Lead-out wire for hub motor used in new energy vehicle, hub motor, and new energy vehicle

Abstract

The present invention provides a lead-out wire for a hub motor used in a new energy vehicle, a hub motor, and a new energy vehicle. The lead-out wire comprises a cable, a sealing sleeve, and a waterproof sleeve; the cable and a wire passing hole in a motor shaft can be sealed by means of the sealing sleeve, thereby achieving a waterproof effect at a motor connecting end of the lead-out wire; one end of a ventilation gap in the cable can be sealed by means of the waterproof sleeve, thereby achieving a waterproof effect at a controller connecting end of the lead-out wire; and a waterproof isolation layer is provided in the cable, so that the waterproof effect of the cable can be further improved. In addition, at the controller connecting end, a portion of the elastic waterproof sleeve is supported by using bent core wires so as to form a ventilation channel communicated with the ventilation gap in the cable, thereby ensuring that the hub motor can still be ventilated with the outside, and because the ventilation channel is formed by ingeniously using the shape and hardness of the core wires and the elasticity of the waterproof sleeve, the waterproof sleeve has a simple structure and is easy to manufacture, the number of the whole parts is smaller, and assembly and maintenance are more convenient.

Description

Hub motor lead-out wire, hub motor and new energy vehicle for new energy vehicle TECHNICAL FIELD

[0001] The application belongs to the technical field of hub motor accessories, and particularly relates to a hub motor lead-out wire, a hub motor and a new energy vehicle for a new energy vehicle. BACKGROUND

[0002] The hub motor integrates a driving device, a transmission device and a braking device into a hub, omits transmission components such as a clutch, a transmission, a transmission shaft, a differential and a transfer, greatly simplifies the mechanical part of an electric vehicle, is conducive to reducing the cost and energy consumption of the vehicle, and enables the subsequent maintenance of the vehicle to be simpler. At present, not only electric two-wheel vehicles widely adopt the hub motor, but also more and more new energy vehicle manufacturers begin to use or consider using the hub motor in new energy vehicles (electric vehicles) to reduce the energy consumption of the new energy vehicles and improve the endurance thereof.

[0003] The hub motor comprises a hub motor body and a lead-out wire. The hub motor body is usually designed in a closed waterproof manner, a wire hole is formed in a motor shaft of the hub motor body, one end of the lead-out wire is connected with a motor winding inside the hub motor body by penetrating through the wire hole, and the other end of the lead-out wire is connected with an external controller outside the hub motor body. At present, the dustproof and waterproof standard of the new energy vehicle has reached IP67, and the hub motor structure described above is difficult to meet such a standard in terms of waterproof grade, and has the following two problems:

[0004] On the one hand, the outer sheath material of the lead-out wire of the hub motor is usually PVC, and is fixed in the wire hole of the motor shaft by means of glue injection, and silicon glue is usually used. The instantaneous current of the lead-out wire is large during use, and can reach more than 30A. Correspondingly, the lead-out wire is obviously heated, and the maximum temperature can reach 180-200 DEG C. Under high temperature, the sheath will soften and deform, and the bonding points between the silicon glue, the sheath and the wire hole will also crack, thereby affecting the waterproof sealing effect.

[0005] On the other hand, an air exchange gap is usually left in the lead-out wire, so that the hub motor body inside and outside can be ventilated, and the air pressure inside the hub motor body is adjusted. At one end of the lead-out wire connected with the controller, a plurality of phase wires and signal wires extend from one end of the sheath to the outside and are connected with the controller. At this end, the air exchange gap is exposed. When the hub motor body inhales air from the outside, negative pressure is generated in the air exchange gap. At this time, water droplets adhering to the phase wires or the signal wires will be sucked into the air exchange gap due to the negative pressure, and then enter the hub motor body inside.

[0006] Therefore, in order to enable the hub motor to be better applied to the new energy vehicle, a hub motor structure capable of achieving a higher waterproof effect is required at present. SUMMARY

[0007] The application is to solve the above problems, and aims to provide a kind of wheel hub motor lead-out line and wheel hub motor of new energy vehicle, which can realize more high-level comprehensive waterproof effect, and can be applied to new energy vehicle, the application adopts the following technical scheme:

[0008] The application provides a kind of wheel hub motor lead-out line for new energy vehicle, for connecting the motor winding in wheel hub motor with external controller, motor shaft of the wheel hub motor has wire hole, it has such technical features, the wheel hub motor lead-out line for new energy vehicle includes: cable, with multiple core wires, waterproof isolation layer covered in the outer layer of the core wire and sheath covered in the outer layer of the waterproof isolation layer, the waterproof isolation layer has ventilation gap in it;Sealing sleeve, set on the cable and close to the cable for connecting one end of the motor winding, for waterproof sealing between the cable and the wire hole;And waterproof cover, set on the cable and close to the cable for connecting one end of the controller, for shielding the ventilation gap, wherein the waterproof cover is made of elastic material, at least one core wire has bending portion and extension portion connected with the bending portion and extending to the outside of the sheath, the extension portion is used to cooperate with the waterproof cover, so that the waterproof cover and the sheath form ventilation passage communicated with the ventilation gap.

[0009] The wheel hub motor lead-out line for new energy vehicle provided by the application can also have the following technical features, wherein the waterproof isolation layer is waterproof yarn, the sealing sleeve is vulcanized rubber sleeve, and the waterproof cover is silicone rubber sleeve.

[0010] The wheel hub motor lead-out line for new energy vehicle provided by the application can also have the following technical features, wherein the multiple core wires include multiple phase lines and at least one signal line, the waterproof cover has: sheath covering part, with protection cavity, for covering one end of the sheath;And multiple core wire covering parts, respectively set on one end of the sheath covering part and having wire hole communicated with the protection cavity, respectively for covering the multiple phase lines, the signal line has the bending portion and the extension portion, and the extension portion cooperates with the sheath covering part to form the ventilation passage.

