 6, the first power lead 40 includes a U1 phase line 41, a V1 phase line 42, and a W1 phase line 43, and the second power lead 50 includes a U2 phase line 51, a V2 phase line 52, and a W2 phase line 53. The circuit board 82 is provided with a first wiring port 83, a second wiring port 84, and a third wiring port 85. The U1 phase line 41 and the U2 phase line 51 are connected to the first wiring port 83, the V1 phase line 42 and the V2 phase line 52 are connected to the second wiring port 84, and the W1 phase line 43 and the W2 phase line 53 are connected to the third wiring port 85. It can be seen that the motor assembly in this embodiment adopts a three-phase winding structure design.

[0083] Of course, in other embodiments, the number of phase lines contained in the first power lead 40 and the second power lead 50 can also be changed according to specific needs to form a two-phase winding or a six-phase winding structure. This embodiment is only an example and not a limitation.

[0084] Furthermore, referring to Figures 2 and 4, in this embodiment, the cross-section of the motor housing 20 is circular to adapt to the shape of the motor assembly, and the controller housing 10 is roughly rectangular to adapt to the shape of the controller assembly. Among them, the motor rear housing end 21 and the controller rear housing end 11 of the overall rear housing structure are in the same horizontal plane, while the motor front housing end 22 and the controller front housing end 12 of the overall front housing structure are in different horizontal planes. Specifically, the distance between the controller front housing end 12 and the controller rear housing end 11 is smaller than the distance between the motor front housing end 22 and the motor rear housing end 21, so that the axial dimension of the motor housing 20 is smaller than the axial dimension of the controller housing 10. The purpose of this design is to make the overall housing highly match the shape of the controller assembly and the motor assembly, thereby maximizing the material savings of the overall housing and reducing the manufacturing cost of the overall housing.

[0085] Specifically, referring to Figures 4 and 5 , the integral front shell structure and the integral rear shell structure are respectively provided with corresponding first and second baffles 101 and 102, and the first and second baffles 101 and 102 are respectively provided with corresponding wire grooves 103. When the integral rear shell structure and the integral front shell structure are spliced ​​together via the integral shell edge structure, the wire grooves 103 on the first and second baffles 101 and 102 cooperate to form the wire passage 203. It should be noted that the size of the wire groove 103 in this embodiment can be adaptively adjusted according to the shape of the power lead wire and is not limited to the illustrated embodiment.

[0086] In some other implementations of this embodiment, the wire groove 103 on the first baffle plate 101 and the wire groove 103 on the second baffle plate 102 can also be staggered along the radial direction of the overall shell to limit the staggered lead-out of the first power lead-in wire 40 and the second power lead-in wire 50.

[0087] Furthermore, referring to Figures 4, 6, and 9, the controller assembly is further provided with a wire separator 86, on which a plurality of first limiting buckles 87 are provided, the first limiting buckles 87 being used to secure the first power lead 40, and a plurality of second limiting buckles 88 being provided on the front shell end portion 12 of the controller, the second limiting buckles 88 being used to secure the second power lead 50. By securing the first power lead 40 with a plurality of first limiting buckles 87, effective isolation and securing of the various phase lines of the first power lead 40 can be achieved, thereby avoiding crossing and interference between the phase lines, optimizing the wiring layout of the various phase lines, and thus greatly improving the space utilization within the second mounting position 202. The same applies to the second limiting buckles 88.

[0088] Specifically, in this embodiment, the first limiting buckle 87 is integrally formed on the separator plate 86. Specifically, the first limiting buckle 87 has two elastic clamping arms arranged opposite to each other, and the phase line can be clamped between the two elastic clamping arms, thereby achieving fixation on the separator plate 86. In this embodiment, the U1 phase line 41 is fixed to the separator plate 86 by three first limiting buckles 87, and the V1 phase line 42 and the W1 phase line 43 are each fixed to the separator plate 86 by one first limiting buckle 87. It should be noted that the number of the first limiting buckles 87 can be adaptively adjusted according to the length of the U1 phase line 41, the V1 phase line 42 and the W1 phase line 43. This embodiment is only an example and not a limitation.

