Electric drive system and aircraft

Abstract

Provided in the present invention are an electric drive system and an aircraft. The electric drive system comprises: an electric motor assembly, which comprises a stator base, wherein a rotor assembly and a stator assembly are mounted on the stator base, the rotor assembly comprises a rotating shaft, the stator assembly is located on the outer side of the rotating shaft, the stator base is provided with an electric-motor flow channel structure, and the electric-motor flow channel structure is arranged between the rotating shaft and the stator assembly; a controller assembly, which is located at the bottom of the electric motor assembly, is connected to the electric motor assembly, and comprises a controller housing, wherein a controller flow channel structure is provided in the controller housing, and the controller flow channel structure is in communication with the electric-motor flow channel structure; and a cooling assembly, which is configured to perform cooling on at least one of the electric motor assembly and the controller assembly. The present application solves the problem in the prior art of the heat dissipation efficiency of an electric drive system being low.

Description

Electric drive system and aircraft TECHNICAL FIELD

[0001] The present application relates to the technical field of electric drive system structure design, in particular to an electric drive system and an aircraft. BACKGROUND

[0002] The existing electric drive system is usually provided with a cooling device to cool the motor, but the cooling device does not consider the cooling requirement of the motor controller, and has the defects of complex structure and low cooling efficiency. Further, the existing electric drive system also has the problems of low integration and low power density.

[0003] SUMMARY

[0004] The main purpose of the present application is to provide an electric drive system and an aircraft to solve the problem of low heat dissipation efficiency of the existing electric drive system.

[0005] In order to achieve the above-mentioned purpose, according to one aspect of the present application, an electric drive system is provided, comprising: a motor assembly, the motor assembly comprising a stator base, a rotor assembly and a stator assembly being installed on the stator base, the rotor assembly comprising a rotating shaft, the stator assembly being located outside the rotating shaft, the stator base being provided with a motor flow channel structure, the motor flow channel structure being arranged between the rotating shaft and the stator assembly; a controller assembly, the controller assembly being located at the bottom of the motor assembly, the controller assembly being connected with the motor assembly, the controller assembly comprising a controller housing, a controller flow channel structure being arranged in the controller housing, the controller flow channel structure being communicated with the motor flow channel structure; a cooling assembly, the cooling assembly being connected with the controller assembly, the cooling assembly comprising a heat exchanger, an internal flow channel of the heat exchanger being communicated with the controller flow channel structure, wherein the cooling assembly is used to perform cooling operation on at least one of the motor assembly and the controller assembly.

[0006] Further, the stator base is provided with a first annular structure and a second annular structure, the first annular structure forming a stator mounting groove for mounting the stator assembly, the stator mounting groove being located outside the rotating shaft along the radial direction of the stator base, the second annular structure being located inside the first annular structure, the inside of the second annular structure forming the motor flow channel structure.

[0007] Further, the second annular structure is an annular groove with an opening on one side, the side of the annular groove away from the controller assembly having the opening, the motor assembly further comprising a water channel sealing plate, the water channel sealing plate being located at the top of the annular groove, the water channel sealing plate being connected with the stator base, the water channel sealing plate being used to seal the opening so as to form the motor flow channel structure between the side wall of the annular groove and the water channel sealing plate.

[0008] Further, the first annular structure and the second annular structure share a side wall.

[0009] Further, the controller assembly is provided with a control circuit board, and the controller flow channel structure is located at the bottom of the control circuit board, and the controller flow channel structure is a cavity flow channel arranged in the controller shell.

[0010] Further, the controller flow channel structure is polygonal in the thickness direction of the controller assembly, and the controller assembly is circular, and each vertex of the polygon is arranged in contact with the circle.

[0011] Further, the cooling assembly is arranged at the bottom of the controller assembly, and the central axis of the motor assembly, the central axis of the controller assembly, and the geometric center line of the cooling assembly are arranged in coincidence.