[0011] The wheel hub motor lead-out line for new energy vehicle provided by the application can also have the following technical features, wherein the side wall of the sheath covering part is cylindrical, and the sheath covering part has: notch, set on one end of the side wall away from the core wire covering part;And channel forming portion, located on one side of the notch along the axial direction of the sheath covering part, and the extension portion of the signal line is used to support the channel forming portion, so as to form the ventilation passage between the channel forming portion and the outer surface of the sheath.

[0012] The new energy vehicle wheel hub motor lead-out wire provided by the application can also have the following technical features: the sealing sleeve has a sleeve fixing part that is sleeved on the cable and is in interference fit with the cable; at least one elastic sealing part is formed on the outer periphery of the sleeve fixing part and used for abutting against the inner wall of the wire hole, the circumferential section of the elastic sealing part is a right-angled triangle or an acute-angled triangle, and the outer edge of the elastic sealing part has a rounded corner.

[0013] The new energy vehicle wheel hub motor lead-out wire provided by the application can also have the following technical features: the sealing sleeve has at least three elastic sealing parts, and two adjacent elastic sealing parts are arranged at intervals, and each elastic sealing part has a tapered ring-shaped guide end surface used for guiding the sealing sleeve when the sealing sleeve is inserted into the wire hole.

[0014] The new energy vehicle wheel hub motor lead-out wire provided by the application can also have the following technical features: the new energy vehicle wheel hub motor lead-out wire further comprises a protective sleeve made of wear-resistant material, which is sleeved on the cable and close to the sealing sleeve and is in interference fit with the cable, and is used for preventing the cable from contacting the hole end edge of the wire hole, wherein the outer diameter of the protective sleeve is smaller than the inner diameter of the wire hole.

[0015] The new energy vehicle wheel hub motor lead-out wire provided by the application can also have the following technical features: the protective sleeve is a vulcanized rubber sleeve.

[0016] The application provides a wheel hub motor arranged in a new energy vehicle, which has the following technical features: the wheel hub motor comprises a wheel hub motor body having a motor shell and a motor winding arranged inside the motor shell, and the new energy vehicle wheel hub motor lead-out wire described above is used for connecting the motor winding and a controller outside the motor shell.

[0017] The application provides a new energy vehicle, which has the following technical features: the new energy vehicle comprises the wheel hub motor described above.

[0018] Inventive action and effect

[0019] The new energy vehicle wheel hub motor lead-out wire, the wheel hub motor and the new energy vehicle according to the application, the lead-out wire comprises a cable, a sealing sleeve arranged at one end of the cable and a waterproof sleeve arranged at the other end of the cable, the sealing sleeve can be used to waterproofly seal the cable and the wire hole on the motor shaft, thereby realizing the waterproof effect of the motor connecting end of the lead-out wire; the waterproof sleeve can be used to shield one end of the air exchange gap in the cable, thereby realizing the waterproof effect of the controller connecting end of the lead-out wire; and a waterproof isolation layer is arranged in the cable, which can further improve the waterproof effect of the cable, that is, even if the outermost sheath of the cable is damaged to a certain extent, the waterproof effect can still be realized through the waterproof isolation layer, thereby ensuring the normal operation of the wheel hub motor. Further, at the controller connecting end, at least one core wire is bent, and the bent core wire is used to support a small part of the elastic waterproof sleeve to form an air exchange channel in communication with the air exchange gap in the cable, thereby ensuring that the wheel hub motor can still exchange air with the outside, and since the core wire form and hardness and the material elasticity of the waterproof sleeve are ingeniously utilized to form the air exchange channel, the waterproof sleeve structure is simple and easy to manufacture, and the overall component quantity of the lead-out wire is also less, and the assembly and maintenance are more convenient.

[0020] As described above, through the new energy vehicle wheel hub motor lead-out wire according to the application, omnidirectional and higher-level waterproof effects can be realized, and the wheel hub motor can still exchange air with the outside. BRIEF DESCRIPTION OF DRAWINGS

[0021] Fig. 1 is a sectional view of the partial structure of the wheel hub motor in the embodiment of the application;

[0022] Fig. 2 is a sectional view of the motor shaft in the embodiment of the application;

[0023] Fig. 3 is a side view of the motor connecting end of the new energy vehicle wheel hub motor lead-out wire in the embodiment of the application;

[0024] Fig. 4 is a side view of the controller connecting end of the new energy vehicle wheel hub motor lead-out wire in the embodiment of the application;

[0025] Fig. 5 is a perspective view of the sealing sleeve in the embodiment of the application;

[0026] Fig. 6 is a sectional view of the sealing sleeve in the embodiment of the application;

[0027] Fig. 7 is a sectional view of the protective sleeve in the embodiment of the application;

[0028] Fig. 8 is a sectional view of the motor connecting end of the new energy vehicle wheel hub motor lead-out wire in the embodiment of the application in use;

[0029] Fig. 9 is an assembly flowchart of the motor connecting end of the new energy vehicle wheel hub motor lead-out wire in the embodiment of the application;

[0030] Fig. 10 is a perspective view of the waterproof sleeve in the embodiment of the present application;

[0031] Fig. 11 is a cross-sectional view I of the waterproof sleeve in the embodiment of the present application;

[0032] Fig. 12 is a cross-sectional view II of the waterproof sleeve in the embodiment of the present application;

[0033] Fig. 13 is a cross-sectional view of the controller connection end of the new energy vehicle wheel hub motor lead-out wire in use in the embodiment of the present application;

[0034] Fig. 14 is an assembly flowchart of the controller connection end of the new energy vehicle wheel hub motor lead-out wire in the embodiment of the present application.

[0035] Fig. 13 is a cross-sectional view of the controller connection end of the new energy vehicle wheel hub motor lead-out wire in use in the embodiment of the present application; DETAILED DESCRIPTION

[0036] In order to make the technical means, creative features, purposes and effects of the present application easy to understand, the new energy vehicle wheel hub motor lead-out wire, wheel hub motor assembly and new energy vehicle of the present application will be specifically described below in combination with embodiments and drawings.

[0037] <EMBODIMENT>

[0038] The present embodiment provides a new energy vehicle which adopts a wheel hub motor as a power device. The structure of the wheel hub motor will be specifically described below, and other structures of the new energy vehicle can adopt corresponding structures in the prior art.