[0089] Furthermore, the orthographic projection of the second limiting buckle 88 on the separator plate 86 does not overlap with the first limiting buckle 87. Therefore, when the controller rear shell end 11 and the controller front shell end 12 are spliced ​​together, the first limiting buckle 87 and the second limiting buckle 88 do not interfere with each other in the axial direction of the controller housing 10, while their radial projections can partially overlap, thereby shortening the axial dimension of the controller housing 10 and fully utilizing the space within the second mounting position 202.

[0090] Second embodiment

[0091] As shown in Figure 5, the electric motorcycle power system of the second embodiment is different from that of the first embodiment in that a wiring floating plate 104 is detachably connected to the wire groove 103 of the first baffle plate 101 and the wire groove 103 of the second baffle plate 102, respectively. The wiring floating plate 104 is provided with a plurality of wire threading holes 105 for the first power lead wire 40, the second power lead wire 50 and the signal wire 206 in the motor housing 20 to pass through the controller housing 10.

[0092] As will be appreciated, the floating wiring plate 104 can isolate the first mounting position 201 in the motor housing 20 from the second mounting position 202 in the controller housing 10. This prevents thermal adhesive from overflowing into the motor housing 20 when the controller housing 10 is being glued, or vice versa.

[0093] In this embodiment, the method of pouring glue for the motor housing 20 is as follows: the motor rear housing end 21 is placed horizontally, and then glue is poured into the first installation position 201 until the glue liquid level reaches a position close to the upper end surface of the wiring float 104, and then it is left to solidify. The same is true for pouring glue for the motor front housing end 22. When the thermal conductive glue in the motor front housing end 22 and the motor rear housing end 21 is solidified, the motor front housing end 22 and the motor rear housing end 21 are spliced ​​together through the motor housing edge 23.

[0094] In this embodiment, the fixing between the floating wiring plate 104 and the first blocking plate 101 or the second blocking plate 102 is mainly achieved by the adhesive force provided by the cured thermal conductive adhesive.

[0095] Furthermore, a wire plug 106 is fitted into the wire hole 105 on the floating wiring plate 104. The wire plug 106 is specifically an O-ring made of silicone. When the first power lead 40, the second power lead 50, and the signal line 206 of the motor assembly pass through the O-ring, the O-ring fits tightly against the outer wall of each wire harness, further improving the sealing effect and preventing thermal adhesive from leaking into the controller housing 10 through the gap between the wiring hole and the wire harness when the motor housing 20 is glued.

[0096] Third embodiment

[0097] As shown in Figures 4 and 10, the electric motorcycle power system of the third embodiment differs from the first embodiment in that a sensor mounting cavity 75 is formed inwardly at the end portion 21 of the motor rear housing corresponding to the position of the output shaft 74. The sensor mounting cavity 75 is provided with a sensor assembly and is sealed by a cover plate 76. The sensor assembly can be any one of a rotary transformer, a magnetic encoder, or a Hall sensor. In this embodiment, a magnetic encoder is preferred because it has a higher cost-performance ratio than the other two. While having excellent control accuracy, it also has a relatively low price and relatively high stability.

[0098] Specifically, the motor rear housing end 21 projects outwardly at the position corresponding to the output shaft 74 to form an annular enclosure 77 surrounding the sensor mounting cavity 75. The cover plate 76 is fixed to the end surface of the annular enclosure 77. The inner wall of the sensor mounting cavity 75 projects inward to form a limiting step 78. The supporting surface of the limiting step 78 is flush with and spaced apart from the cover plate 76. It will be appreciated that the additional protrusion of the annular enclosure 77 on the outer surface of the motor rear housing end 21 further increases the space of the sensor mounting cavity 75 in the axial direction of the output shaft 74, thereby providing sufficient space for the sensor assembly to facilitate assembly. The cover plate 76 is fixed to the annular enclosure 77 to seal the sensor mounting cavity 75, protect the sensor assembly from external environmental factors, and improve the stability and reliability of the device.