[0012] Further, the motor assembly further comprises a rotor disc and a rotor sleeve, the rotor disc is connected with the rotating shaft, the rotor disc is located at the top of the stator base, the rotor disc is connected with the stator base, the rotor sleeve is arranged between the rotor disc and the stator base, and the rotor sleeve has a supporting portion for supporting at least one of the magnet steel and the rotor core.

[0013] Further, the end of the rotor sleeve close to the rotor disc abuts against the rotor disc through a first step surface.

[0014] Further, the end of the rotor sleeve away from the rotor disc is formed with a plurality of first matching protrusions, the plurality of first matching protrusions are arranged at intervals along the radial direction of the rotor sleeve, and a first matching groove is formed between adjacent first matching protrusions, and the end of the stator base close to the rotor sleeve is provided with a plurality of second matching protrusions, the plurality of second matching protrusions are arranged at intervals along the radial direction of the stator base, and a second matching groove is formed between adjacent second matching protrusions, wherein the plurality of first matching protrusions and the plurality of second matching protrusions are arranged in a staggered manner, the plurality of first matching protrusions and the plurality of second matching grooves are correspondingly matched, and the plurality of second matching protrusions and the plurality of first matching grooves are correspondingly matched, so as to form a labyrinth seal structure between the rotor sleeve and the stator base.

[0015] Further, the motor assembly comprises a protective cover, the protective cover is located outside the stator base, and the inner side wall of the first annular structure and the protective cover jointly form a stator mounting groove, the end of the rotor sleeve away from the rotor disc is formed with a plurality of first matching protrusions, the plurality of first matching protrusions are arranged at intervals along the radial direction of the rotor sleeve, and a first matching groove is formed between adjacent first matching protrusions, and the end of the protective cover close to the rotor sleeve is provided with a plurality of second matching protrusions, the plurality of second matching protrusions are arranged at intervals along the radial direction of the protective cover, and a second matching groove is formed between adjacent second matching protrusions, wherein the plurality of first matching protrusions and the plurality of second matching protrusions are arranged in a staggered manner, the plurality of first matching protrusions and the plurality of second matching grooves are correspondingly matched, and the plurality of second matching protrusions and the plurality of first matching grooves are correspondingly matched, so as to form a labyrinth seal structure between the protective cover and the rotor sleeve.

[0016] Further, the end of the protective cover close to the rotor sleeve is further formed with a second stepped surface, the supporting part is matched with the second stepped surface, and the plastic sleeve is arranged between the supporting part and the second stepped surface.

[0017] Further, the plastic sleeve is in interference fit with the protective cover, and the plastic sleeve is in clearance fit with the rotor sleeve.

[0018] Further, the stator assembly comprises a stator core and a stator winding, the stator winding is wound on the stator core, part of the stator winding is connected to form a set of three-phase motor control circuit through the bus bar, another part of the stator winding is connected to form another set of three-phase motor control circuit through the bus bar, and the two sets of three-phase motor control circuit work independently.

[0019] Further, the controller assembly is provided with two drive control units, the two drive control units are respectively connected with the two sets of three-phase motor control circuit, and the two drive control units work independently.

[0020] Further, the two drive control units are integrally arranged on the same circuit board, and the two drive control units are symmetrically arranged about the geometric center line of the circuit board.

[0021] Further, the controller flow channel structure is provided with two cooling zones, the two cooling zones are respectively arranged corresponding to the two drive control units, and the water inlet hole of the controller flow channel structure is arranged between the two cooling zones, so that the cooling liquid entering the controller flow channel structure is divided into two liquid flow paths and enters the two cooling zones.

[0022] Further, the two cooling zones are symmetrically arranged about the geometric center line of the controller flow channel structure, and the water inlet hole is located on the geometric center line of the controller flow channel structure.

[0023] Further, the controller flow channel structure has a water outlet hole, the controller flow channel structure is provided with a flow guide member at the water outlet hole, and the flow guide member is used for guiding the two liquid branches after passing through the two cooling zones into the water outlet hole.