[0039] Fig. 1 is a cross-sectional view of part of the structure of the wheel hub motor in the present embodiment.

[0040] As shown in FIG. 1, the wheel hub motor 100 comprises a wheel hub motor lead-out wire 10 (hereinafter referred to as lead-out wire 10) for a new energy vehicle and a wheel hub motor body 20.

[0041] The wheel hub motor body 20 comprises a motor housing 21, a motor shaft 22 passing through the motor housing 21, and a motor winding and internal lead wire, etc. (not shown in the figure) arranged inside the motor housing 21.

[0042] One end of the motor shaft 22 protrudes outside the motor housing 21, one end of the lead-out wire 10 passes through the wire hole on the motor shaft 22 into the motor housing 21 and is electrically connected with the motor winding, and the other end of the lead-out wire 10 is located outside the motor housing 21 and is electrically connected with the external controller.

[0043] FIG. 2 is a cross-sectional view of the motor shaft in the present embodiment.

[0044] As shown in FIG. 2, the motor shaft 22 is provided with a wire hole 221 for the lead-out wire 10 to pass through. The wire hole 221 comprises a first hole section 2211 and a second hole section 2212, both of which have a substantially circular axial cross-section and substantially the same inner diameter. One end of the first hole section 2211 is located at one end of the motor shaft 22, i.e. outside the motor housing 21, and forms a penetration opening 221a at one end of the motor shaft 22, and the other end of the first hole section 2211 is located at the middle of the motor shaft 22 and communicates with one end of the second hole section 2212. The other end of the second hole section 2212 is located at the side of the motor shaft 22 and forms a penetration opening 221b at the side. Moreover, the extension direction of the first hole section 2211 is substantially the axial direction of the motor shaft 22, and the extension direction of the second hole section 2212 is inclined relative to the extension direction of the first hole section 2211, and the included angle between the two is obtuse, i.e. a bending portion is formed between the first hole section 2211 and the second hole section 2212.

[0045] In addition, the motor shaft 22 is also provided with a glue injection hole 222, and the extension direction of the glue injection hole 222 is substantially the radial direction of the motor shaft 22. The inner diameter of the glue injection hole 222 is much smaller than the inner diameter of the wire hole 221. One end of the glue injection hole 222 communicates with the first hole section 2211, and the other end of the glue injection hole 222 is located at the side of the motor shaft 22 and forms a glue injection opening 222a at the side. One glue injection hole 222 is shown in the figure, and more glue injection holes 222 can be provided according to actual needs, but considering the overall structural strength of the motor shaft 22, the number of glue injection holes 222 should not be too many.

[0046] The lead-out wire structure of the present embodiment will be described in detail below in combination with the structure of the motor shaft 22.

[0047] FIG. 3 is a side view of the motor connection end of the wheel hub motor lead-out wire for a new energy vehicle in the present embodiment, and FIG. 4 is a side view of the controller connection end of the wheel hub motor lead-out wire for a new energy vehicle in the present embodiment.

[0048] As shown in FIG. 3 and FIG. 4, one end of the lead-out wire 10 is a motor connection end 10a for extending into the inside of the hub motor body 20 through the wire hole 221 on the motor shaft 22; the other end of the lead-out wire 10 is a controller connection end 10b for connecting to an external controller.

[0049] The lead-out wire 10 includes a cable 11, which includes a sheath 111, an insulating layer, a water-blocking isolation layer (not shown in the figure), and a plurality of core wires. The plurality of core wires are arranged in close contact with each other, the water-blocking isolation layer is wrapped outside the plurality of core wires, the insulating layer is further wrapped outside the water-blocking isolation layer, and the sheath 111 is further wrapped outside the insulating layer. The material of the sheath 111 is chlorinated polyethylene (CPE), which has the characteristics of high temperature resistance and wear resistance. The material of the insulating layer is fluoroplastic. The water-blocking isolation layer is a water-blocking yarn material, which can play a waterproof sealing role. A certain air exchange gap is left between the water-blocking isolation layer and the plurality of core wires. The air exchange gap penetrates along the extension direction of the cable 11 and communicates with the inside of the hub motor body 20, so that the hub motor body 20 can exchange air with the outside through the air exchange gap.

[0050] In this embodiment, the plurality of core wires include three phase wires 112 and four signal wires 113, wherein the three phase wires 112 have the same outer diameter and relatively thick outer diameter, and the four signal wires 113 have the same outer diameter and outer diameter much smaller than that of the phase wires 112. The phase wires 112 and the signal wires 113 each include one or more conductor wires inside and a protective insulating layer wrapped outside the conductor wires, and the protective insulating layer has certain elasticity and hardness. The protective insulating layers of the three phase wires 112 are respectively colored differently for easy identification, and the protective insulating layers of the four signal wires 113 are also respectively colored differently.

[0051] The structure of the two ends of the lead-out wire 10 will be described in detail below.

[0052] As shown in FIG. 3, at the motor connection end 10a, a sealing sleeve 12 and a protective sleeve 13 are arranged on one end of the cable 11.

[0053] FIG. 5 is a perspective view of the sealing sleeve in this embodiment, and FIG. 6 is a sectional view of the sealing sleeve in this embodiment.

[0054] As shown in FIG. 5 and FIG. 6, the sealing sleeve 12 is used to realize the sealing between the cable 11 and the wire hole 221. The sealing sleeve 12 is made of rubber and vulcanized on the cable 11, which has certain elasticity and is waterproof. The sealing sleeve 12 includes a sleeve joint fixing part 121, a guide end part 122, and a plurality of elastic sealing parts 123 formed integrally.

[0055] The sleeve fixing portion 121 is used for sleeving on the cable 11, and is substantially cylindrical, that is, the inside of the sealing sleeve 12 has a through hole 121a with a circular cross section for sleeving.

[0056] The guide end portion 122 is used for guiding when the cable 11 is inserted through the wire hole 221, so that the cable 11 is more easily inserted. The guide end portion 122 is formed on one end of the sleeve fixing portion 121 in the axial direction, and is annular, with a cross section in the circumferential direction being triangular. In the direction D1 in the drawing (that is, in the axial direction of the sealing sleeve 12 from one end having the guide end portion 122 to the other end), the thickness of the guide end portion 122 gradually increases.