[0099] The assembly state of the sensor assembly in the sensor mounting cavity 75 is shown in FIG10 . Specifically, the sensor assembly includes a control circuit board 791, a magnetic head 792, and a sensor chip 793. The control circuit board 791 is horizontally arranged on the limiting step 78. Due to the provision of the annular enclosure 77, the control circuit board 791 is arranged at a certain distance relative to the cover plate 76 when assembled on the limiting step 78, so as to control the layout of the signal line 206 on the control circuit board 791. The magnetic head 792 is embedded in the output shaft 74 at one end facing the control circuit board 791. The sensor chip 793 is arranged on the control circuit board 791 and is arranged opposite to the magnetic head 792 so that the sensor chip 793 senses the rotation of the magnetic head 792 to obtain the position signal of the motor and feeds the position signal back to the controller in real time. In addition, since the magnetic head 792 is installed on the output shaft 74 in an embedded manner, the axial dimension of the output shaft 74 can be shortened, thereby reducing the axial dimension of the motor housing 20.

[0100] The sensor chip 793 can be directly mounted on the control circuit board 791, avoiding the use of the signal line 206 and effectively improving the reliability of signal transmission.

[0101] Specifically, in this embodiment, a plurality of bolt holes arranged in a ring are provided on the end face of the annular enclosure 77. Therefore, the cover plate 76 and the annular enclosure 77 can be fixed by bolts. This design facilitates maintenance personnel to only open the cover plate 76 for repair and replacement when a sensor component fails. Compared with removing the entire outer shell, the maintenance cost and time cost are greatly reduced.

[0102] As shown in FIG11 , a wire-passing bottom groove 794 is provided on the inner side surface of the motor rear housing end 21. One end of the wire-passing bottom groove 794 extends into the sensor mounting cavity 75 and the other end extends to the edge of the motor rear housing end 21. The side of the control circuit board 791 facing away from the sensor chip 793 is connected to the signal line 206. The signal line 206 passes through the side wall of the sensor mounting cavity 75 and is routed into the controller housing 10 through the wire-passing bottom groove 794. As can be understood, since the annular enclosure 77 protrudes a certain distance from the motor rear housing end 21 along the axis of the motor housing 20, when the control circuit board 791 is assembled on the receiving surface of the limiting step 78, a certain space is still formed between the cover plate 76. Therefore, the signal line 206 can be arranged in the space formed between the cover plate 76 and the control circuit board 791, and passes through the wire-passing channel 203 along the wire-passing bottom groove 794 to enter the second mounting position 202 to be electrically connected to the controller assembly. Since the wire bottom groove 794 is formed by cutting out the inner side surface of the motor rear shell end 21, the signal line 206 can be buried therein without interfering with the layout of the first stator 71 on the motor rear shell end 21. The routing of the signal line 206 is arranged inside the shell, and there is no need to route it in the external component pipeline of the motor shell 20, which greatly improves the compactness of the motor shell 20 structure and further reduces the volume of the motor shell 20.

[0103] Furthermore, as shown in conjunction with FIG8 and FIG11 , the outer side surfaces of the motor rear housing end portion 21 and the controller rear housing end portion 21 are provided with heat dissipation structures, and the projection of part of the heat dissipation structures in the axial direction of the motor housing 20 coincides with the line bottom groove 794. It is understandable that after the line bottom groove 794 is cut out at the motor rear housing end portion 21, in order not to affect the strength of the overall structure of the motor housing 20, the housing wall is thickened at the corresponding outer side surface of the motor rear housing end portion 21, and the thickened portion of the housing is combined with the heat dissipation structure on the surface of the entire machine, thereby helping the motor housing 20 to have sufficient strength while not affecting the heat dissipation of the housing.

[0104] Specifically, as shown in FIG8 , the heat dissipation structure includes a first heat dissipation rib 301 and a second heat dissipation rib 302 . There are multiple first heat dissipation ribs 301 . The multiple first heat dissipation ribs 301 are arranged on the outer surface of the controller rear shell end portion 21 along the length direction of the controller rear shell end portion 21 , and two adjacent first heat dissipation ribs 301 are arranged at intervals. In addition, a layer of high thermal conductivity material is attached to the inner side surface of the controller rear shell end portion 21 to accelerate the heat dissipation of the controller.

[0105] The second heat dissipation rib 302 is provided on the outer surface of the motor rear housing end 21 and surrounds the annular enclosure 77 .