[0024] Further, the cooling assembly further comprises a water pump, the water pump is in communication with the controller flow channel structure, and the internal flow channel of the heat exchanger is in communication with the water pump.

[0025] According to another aspect of the present application, a kind of aircraft is provided, and the aircraft has electric drive system, and electric drive system is the electric drive system described above.

[0026] The application has the advantages that the controller flow channel structure is arranged in the controller shell, the controller flow channel structure is communicated with the motor flow channel structure, the cooling assembly can perform cooling work on at least one of the motor assembly and the controller assembly, the controller cooling and the motor cooling are integrated, the cooling structure of the electric drive system is simplified, the integration of the electric drive system is improved, the power density of the electric drive system is improved, and the cooling efficiency of the electric drive system is improved. The application solves the problem of low cooling efficiency of the electric drive system in the prior art. BRIEF DESCRIPTION OF DRAWINGS

[0027] The description and drawings of the specification constitute a part of this application. The illustrative embodiments of the application and their description serve to explain the application without limiting the application. In the drawings:

[0028] Fig. 1 shows a structural schematic diagram of an embodiment of the electric drive system according to the application;

[0029] Fig. 2 shows a front view of an embodiment of the motor assembly without a protective cover according to the application;

[0030] Fig. 3 shows a sectional view of the A-A section in Fig. 2;

[0031] Fig. 4 shows a sectional view of the B-B section in Fig. 3;

[0032] Fig. 5 shows a sectional view of an embodiment of the motor assembly without the stator assembly and the rotor assembly according to the application;

[0033] Fig. 6 shows a structural schematic diagram of a first embodiment of the stator base according to the application;

[0034] Fig. 7 shows a structural schematic diagram of an embodiment of the stator assembly according to the application;

[0035] Fig. 8 shows a structural schematic diagram of an embodiment of the rotating shaft according to the application;

[0036] Fig. 9 shows a sectional view of a first embodiment of the controller assembly according to the application;

[0037] Fig. 10 shows a structural schematic diagram of a second embodiment of the controller assembly according to the application;

[0038] Fig. 11 shows a structural schematic diagram of a third embodiment of the controller assembly according to the application;

[0039] Fig. 12 shows a structural schematic diagram of a second embodiment of the stator base according to the application;

[0040] Fig. 13 shows a structural diagram of an embodiment of a controller flow channel structure according to the present application.

[0041] Wherein, the above figures include the following reference signs: 1, motor assembly; 11, stator base; 111, motor flow channel structure; 112, stator mounting groove; 12, rotor assembly; 121, rotating shaft; 13, stator assembly; 131, stator winding; 14, water channel sealing plate; 2, controller assembly; 21, controller flow channel structure; 211, cooling area; 212, water inlet hole; 213, water outlet hole; 214, flow guide; 22, drive control unit; 3, cooling assembly; 31, heat exchanger; 32, water pump; 4, rotor rotating disc; 5, rotor sleeve; 51, bearing part; 52, first step surface; 53, second step surface; 8, labyrinth seal structure; 9, protective cover; 10, plastic shaft sleeve; 100, W-phase first winding; 101, V-phase first winding; 102, U-phase first winding; 103, W-phase second winding; 104, V-phase second winding; 105, U-phase second winding. DETAILED DESCRIPTION

[0042] It should be noted that the embodiments and features of the embodiments in the present application can be combined with each other without conflict. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0043] It should be noted that the terms used herein are only intended to describe specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise, and it should be further understood that the terms "comprise" and / or "include" as used herein specify the presence of stated features, steps, operations, devices, components and / or combinations thereof.