[0057] The elastic sealing portion 123 is used for achieving waterproof sealing between the cable 11 and the wire hole 221 by elastic deformation. A plurality of elastic sealing portions 123 are formed on the outer circumferential surface of the sleeve fixing portion 121, and are spaced apart from each other. Each elastic sealing portion 123 is annular, with a cross section in the circumferential direction being a right-angled triangle with a round corner, so that the elastic sealing portion 123 has a second guide end surface 1231 which is conical annular. In an alternative, the cross section in the circumferential direction of the elastic sealing portion 123 can also be an acute-angled triangle. In the direction D1 in the drawing, the thickness of the elastic sealing portion 123 gradually increases, that is, in the position of the elastic sealing portion 123, the outer diameter of the sealing sleeve 12 gradually increases in the direction D1, and the inclination direction of the second guide end surface 1231 is substantially the same as that of the first guide end surface 1221 of the guide end portion 122. In addition, the outer edge 1232 of the elastic sealing portion 123 has a round corner, so that the outer edge 1232 is more easily formed into a smooth annular surface when subjected to radial pressure, and the stress on the annular surface can be transmitted in the radial direction to the sleeve fixing portion 121. A shallow annular groove 1233 is formed between the adjacent elastic sealing portions 123, with a cross section in the circumferential direction being substantially trapezoidal, and the groove opening of the annular groove 1233 is the long side of the trapezoid.

[0058] In this embodiment, there are three elastic sealing portions 123 with the same size, and the spacing d3 between the adjacent elastic sealing portions 123 is substantially the same. The axial length l1 of the sealing sleeve 12 is relatively small, and is about 1 / 4 to 1 / 3 of the extension length of the first hole section 2211.

[0059] In the state without external force (that is, in the state without elastic expansion of the sealing sleeve 12), the outer diameter d2 of the elastic sealing portion 123 on the sealing sleeve 12 is slightly larger than the inner diameter of the wire hole 221.

[0060] Fig. 7 is a sectional view of the protective sleeve in this embodiment.

[0061] As shown in FIG. 7, the protective sleeve 13 is also made of rubber, vulcanized on the cable 11 close to the sealing sleeve 12 and further away from the lead-in end 11a relative to the sealing sleeve 12, and has certain elasticity and good wear resistance. The protective sleeve 13 is in a cylindrical shape, that is, the inside of the protective sleeve 13 has a through hole 13a with a circular cross section.

[0062] The axial length l2 of the protective sleeve 13 is relatively long, close to the extension length of the first hole section 2211. In addition, when sleeved on the cable 11, the protective sleeve 13 is spaced apart from the sealing sleeve 12 by a predetermined distance, so that when the sealing sleeve 12 is located in the second hole section 2212, the penetration opening 2211a is located at the protective sleeve 13, and when the position of the sealing sleeve 12 is adjusted within a certain range in the second hole section 2212, the penetration opening 2211a is always located at the protective sleeve 13 without directly contacting the protective sleeve 111 of the cable 11 before and after the protective sleeve 13.

[0063] FIG. 8 is a schematic diagram of the use state of the motor connection end of the lead-out wire of the wheel hub motor for new energy vehicles in the embodiment.

[0064] As shown in FIG. 8, based on the above size characteristics of the sealing sleeve 12, after the lead-out wire 10 penetrates through the wire hole 221, the sealing sleeve 12 is in interference fit with the wire hole 221, and one circle of the outer edge 1232 of the elastic sealing part 123 abuts against the inside of the wire hole 221, and the outer edge 1232 is elastically deformed to form an outer circumferential surface 1232a in a substantially annular shape, which abuts against the inside of the wire hole 221, so as to realize the sealing between the cable 11 and the wire hole 221.

[0065] Based on the above size characteristics of the protective sleeve 13, after the lead-out wire 10 penetrates through the wire hole 221, the penetration opening 2211a is located at the protective sleeve 13, and because the axial length of the protective sleeve 13 is relatively long, when the position of the sealing sleeve 12 is adjusted within a small range in the first hole section 2211, the penetration opening 2211a is always located at the protective sleeve 13, that is, the relatively sharp penetration opening 2211a (that is, one end edge of the first hole section 2211) does not directly contact the protective sleeve 111 of the cable 11, so as to avoid damaging the protective sleeve 111 of the cable 11 when the lead-out wire 10 is penetrated or its installation position is adjusted.

[0066] In this embodiment, the material of the sealing sleeve 12 is nitrile rubber (NBR), which has a wider temperature range for use, a long-term use temperature of 120°C, good low-temperature resistance, a minimum glass transition temperature of -55°C, good water resistance, air tightness, and oil resistance. In the above state without external force, the outer diameter d2 of the elastic sealing part 123 on the sealing sleeve 12 is about 0.7 mm to 1 mm larger than the inner diameter of the wire passing hole 221, the spacing d3 of the elastic sealing part 123 is about 3 mm, and the axial length l1 of the sealing sleeve 12 is 12 mm to 16 mm. After assembly, the outer diameter of the elastic sealing part 123 is the inner diameter of the wire passing hole 221.

[0067] The material of the protective sleeve 13 is nitrile rubber, which has a Shore hardness of 60A and has the characteristics of high temperature resistance and wear resistance. The outer diameter d5 of the protective sleeve 13 is about 0.5 mm smaller than the inner diameter of the wire passing hole 221, and the axial length l2 of the protective sleeve 13 is 30 mm to 50 mm.

[0068] In addition, waterproof glue, such as silicone, can be injected into the wire passing hole 221 through the glue injection hole 222a on the motor shaft 22 to fix the motor connection end 10a in the wire passing hole 221 and achieve secondary waterproof sealing between the cable 11 and the wire passing hole 221. According to the position of the glue injection hole 222 and the installation position of the sealing sleeve 12 in the wire passing hole 221, waterproof glue can be injected into one of the annular grooves 1233 of the sealing sleeve 12, in which case only a small amount of waterproof glue can achieve effective secondary waterproof sealing; or waterproof glue can be injected between the cable 11 segment in front of the sealing sleeve 12 and the wire passing hole 221, in which case waterproof glue can be provided in the first hole segment 2211 in front of the sealing sleeve 12 for better fixation. In addition, when there are multiple glue injection holes 222, waterproof glue can be provided in multiple annular grooves 1233 at the same time, or in one annular groove 1233 and in the first hole segment 2211 in front of the sealing sleeve 12.