[0106] In actual application, when the vehicle is driving, natural wind can flow along the first heat dissipation rib 301 and the second heat dissipation rib 302, so that the first heat dissipation rib 301 takes away the heat conducted from the controller to the end portion 21 of the rear shell of the controller, and the second heat dissipation rib 302 takes away the heat conducted from the motor and sensor assembly to the end portion 21 of the rear shell of the motor.

[0107] Continuing with FIG8 , the second heat dissipating ribs 302 include at least three arcuate heat dissipating ribs 3021 arranged in a circular array centered around the center of the annular panel 77. A linear heat dissipating rib 3022 is disposed between adjacent arcuate heat dissipating ribs 3021. Specifically, in this embodiment, three equally spaced arcuate heat dissipating ribs 3021 are disposed around the annular panel 77, corresponding to three linear heat dissipating ribs 3022. Each linear heat dissipating rib 3022 has one end connected to the peripheral surface of the annular panel 77 and the other end extending outward in the radial direction of the annular panel 77.

[0108] One of the three linear heat dissipation ribs 3022 is arranged along the length of the air-cooling outer plate 31 and is connected to the first heat dissipation rib 301. This allows the first heat dissipation rib 301 to dissipate heat from the controller rear housing end 21 while also directing some airflow to the motor rear housing end 21. This design optimizes the direction of airflow and improves heat dissipation. In this embodiment, the projection of the linear heat dissipation rib 3022 arranged along the length of the air-cooling outer plate 31, on the axis opposite to the motor rear housing end 21, coincides with the bottom groove 794.

[0109] In addition, the arrangement of the three arc-shaped heat dissipation ribs 3021 takes into account that the direction of natural wind is not single. Even when the vehicle is driving in a straight line at high speed, there are wind flows from the side, top, and bottom. Therefore, the arc-shaped heat dissipation ribs 3021 that bend upward and downward on the end part 21 of the rear shell of the motor can fully guide the wind flows from various wind directions, so that the second heat dissipation ribs 302 can more effectively dissipate the heat of the motor and sensor components.

[0110] Furthermore, the second heat dissipation rib 302 also includes an annular heat dissipation rib 3023, which is arranged on the side of the arc-shaped heat dissipation rib 3021 away from the annular enclosure 77. Its main purpose is to enable the second heat dissipation rib 302 to fully occupy the outer side surface of the motor rear shell end 21 and increase the heat dissipation area of ​​the motor rear shell end 21.

[0111] As shown in Figures 10 and 11, an inner sleeve 795 is provided on the inner side surface of the motor rear housing end 21, corresponding to the position of the output shaft 74. The central axis of the inner sleeve 795 passes through and communicates with the sensor mounting cavity 75, so that the magnetic head 792 provided at the end of the output shaft 74 can be located in the sensor mounting cavity 75, corresponding to the sensor chip 793. A plurality of reinforcing ribs 796 are connected between the inner sleeve 795 and the motor rear housing end 21. Specifically, the reinforcing ribs 796 are triangular rib structures, annularly arrayed on the circumferential surface of the inner sleeve 795, and assist in enhancing the axial rigidity of the inner sleeve 795 so as to better adapt to the stress characteristics of the housing. Compared with the method of thickening the inner sleeve 795 as a whole to improve strength, the use of reinforcing ribs 796 can effectively reduce the amount of housing material used, expand the gap between the housing and the internal winding of the motor, and facilitate the offline operation of the motor winding and its wiring processing.

[0112] As shown in Figure 10, an avoidance step 797 and a first bearing chamber 798 are formed on the inner wall of the inner sleeve 795 from top to bottom along the axial direction, wherein the avoidance step 797 is used to avoid the shaft step on the output shaft 74 for fixing the rotor structure 73, and the first bearing chamber 798 is equipped with a first bearing 799; a second bearing chamber 7910 is provided on the inner side surface of the front housing end 12 of the motor at a position corresponding to the inner sleeve 795, and a second bearing 7911 is equipped in the second bearing chamber 7910, one end of the output shaft 74 is connected to the first bearing 799, and the other end passes through the second bearing 7911 and extends out of the housing.