[0044] It should be noted that the terms "first", "second", and the like in the specification and claims of the present application and the above-described figures are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the terms used in this way can be interchanged as appropriate, so that the embodiments of the present application described herein can be implemented in an order other than that illustrated or described herein. In addition, the terms "include" and "have" and any variations thereof are intended to cover non-exclusive inclusion, for example, a process, method, system, product or device that includes a series of steps or units does not have to be limited to only those steps or units clearly listed, but can include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0045] Now, exemplary embodiments according to this application will be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in various different forms, and should not be construed as being limited to only the embodiments set forth herein. It should be understood that the embodiments are provided so that the present application will be thorough and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art, and in the drawings, the thicknesses of layers and regions are exaggerated for clarity, and the same reference numerals are used throughout the drawings to designate the same elements, so that a description thereof will not be repeated.

[0046] An outer rotor motor is a special type of motor in which the rotor is located on the outside of the motor, while the stator is located in the center. Compared to traditional inner rotor motors, outer rotor motors have unique structural and performance characteristics, making them suitable for specific application scenarios.

[0047] The rotor of an outer rotor motor rotates around the stator, which is opposite to the layout of traditional motors. Due to the external location of the rotor, outer rotor motors generally have high torque density, capable of providing large torque in a compact size. The design of outer rotor motors helps achieve high power density, i.e., providing large power output in a smaller volume.

[0048] Outer rotor motors generally have lower noise levels, as the unbalanced mass of the rotor is far from the center of rotation.

[0049] Due to lower mechanical losses, outer rotor motors can achieve higher operating efficiency.

[0050] The compact design of outer rotor motors makes them suitable for applications where space is limited.

[0051] Outer rotor motors can be installed in various ways, such as direct drive or through transmission devices such as couplings, gears, etc.

[0052] Due to the outer surface of the rotor being far from the center of rotation, outer rotor motors are suitable for high-speed operation applications.

[0053] Due to the advantages of outer rotor motors described above, their applications are becoming more and more widespread. However, the cooling structure of the outer rotor motor in the prior art is complex, can only cool the motor, and has low cooling efficiency.

[0054] In combination with FIGS. 1-13, according to the specific embodiments of the present application, an electric drive system is provided, comprising: a motor assembly 1, a controller assembly 2, and a cooling assembly 3. The motor assembly 1 comprises a stator base 11, a rotor assembly 12 and a stator assembly 13 are mounted on the stator base 11, the rotor assembly 12 comprises a rotating shaft 121, the stator assembly 13 is located outside the rotating shaft 121, the stator base 11 is provided with a motor flow channel structure 111, the motor flow channel structure 111 is arranged between the rotating shaft 121 and the stator assembly 13; the controller assembly 2 is located at the bottom of the motor assembly 1, the controller assembly 2 is connected with the motor assembly 1, the controller assembly 2 comprises a controller housing, a controller flow channel structure 21 is arranged in the controller housing, the controller flow channel structure 21 is in communication with the motor flow channel structure 111; the cooling assembly 3 is connected with the controller assembly 2, the cooling assembly 3 comprises a heat exchanger 31, an internal flow channel of the heat exchanger 31 is in communication with the controller flow channel structure 21, wherein the cooling assembly 3 is used for performing cooling work on at least one of the motor assembly 1 and the controller assembly 2.

[0055] By arranging the controller flow channel structure 21 in the controller housing and making the controller flow channel structure 21 in communication with the motor flow channel structure 111, the cooling assembly 3 can perform cooling work on at least one of the motor assembly 1 and the controller assembly 2, so that the controller cooling and the motor cooling are integrated, which simplifies the cooling structure of the electric drive system, improves the integration of the electric drive system, and further improves the power density of the electric drive system, and on the other hand, the cooling efficiency of the electric drive system is improved. By using the technical solution of the present application, the problem of low heat dissipation efficiency of the electric drive system in the prior art is effectively solved.

[0056] In combination with FIGS. 4, 5 and 12, further, the stator base 11 is provided with a first annular structure and a second annular structure, the first annular structure forms a stator mounting groove 112 for mounting the stator assembly 13, along the radial direction of the stator base 11, the stator mounting groove 112 is located outside the rotating shaft 121, the second annular structure is located inside the first annular structure, and the internal part of the second annular structure forms the motor flow channel structure 111.