[0069] That is, the hub motor 20 further includes at least one glue joint composed of waterproof glue, which is provided between the cable 11 and the wire passing hole 221 or between the sealing sleeve 12 and the wire passing hole 221, and is specifically located at the above glue injection position.

[0070] FIG. 9 is an assembly flowchart of the motor connection end of the hub motor lead-out wire for new energy vehicles in this embodiment.

[0071] As shown in FIG. 9, the motor connection end 10a of the lead-out wire 10 can be assembled onto the motor shaft 22 according to the following steps:

[0072] Step S1-1, the motor connection end 10a is inserted into the wire passing hole 221 from the insertion opening 2211a on the motor shaft 22.

[0073] Step S1-2, the lead-out wire 10 is continuously inserted into the wire hole 221 until the insertion opening 2211a is located at the middle of the protective sleeve 13, at this time the sealing sleeve 12 is located in the first hole section 2211 and close to the second hole section 2212, and the sealing sleeve 12 is in interference fit with the first hole section 2211 to achieve waterproof sealing.

[0074] Wherein, the first guide end face 1221 and the second guide end face 1231 on the sealing sleeve 12 guide the entry of the sealing sleeve 12 when the lead-out wire 10 is inserted, making it easier to install.

[0075] Step S1-3, the installation position of the sealing sleeve 12 in the first hole section 2211 is adjusted in a small range according to the need of glue injection.

[0076] That is, the position of the sealing sleeve 12 is adjusted in a small range so that the glue injection hole 22 is roughly aligned with one of the annular grooves 1233 on the sealing sleeve 12 or roughly aligned with the cable section in front of or behind the sealing sleeve 12.

[0077] Step S1-4, waterproof glue is injected into the wire hole 221 through the glue injection hole 222, so as to fix the motor connection end 10a in the wire hole 221 and achieve secondary waterproof sealing through the waterproof glue.

[0078] Through the above steps, the assembly of the motor connection end 10a of the lead-out wire 10 is completed, and good waterproof sealing effect between the motor connection end 10a and the motor shaft 22 is achieved.

[0079] As shown in FIG. 4, a waterproof sleeve 15 is provided on the controller connection end 10b of the cable 11.

[0080] At this end, the sheath 111 of the cable 11 is truncated, and a plurality of phase lines 112 and a plurality of signal lines 113 extend outward from the truncated end of the sheath 111 and are further separated from each other and connected to respective connection terminals of the controller, thus causing one end of the air gap to be exposed. The waterproof sleeve 15 is used to shield this end of the air gap, thereby achieving the waterproof effect of the controller connection end 10b.

[0081] FIG. 10 is a perspective view of the waterproof sleeve in the embodiment, FIG. 11 is a cross-sectional view I of the waterproof sleeve in the embodiment, and FIG. 12 is a cross-sectional view II of the waterproof sleeve in the embodiment.

[0082] As shown in FIGS. 10 to 12, the waterproof sleeve 15 is made of waterproof silicone rubber and includes an integrated sheath covering part 151 and a plurality of core wire covering parts 152. In the embodiment, the core wire covering parts 152 are three and are used to cover the three phase lines 112, respectively.

[0083] The sheath covering portion 151 is used to cover the outside of one end of the sheath 111. The side wall of the sheath covering portion 151 is cylindrical. A protection cavity 1511 is formed inside the sheath covering portion 151. In the absence of external force, the inner diameter d6 of the protection cavity 1511 is slightly larger than the outer diameter of the sheath 111, so that there is a certain gap between the sheath covering portion 151 and the sheath 111. The sheath covering portion 151 can be covered on the outer surface of the sheath 111, facilitating air permeation.

[0084] A substantially rectangular notch 1512 is formed on the side wall of the sheath covering portion 151 away from the core wire covering portion 152. The corners of the notch 1512 are rounded to prevent cracking due to stress concentration. The length l3 of the notch 1512 is about 1 / 3 to 1 / 2 of the axial length of the sheath covering portion 151, and the width w1 of the notch 1512 is about 1 / 2 of the outer diameter of the sheath covering portion 151. The part of the sheath covering portion 151 on one side of the length direction of the notch 1512 is a channel forming portion 1513. Since the length of the channel forming portion 1513 (the length along the axial direction of the sheath covering portion 151) is smaller than the length of other parts of the sheath covering portion 151, the channel forming portion 1513 is more prone to deformation than other parts.

[0085] One end of the sheath covering portion 151 in the axial direction is a circular opening, and the other end is a connecting end 1515. The shape of the connecting end 1515 is substantially a circular plate. Three circular through holes are formed on the connecting end 1515. The centers of the three through holes and the line connecting them form an equilateral triangle.

[0086] The three core wire covering portions 152 extend from the edges of the three through holes to the outside of the sheath covering portion 151. The extension direction is substantially the same as the axial direction of the sheath covering portion 151. The extension length is about 1 / 4 to 1 / 3 of the axial length of the sheath covering portion 151. There is a certain gap between adjacent two core wire covering portions 152. Each core wire covering portion 152 is substantially cylindrical. From the circumferential cross-section of the core wire covering portion 152, the outer edge of the outer end portion is rounded, and the outer edge at the connection position with the sheath covering portion 151 is also rounded, thereby forming a reinforcing portion 1522 at the connection position.

[0087] The core wire covering portion 152 has a threading hole 1521 passing through in the axial direction. One end of the threading hole 1521 communicates with the protection cavity 1511 and has a threading-in opening 1521a. The other end of the threading hole 1521 communicates with the outside and has a threading-out opening 1521b. From the circumferential cross-section of the core wire covering portion 152, the edge of the threading-in opening 1521a is rounded, and the edge of the threading-out opening 1521b is a right angle, thereby facilitating the threading of the phase wire 112 from the threading-in opening 1521a.