[0113] Fourth embodiment

[0114] As shown in FIG1 and FIG12 , the electric motorcycle power system of the fourth embodiment differs from the first embodiment in that the electric motorcycle power system further includes:

[0115] A reducer 91 , the reducer 91 being located on one side of the motor front housing end 22 and connected to the output shaft 74 ;

[0116] The wheel 92 is located on a side of the reducer 91 away from the motor front housing end 22 , and the reducer 92 is drivingly connected to the wheel 92 .

[0117] The controller assembly is arranged in the X-axis direction of the motor assembly, and the reducer 91 is arranged in the Y-axis direction of the motor assembly and is located in the center of the wheel 92, which can effectively utilize the space in the Y-axis direction of the entire vehicle. The advantage is that when designing a four-wheel off-road electric motorcycle, a narrower wheel 92 spacing can be selected, thereby greatly reducing the design weight of the entire vehicle and obtaining a lighter product.

[0118] Furthermore, the wheel 92, the speed reducer 91, and the motor housing 20 are coaxially arranged and arranged in sequence along the axis of the motor housing 20. By defining the installation method of the wheel 92, the speed reducer 91, and the motor housing 20, the electric motorcycle power system can be assembled in the same direction, thereby improving its production efficiency.

[0119] Specifically, screw holes 96 are provided on the periphery of the reducer 91, and through holes 97 corresponding to the screw holes 96 are provided on the motor rear shell end 21 and the motor front shell end 22, so that bolts pass through the through holes 97 on the motor rear shell end 21 and the motor front shell end 22 in sequence to connect with the screw holes 96, thereby realizing the assembly of the reducer 91 on the motor housing 10.

[0120] The wheel 92 includes an inner ring and an outer ring, wherein the inner ring and the outer ring are connected via spokes, and the reducer 91 is connected to the inner ring via splines.

[0121] In order to reduce the size of the electric motorcycle power system in the axial direction of the motor housing 20, further, the reducer 91 is located on the inner side of the wheel 92. Furthermore, the reducer 91 is arranged in the center of the wheel 92. Specifically, the inner circle of the wheel 92 forms a shielding area, and the reducer 91 is located in the center of the shielding area. By limiting the position of the reducer 91 on the wheel 92, after the electric motorcycle power system is assembled, the reducer 91 is located in the shielding area, avoiding excessive exposure of the reducer 91 to the outside of the axial direction of the wheel 92, thereby causing it to occupy a larger volume in the axial direction of the wheel 92.

[0122] The electric motorcycle power system also includes:

[0123] Frame body;

[0124] A connecting member, through which the frame body supports and connects the integral front shell structure and the integral rear shell structure, and the connecting member is arranged on at least one side of the integral front shell structure and / or the integral rear shell structure in the axial direction.

[0125] Specifically, referring to FIG1 , the connecting member includes:

[0126] A suspension link 93 is provided with a shock-absorbing spring along its length. One end of the suspension link 93 is connected to the frame body, and the other end of the suspension link 93 is connected to the motor housing 20. The suspension link 93 connects the frame body and the housing and can cooperate with the shock-absorbing spring to buffer external forces acting on the wheel 92.

[0127] A fixed link 94 , one end of which in the length direction is connected to the frame body, and the other end of which in the length direction is connected to the integral front shell structure and the integral rear shell structure.

[0128] In order to improve the connection strength between the suspension link 93 and the main shell, it is also convenient for disassembly and maintenance between the frame and the main shell.

[0129] Furthermore, the connecting piece further comprises:

[0130] The connecting bracket 95 is used to detachably connect the suspension link 93 to the motor housing 20 .

[0131] Referring to FIG1 , specifically, the connecting bracket 95 is triangular in shape, one corner of which is bolted to one end of the suspension link 93 in the longitudinal direction. The suspension link 93 is connected to the side of the motor housing 20 facing away from the controller housing 10. The other two corners of the connecting bracket 95 are spaced apart along the circumference of the motor housing 20 and are bolted to the motor housing 20. The triangular shape of the connecting bracket 95 provides better support stability when connecting the suspension link 93 and the motor housing 20 due to its shape.