[0057] In the technical solution of the above embodiment, starting from the structure of the external rotor motor, the internal space of the stator base 11 is fully utilized to realize water cooling of the stator assembly 13 inside the first annular structure.

[0058] Optionally, the first annular structure can be any form of structure, such as a groove with an opening at the top, a structure with openings at the top and side, the first annular structure can independently mount the stator assembly 13, or the first annular structure can cooperate with other structures to jointly mount the stator assembly 13.

[0059] As shown in FIG. 6, the second annular structure is an annular groove with an opening on one side, the annular groove has an opening on the side away from the controller assembly 2, the motor assembly 1 further comprises a water channel sealing plate 14, the water channel sealing plate 14 is located at the top of the annular groove, the water channel sealing plate 14 is connected with the stator base 11, and the water channel sealing plate 14 is used for sealing the opening, so that the motor flow channel structure 111 is formed between the side wall of the annular groove and the water channel sealing plate 14.

[0060] In the technical scheme of the above embodiment, the water channel sealing plate 14 is used for sealing the opening of the annular groove, preventing the cooling liquid from leaking, and improving the sealing performance and reliability of the system. Since the middle part of the stator base 11 needs to be installed with the rotating shaft, the second annular structure is designed as the annular groove, so that the motor flow channel structure 111 and the rotating shaft mounting structure are basically flush, and the structural characteristics of the stator base are fully utilized.

[0061] Optionally, the water channel sealing plate 14 is integrally formed with the stator base 11.

[0062] Further, the first annular structure and the second annular structure share a side wall.

[0063] In the technical scheme of the above embodiment, the shared side wall can improve the cooling efficiency of the cooling liquid passing through the motor flow channel structure 111 in the second annular structure, reduce the occupied space of the cooling system, and improve the power density of the electric drive system.

[0064] Optionally, the stator base body center is provided with front and rear bearing seats for fixing front and rear bearings respectively. The stator base body is hollow designed, and one end is welded with the water channel sealing plate, so that a U-shaped motor water channel is formed inside.

[0065] As shown in FIG. 13, the controller assembly 2 is provided with a control circuit board, and the controller flow channel structure 21 is located at the bottom of the control circuit board. The controller flow channel structure 21 is a cavity flow channel arranged in the controller housing.

[0066] In the technical scheme of the above embodiment, the heat generating components of the control circuit board can be effectively cooled through the controller flow channel structure 21.

[0067] As shown in FIG. 13, the controller flow channel structure 21 is polygonal in the thickness direction of the controller assembly 2, the controller assembly 2 is circular, and each vertex of the polygon is arranged in contact with the circle.

[0068] In the technical scheme of the above embodiment, by setting the relative relationship between the controller flow channel structure 21 and the controller assembly 2, the controller flow channel structure 21 can have a larger cooling area.

[0069] Further, the cooling assembly 3 is arranged at the bottom of the controller assembly 2, and the central axis of the motor assembly 1, the central axis of the controller assembly 2 and the geometric center line of the cooling assembly 3 are arranged coincidently.

[0070] The above arrangement can improve the integration of the electric drive system, facilitate assembly, and make the motor operation more stable.

[0071] As shown in FIGS. 4 and 5, the motor assembly 1 further includes a rotor disc 4 and a rotor sleeve 5. The rotor disc 4 is connected with the rotating shaft 121 and is arranged at the top of the stator base 11. The rotor sleeve 5 is arranged between the rotor disc 4 and the stator base 11, and the rotor sleeve 5 has a supporting portion 51 for supporting at least one of the magnetic steel and the rotor core.

[0072] By supporting the magnetic steel through the rotor sleeve 5, direct contact between the magnetic steel and the rotor disc can be avoided, and possible wear and direct thermal influence of the magnetic steel can be reduced. The supporting portion 51 is used for supporting the rotor core, which can provide additional support and reduce deformation of the rotor assembly. The supporting portion 51 is used for supporting the magnetic steel, which ensures that the magnetic steel is in the correct position to achieve precise magnetic field distribution. Through the cooperation of the rotor disc 4 and the rotor sleeve, the stability of the rotor assembly during operation can be ensured.