[0088] In the state without external force, the inner diameter d7 of the threading hole 1521 is slightly smaller than the outer diameter of the phase wire 112, so that the core wire covering part 152 can be tightly wrapped on the outer surface of the phase wire 112, and the thickness th2 of the core wire covering part 152 and its material can generate sufficient radial pressure on the phase wire 112, which can effectively prevent water from entering during long-term use. In addition, the thickness th2 of the core wire covering part 152 is substantially the same as the thickness th1 of the side wall of the sheath covering part 151.

[0089] From the circumferential cross section of the connecting end 1515, the edge of the connecting end 1515 is rounded, and the edge of the connecting end 1515 closest to each core wire covering part 152 is slightly convex outward along the axial direction of the sheath covering part 151, and a support part 15151 is formed at this position for supporting the connecting end of the core wire covering part 152. Because one side of the core wire covering part 152 is very close to the edge of the connecting end 1515, the connecting end of the core wire covering part 152 on this side is relatively more prone to cracking when deformed under force (for example, bent by force from the phase wire 112), so the support part 15151 is provided to solve this problem.

[0090] In this embodiment, the thickness th1 of the side wall of the sheath covering part 151 is 1 mm, the axial length of the sheath covering part 151 is 25-30 mm, the length l3 of the notch 1515 is 8-10 mm, the width w1 of the notch 1515 is 5-7 mm, and the inner diameter d6 of the protection cavity 1511 is about 3 mm larger than the outer diameter of the cable 11. The thickness th2 of the core wire covering part 152 is 1 mm, the inner diameter d7 of the threading hole 1521 is about 0.7-1 mm smaller than the outer diameter of the phase wire 112, and the length l4 of the threading hole 1521 is 5-7 mm.

[0091] FIG. 13 is a cross-sectional schematic view of the controller connecting end of the new energy vehicle hub motor lead-out wire in use in this embodiment.

[0092] As shown in FIG. 13, in use, the three phase lines 112 exposed from one end of the sheath 111 are respectively inserted into the three core line covering portions 152, and the one end of the sheath 111 is sleeved into the protection cavity 1511 of the sheath covering portion 151. The portions of the plurality of signal lines 113 outside the one end of the sheath 111 are bent, the bent portions 1131 of the signal lines 113 are arranged in the protection cavity 1511, one end of the signal lines 113 extends from the protection cavity 1511 to outside the sheath covering portion 151 through the gap 1512, and the extension portions 1132 connected with the bent portions 1131 of the signal lines 113 are arranged between the passage forming portion 1513 and the outer surface of the sheath 111. Since the signal lines 113 have a certain hardness and the signal lines 113 are multiple, the plurality of bent signal lines 113 prop up the passage forming portion 1513, and a small-scale ventilation passage 1513a is formed between the passage forming portion 1513 and the outer surface of the sheath 111.

[0093] One end of the ventilation passage 1513a communicates with the protection cavity 1511, that is, communicates with the ventilation gap 114 between the cores, and the other end of the ventilation passage 1513a communicates with the outside. The extension direction of the ventilation passage 1513a is substantially the extension direction of the signal lines 113 near the one end of the sheath 111, and the included angle between the extension direction and the axial direction of the one end of the sheath 111 (that is, the extension direction of the ventilation gap at the one end) is an acute angle. The cross section of the ventilation passage 1513a along the extension direction is substantially crescent-shaped, and the cross-sectional size of the ventilation passage 1513a gradually increases from the one end communicating with the protection cavity 1511 to the other end communicating with the outside.

[0094] When the hub motor is internally heated, the air in the hub motor is heated and expanded, so that a positive pressure is generated in the ventilation gap. At this time, the air in the hub motor can be sequentially discharged to the outside through the ventilation gap 114, the protection cavity 1511 and the ventilation passage 1513a. At the same time, since each phase line 112 is tightly wrapped by the corresponding core line covering portion 152, water from the outside cannot flow into the ventilation gap 114 along the phase line 112. Since the air is being discharged outward through the ventilation passage 1513a at this time, water from the outside cannot enter the hub motor from the ventilation passage 1513a.

[0095] Afterwards, when the wheel hub motor is internally cooled, the air inside the wheel hub motor shrinks due to the cooling, so that a negative pressure is generated in the air exchange gap 114, at this time, the external air can enter the wheel hub motor in turn through the air exchange channel 1513a, the protection cavity 1511 and the air exchange gap 114 under the action of the negative pressure. At the same time, since each phase wire 112 is tightly wrapped by the corresponding core wire wrapping part 152, the external water cannot flow into the air exchange gap 114 along the phase wire 112. In addition, since the inner diameter of one end of the air exchange channel 1513a is very small, and the angle between the extension direction of the air exchange channel 1513a and the extension direction of the air exchange gap 114 near the waterproof sleeve 15 is an acute angle with a small angle, at this time, the external water also cannot enter the wheel hub motor from the air exchange channel 1513a.

[0096] Fig. 14 is an assembly flow chart of the controller connection end of the wheel hub motor lead-out wire for new energy vehicles in the embodiment.

[0097] As shown in Fig. 14, the controller connection end 10b of the lead-out wire 10 can be connected with the controller according to the following steps:

[0098] Step S2-1, a part of the sheath 11 of the controller connection end 10b is cut off, so that a plurality of phase wires 112 and a plurality of signal wires 113 are exposed.

[0099] Step S2-2, the plurality of phase wires 112 are respectively inserted into the threading holes 1521 of the plurality of core wire wrapping parts 152 of the waterproof sleeve 15.

[0100] Step S2-3, the plurality of signal wires 113 are bent near the cut end of the sheath 111, so that the signal wires 113 form a bent part 1131 and an extension part 1132.

[0101] It can be understood that the execution order of Step S2-2 and Step S2-3 is not strictly required.

[0102] Step S2-4, the cut end of the sheath 111 and the bent part 1131 of the signal wire 113 are sleeved into the protection cavity 1511 of the sheath wrapping part 151, and the sheath wrapping part 151 wraps the end of the sheath 111.