[0132] Fifth embodiment

[0133] As shown in FIG3 and FIG4 , the assembly method of the glue potting structure of the fifth embodiment includes the following steps:

[0134] Place the controller housing vertically on the ground so that the glue filling port on the end of the controller rear shell is located directly above the wire outlet;

[0135] Filling thermal conductive glue from the glue filling port at the end of the controller rear shell until the liquid level of the thermal conductive glue closes the lead-in port of the anti-overflow plate and then stops filling;

[0136] After the thermal conductive glue poured into the controller housing for the first time is solidified, the glue is poured a second time through the glue pouring port until the liquid level of the thermal conductive glue is consistent with the height of the glue pouring port, and then the glue pouring is stopped;

[0137] After the thermal conductive glue poured into the controller housing for the second time is solidified, the glue pouring process of the controller housing is completed.

[0138] The controller housing is potted with glue in a vertical state, so the liquid level of the thermal conductive glue gradually rises along the radial direction of the controller housing. Compared with the existing solution of potting the controller housing in a horizontal state, this avoids the influence of the viscosity and tension of the thermal conductive glue, which may cause insufficient filling of the gap between the end of the controller front shell and the controller component. This design helps to ensure that the thermal conductive glue can fully fill the entire controller housing, including the gap between the circuit board, thereby better ensuring the efficiency of heat transfer and further improving the heat dissipation performance and service life of the controller.

[0139] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0140] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. An electric motorcycle power system, characterized in that, It includes a motor housing and a controller housing provided on one side of the motor housing. The controller housing includes a controller front housing end portion, a controller rear housing end portion, and a controller housing edge portion connecting the two. A controller assembly is provided between the controller front housing end portion and the controller rear housing end portion. A potting port and a wire outlet are provided on the controller rear housing end portion. The potting port is located at one end in the radial direction on the surface of the controller rear housing end portion, and the wire outlet is located at the other end in the radial direction on the surface of the controller rear housing end portion. An anti-overflow plate is provided on the outer side surface of the controller rear housing end portion corresponding to the wire outlet. A wire lead port facing the potting port is formed between the anti-overflow plate and the controller rear housing end portion.

2. The electric motorcycle power system according to claim 1, characterized in that, The two ends of the controller assembly in the radial direction are respectively arranged at intervals from the controller housing to form a potting channel opposite to the potting port and a wire lead channel opposite to the wire outlet.

3. The electric motorcycle power system according to claim 2, characterized in that, The controller assembly includes a controller body, a circuit board provided on the controller body, and a second wire harness connected to the circuit board. The second wire harness passes through the wire lead port of the anti-overflow plate along the wire lead channel and exits the controller housing.

4. The electric motorcycle power system according to claim 1, wherein The anti-overflow plate includes a top cover and a left limiting portion, a rear limiting portion, and a right limiting portion continuously provided along the periphery of the top cover. The wire lead port facing the potting port direction is formed at one end of the left limiting portion and the right limiting portion away from the rear limiting portion.

5. The electric motorcycle power system according to claim 1, characterized in that, The motor housing includes a motor front housing end portion, a motor rear housing end portion, and a motor housing edge portion. The motor front housing end portion is integrally connected to one side in the horizontal direction of the controller front housing end portion to form an overall front housing structure. The motor rear housing end portion is integrally connected to one side in the horizontal direction of the controller rear housing end portion to form an overall rear housing structure. The motor housing edge portion is integrally connected to one side in the horizontal direction of the controller housing edge portion to form an overall housing edge structure for connecting the overall front housing structure and the overall rear housing structure. A motor assembly is provided between the motor front housing end portion and the motor rear housing end portion. The motor assembly and the controller assembly are arranged horizontally at intervals.

6. The electric motorcycle power system according to claim 5, characterized in that, The motor rear housing end portion and the controller rear housing end portion are coplanar and form an air-cooled outer vertical plate.

7. The electric motorcycle power system according to claim 5, characterized in that, The motor assembly includes an output shaft, a stator structure, and a rotor structure. The output shaft is rotatably arranged in the motor housing and one end extends out of the motor front housing end portion. The stator structure includes a first stator provided on the motor rear housing end portion and a second stator provided on the motor front housing end portion. The rotor structure is arranged between the first stator and the second stator and is fixedly connected to the output shaft.