[0103] Step S2-5, the relative positions of the waterproof sleeve 15, the sheath 111 and the plurality of signal wires 113 are adjusted, so that the extension part 1132 of the plurality of signal wires 113 is located between the channel forming part 1513 of the sheath wrapping part 15 and the sheath 111, at this time, the signal wire 113 slightly lifts the channel forming part 1513, so as to form an air exchange channel between the channel forming part 1513 and the outer surface of the sheath 111.

[0104] Step S2-6, the outer end of the plurality of phase lines 112 and the outer end of the plurality of signal lines 113 are connected to the corresponding connection terminals on the controller respectively.

[0105] Through the above steps, the assembly of the controller connection end 10b of the lead-out wire 10 is completed, and the waterproof sealing of the controller connection end 10b (at the branch position of the phase line 112 and the signal line 113) is realized, while not affecting the external ventilation of the hub motor body 20.

[0106] Effects of the embodiment

[0107] The hub motor lead-out wire, the hub motor and the new energy vehicle provided by the embodiment can realize all-round and higher-level waterproof effect, and do not affect the ventilation of the hub motor and the outside.

[0108] In the embodiment, the waterproof isolation layer is waterproof yarn, the sealing sleeve is vulcanized rubber sleeve, and the waterproof sleeve is silicone rubber sleeve, which are all conventional materials and mature related processes, so that the lead-out wire can be produced efficiently and in large quantities.

[0109] Further, the circumferential section of the elastic sealing part of the sealing sleeve is a right triangle, and the outer edge has a round corner, so that the sealing sleeve is more easily assembled into the through hole, and the outer edge is more easily formed into a flat ring shape when subjected to radial pressure, so that the elastic sealing part can be better attached to the inner wall of the through hole, and the edge of the elastic sealing part is not easily deformed after long-term use, so that better waterproof sealing effect can be achieved.

[0110] Further, the circumferential section of the elastic sealing part of the sealing sleeve is triangular, and has an inclined second guide end face, and the sealing sleeve also has a guide end part with an inclined first guide end face, so that when the sealing sleeve is installed from the opening of the first hole section of the wire passing hole, the first and second guide end faces can guide the sealing sleeve to enter the wire passing hole more easily, and the installation is more convenient.

[0111] Further, the sealing sleeve has three elastic sealing parts, so that even if one of the elastic sealing parts deteriorates or fails due to some reasons, the other two elastic sealing parts can still achieve a waterproof sealing effect.

[0112] Further, the protective sleeve is spaced apart from the sealing sleeve by a predetermined distance, so that no matter how much the sealing sleeve moves in the first hole section of the wire passing hole, the entry opening of the wire passing hole is always located at the protective sleeve, so that the installation position of the sealing sleeve in the wire passing hole can be conveniently adjusted, and the hole end edge of the wire passing hole does not directly contact the sheath of the cable when the sealing sleeve is installed and when the installation position of the sealing sleeve is adjusted, so that the relatively sharp hole end edge does not damage the sheath and affect the waterproof insulation effect of the cable. Moreover, the user does not need to worry about this problem when adjusting the installation position of the sealing sleeve, and the installation and adjustment of the sealing sleeve are more convenient and fast.

[0113] Further, the motor shaft also has a glue injection hole, and according to the position of the glue injection hole and the position of the sealing sleeve in the wire passing hole, silicone can be injected into the annular groove of the sealing sleeve or into the first hole section in front of or behind the sealing sleeve, so as to achieve secondary sealing between the cable and the wire passing hole, further improve the waterproof sealing effect, and the glue injection can also fix the cable, so that the cable and the wire passing hole are less likely to be separated, and the reliability of the hub motor is higher.

[0114] Further, the waterproof sleeve has a sheath covering part and a plurality of core wire covering parts, the sheath covering part is in interference fit with the sheath, and the core wire covering parts are in interference fit with the corresponding phase lines, so that the waterproof effect can be achieved, and the waterproof effect is not likely to deteriorate under the conditions of environmental temperature change and long-term use.

[0115] Further, a notch is formed on the sheath covering part of the waterproof sleeve to form a channel forming part, and the notch is rectangular, so that it is easy to process, and the length of the notch is 1 / 3 to 1 / 2 of the axial length of the sheath covering part, which is relatively small, so that the notch does not affect the tightness of the sheath covering part on the sheath, and in addition, the corner of the notch is rounded, so that cracking and other problems caused by stress concentration can be avoided, and the reliability of the cable connected to the waterproof sleeve is higher.

[0116] Further, the edge of the threading hole of the core wire covering part has a rounded corner, which can play a guiding role when the phase wire is threaded from the threading opening, so that the phase wire is easier to thread.

[0117] Further, a gap is left between the two adjacent core wire covering parts, and the core wire covering part can slightly bend along with the bending of the corresponding phase wire, so that surface defects caused by the side of the covered part of the phase wire being subjected to excessive stress due to the inability to bend can be avoided. In addition, the connecting position of the core wire covering part and the sheath covering part has a reinforcing part, and the outer edge of the connecting position has a supporting part, so that even when the core wire covering part is deformed along with the bending of the phase wire, the connecting position of the core wire covering part and the sheath covering part will not crack or the like. In this way, when the one end of the hub motor lead wire is connected with the controller, the wiring of the plurality of phase wires is less restricted.

[0118] The above embodiments are only used to illustrate the specific embodiments of the present application, and the present application is not limited to the description range of the above embodiments. Those skilled in the art should understand that the present application is not limited by the above embodiments, and the above embodiments and the description in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

[0119] For example, in the above embodiments, the phase wire is three, and the signal wire is four. In an alternative, the phase wire may, for example, be five, and correspondingly, the cable connection waterproof sleeve has five core wire covering parts, and the corresponding technical effects can also be achieved. The number of signal wires can also be less or more.

[0120] In the above embodiments, the side wall of the sheath covering part has a notch for forming the channel forming part, and the notch is a rectangular notch with rounded corners. In an alternative, the notch can also be other shapes, such as a trapezoidal notch with rounded corners.

[0121] In the above embodiments, the three phase wires have the same outer diameter, so the three core wire covering parts have the same size. In an alternative, according to the actual size of the plurality of core wires, the inner diameter and / or axial length of the plurality of core wire covering parts can also be set to be different, respectively matching each core wire.

[0122] In the above embodiments, the sealing sleeve has three elastic sealing parts. In an alternative, the sealing sleeve can also have more elastic sealing parts.

[0123] In the above embodiment, the cross section of the elastic sealing part on the sealing sleeve is substantially a right triangle, in an alternative, the cross section of the elastic sealing part can also be an acute triangle, or a right triangle or an acute triangle with a convex edge. Alternatively, the multiple turns of the elastic sealing part can also be a combination of different shapes, for example, the cross section of the first turn of the elastic sealing part from the leading end is a right triangle, and the cross section of the subsequent multiple turns of the elastic sealing part is an acute triangle.

[0124] In the above embodiment, the cable is sequentially provided with a sheath, an insulation layer, a waterproof isolation layer (waterproof yarn) and multiple core wires from the outer layer to the inner layer, in an alternative, the cable can also have other structures, for example, further having other intermediate layers, etc.

[0125] In the above embodiment, the wire passing hole on the motor shaft is a two-section structure, in an alternative, the wire passing hole on the motor shaft can also have other structures, for example, a circular arc-shaped wire passing hole.

Claims

1. A wheel hub motor lead wire for a new energy vehicle for connecting a motor winding in a wheel hub motor with an external controller, the motor shaft of the wheel hub motor having a wire passing hole, characterized in that, The in-out cable of the wheel hub motor of the new energy vehicle comprises: a cable having a plurality of core wires, a waterproof isolation layer covering the outer layer of the core wires, and a sheath covering the outer layer of the waterproof isolation layer, the waterproof isolation layer having a ventilation gap therein; a sealing sleeve arranged on the cable and close to one end of the cable for connecting the winding of the motor, for waterproof sealing between the cable and the wire hole; and a waterproof sleeve arranged on the cable and close to one end of the cable for connecting the controller, for shielding the ventilation gap, wherein the waterproof sleeve is made of an elastic material, at least one of the core wires has a bending portion and an extension portion connected with the bending portion and extending to the outside of the sheath, the extension portion is used for cooperating with the waterproof sleeve, so that the waterproof sleeve and the sheath form a ventilation channel communicating with the ventilation gap, the waterproof sleeve has a sheath covering portion for covering the outside of one end of the sheath, and the side wall thereof is in a cylindrical shape; a notch is formed on the side wall of one end of the sheath covering portion, the part of the sheath covering portion on one side of the notch is a channel forming portion with a length smaller than that of other parts of the sheath covering portion, one end of the core wire having the bending portion extends to the outside of the sheath covering portion through the notch, and the extension portion of the core wire is arranged between the channel forming portion and the outer surface of the sheath, supporting the channel forming portion, so as to form the ventilation channel between the channel forming portion and the outer surface of the sheath.

2. The in-out cable of the wheel hub motor of the new energy vehicle according to claim 1, wherein: wherein the waterproof isolation layer is waterproof yarn, the sealing sleeve is a butyronitrile rubber sleeve, and the waterproof sleeve is a silicone rubber sleeve.

3. The in-out cable of the wheel hub motor of the new energy vehicle according to claim 1, wherein: wherein, the plurality of core wires include a plurality of phase wires and at least one signal wire, the waterproof sleeve has: a sheath covering portion having a protection cavity for covering one end of the sheath; and a plurality of core wire covering portions respectively arranged at one end of the sheath covering portion and having a wire hole communicating with the protection cavity, for covering the plurality of phase wires, the signal wire has the bending portion and the extension portion, and the extension portion cooperates with the sheath covering portion to form the ventilation channel.

4. The in-out cable of the wheel hub motor of the new energy vehicle according to claim 3, wherein: wherein, the side wall of the sheath covering portion is in a cylindrical shape, the sheath covering portion has: a notch arranged at one end of the side wall away from the core wire covering portion; and a channel forming portion located on one side of the notch along the axial direction of the sheath covering portion, the extension portion of the signal wire is used for supporting the channel forming portion, so as to form the ventilation channel between the channel forming portion and the outer surface of the sheath.

5. The in-out cable of the wheel hub motor of the new energy vehicle according to claim 1, wherein: wherein the sealing sleeve has: a sleeve joint fixing portion jointed on the cable and in interference fit with the cable. At least one elastic sealing part is formed on the outer periphery of the sleeve fixing part, and is used to abut against the inner wall of the wire passing hole, The circumferential section of the elastic sealing part is a right triangle or an acute triangle, and the outer edge of the elastic sealing part has a round corner.

6. The new energy vehicle wheel hub motor lead-out wire according to claim 5, characterized in that: wherein The sealing sleeve has at least three elastic sealing parts, The adjacent two elastic sealing parts are arranged at intervals, Each elastic sealing part has a tapered ring-shaped guide end surface for guiding the sealing sleeve when the sealing sleeve penetrates into the wire passing hole.

7. The new energy vehicle wheel hub motor lead-out wire according to claim 1, characterized in that, Further comprising: A protective sleeve made of wear-resistant material, which is sleeved on the cable and close to the sealing sleeve, and is in interference fit with the cable, for preventing the cable from contacting the hole end edge of the wire passing hole, Wherein, the outer diameter of the protective sleeve is smaller than the inner diameter of the wire passing hole.

8. The new energy vehicle wheel hub motor lead-out wire according to claim 7, characterized in that: wherein The protective sleeve is a vulcanized rubber sleeve.

9. A wheel hub motor arranged in a new energy vehicle, characterized in that, Comprising: A wheel hub motor body having a motor shell and a motor winding arranged inside the motor shell; And A new energy vehicle wheel hub motor lead-out wire for connecting the motor winding with a controller outside the motor shell, Wherein, the new energy vehicle wheel hub motor lead-out wire is any one of the new energy vehicle wheel hub motor lead-out wires according to claims 1-8.

10. A new energy vehicle, characterized in that, Comprising: A wheel hub motor, Wherein, the wheel hub motor is the wheel hub motor according to claim 9.

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