8. The electric motorcycle power system according to claim 7, characterized in that, The stator structure, the rotor structure, and the output shaft form an axial flux motor. The buckling direction of the overall front housing structure and the overall rear housing structure is the same as the axial direction of the axial flux motor.

9. The electric motorcycle power system according to claim 7, wherein, A sensor mounting cavity is recessed in the motor rear housing end portion corresponding to the position of the output shaft. A sensor assembly is arranged in the sensor mounting cavity and is closed by a cover plate.

10. The electric motorcycle power system according to claim 9, wherein, The end of the motor rear shell protrudes outward at the position corresponding to the output shaft to form an annular enclosure surrounding the sensor installation cavity, the cover plate is fixed on the end face of the annular enclosure, the inner wall of the sensor installation cavity protrudes inward to form a limiting step, and the supporting surface of the limiting step is flush with the cover plate and is spaced apart.

11. The electric motorcycle power system according to claim 10, characterized in that, The sensor assembly includes a control circuit board, a magnetic head and a sensor chip. The control circuit board is horizontally arranged on the limiting step. The magnetic head is embedded in one end of the output shaft facing the control circuit board. The sensor chip is arranged on the control circuit board and opposite to the magnetic head.

12. The electric motorcycle power system according to claim 11, characterized in that, The inner side surface of the end of the rear shell of the motor is provided with a wire passing bottom groove, one end of the wire passing bottom groove extends into the sensor installation cavity, and the other end extends to the edge of the end of the rear shell of the motor. The side of the control circuit board facing away from the sensor chip is connected to the signal line, and the signal line passes through the side wall of the sensor installation cavity and is routed to the controller housing through the wire passing bottom groove.

13. The electric motorcycle power system according to claim 12, wherein, The outer side surfaces of the motor rear shell end and the controller rear shell end are provided with heat dissipation structures, and the projection of part of the heat dissipation structure in the axial direction of the motor housing coincides with the bottom groove of the wire.

14. The electric motorcycle power system according to claim 7, characterized in that, Also includes: A reducer, the reducer is located at one side of the end of the front housing of the motor and connected to the output shaft; The wheel is located at a side of the reducer away from the end of the front housing of the motor, and the reducer is drivingly connected to the wheel.

15. The electric motorcycle power system according to claim 7, characterized in that, A first power lead is provided on the first stator, a second power lead is provided on the second stator, a wire passing channel is provided between the motor assembly and the controller assembly, the first power lead and the second power lead are electrically connected to the controller assembly through the wire passing channel, and the projections of the first power lead and the second power lead in the axial direction of the shell do not overlap.

16. The electric motorcycle power system according to claim 15, characterized in that, It also includes a wire separator plate arranged on the controller component, and the wire separator plate is provided with a plurality of first limit buckles, and the first limit buckles are used to fix the first power lead wire. The end of the front shell of the controller is provided with a plurality of second limit buckles, and the second limit buckles are used to fix the second power lead wire.

17. The electric motorcycle power system according to claim 16, wherein, The orthographic projection of the second limit buckle on the separator plate does not overlap with the first limit buckle.

18. The electric motorcycle power system according to claim 15, characterized in that, A wiring floating plate is detachably connected to the wiring passage, and a plurality of wire threading holes are provided on the wiring floating plate. The wire threading holes are configured to be suitable for the first power lead wire and the second power lead wire to pass through.

19. A potting process for an electric motorcycle power system, characterized in that, The electric motorcycle power system applied to any one of claims 1 to 18 above, wherein the glue pouring process of the electric motorcycle power system comprises: Place the controller housing vertically on the ground so that the glue injection port on the end of the controller rear housing is located directly above the wire outlet; Filling the thermal conductive glue from the glue filling port at the end of the rear shell of the controller until the liquid level of the thermal conductive glue closes the lead-in port of the anti-overflow plate and then stops filling the glue; After the thermal conductive adhesive filled into the controller housing for the first time is cured, secondary filling is carried out through the filling port until the liquid level of the thermal conductive adhesive is consistent with the height of the filling port, and then the filling stops. After the thermal conductive adhesive filled into the controller housing for the second time is cured, the filling process of the controller housing is completed.

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