[0073] As shown in FIGS. 4 and 5, one end of the rotor sleeve 5 close to the rotor disc 4 is in abutment with the rotor disc 4 through a first stepped surface 52.

[0074] In the above embodiment, the first stepped surface 52 facilitates the positioning and assembly between the rotor sleeve 5 and the rotor disc 4, and avoids axial jump or radial runout between the two.

[0075] Further, one end of the rotor sleeve 5 away from the rotor disc 4 is formed with a plurality of first matching protrusions, the plurality of first matching protrusions are arranged at intervals along the radial direction of the rotor sleeve 5, and a first matching groove is formed between adjacent first matching protrusions. One end of the stator base 11 close to the rotor sleeve 5 is provided with a plurality of second matching protrusions, the plurality of second matching protrusions are arranged at intervals along the radial direction of the stator base 11, and a second matching groove is formed between adjacent second matching protrusions. The plurality of first matching protrusions and the plurality of second matching protrusions are arranged in a staggered manner, the plurality of first matching protrusions and the plurality of second matching grooves are correspondingly matched, and the plurality of second matching protrusions and the plurality of first matching grooves are correspondingly matched, so as to form a labyrinth seal structure 8 between the rotor sleeve 5 and the stator base 11.

[0076] In the technical scheme of the above embodiment, the labyrinth sealing structure 8 can significantly improve the sealing performance between the rotor sleeve 5 and the stator base 11, and can well protect the stator assembly. At this time, the first annular structure on the stator base 11 is a groove, and a plurality of second matching protrusions are arranged on the side wall of the groove towards the rotor sleeve 5.

[0077] In combination with FIG. 5, the motor assembly 1 includes a protective cover 9 located outside the stator base 11, and the inner side wall of the first annular structure and the protective cover 9 jointly form a stator mounting groove 112. The end of the rotor sleeve 5 away from the rotor disc 4 is formed with a plurality of first matching protrusions, the first matching protrusions are arranged at intervals along the radial direction of the rotor sleeve 5, and the first matching grooves are formed between adjacent first matching protrusions. The end of the protective cover 9 close to the rotor sleeve 5 is provided with a plurality of second matching protrusions, the second matching protrusions are arranged at intervals along the radial direction of the protective cover 9, and the second matching grooves are formed between adjacent second matching protrusions. Among them, the plurality of first matching protrusions and the plurality of second matching protrusions are arranged in a staggered manner, the plurality of first matching protrusions and the plurality of second matching grooves are correspondingly matched, and the plurality of second matching protrusions and the plurality of first matching grooves are correspondingly matched, so as to form a labyrinth sealing structure 8 between the protective cover 9 and the rotor sleeve 5.

[0078] In the technical scheme of the above embodiment, the labyrinth sealing structure 8 can significantly improve the sealing performance between the rotor sleeve 5 and the protective cover 9, and can well protect the stator assembly. At this time, the inner side wall of the first annular structure and the protective cover 9 jointly form a stator mounting groove 112.

[0079] Through the sealing design of the outer rotor in the above embodiment, the dust and water protection of the stator assembly is realized, and the working life of the motor is improved.

[0080] In combination with FIG. 5, the end of the protective cover 9 close to the rotor sleeve 5 is also formed with a second stepped surface 53, the supporting part 51 is matched with the second stepped surface 53, and the plastic shaft sleeve 10 is arranged between the supporting part 51 and the second stepped surface 53.

[0081] In the technical scheme of the above embodiment, the second stepped surface 53 is matched with the second stepped surface 53, which improves the working stability of the rotor assembly and simplifies the assembly difficulty of the stator assembly.

[0082] Optionally, the magnetic steel sleeve assembly includes a rotor sleeve, a rotor core, a rotor disc, and a magnetic steel.

[0083] Optionally, in order to ensure the reliability of the bearing torque, on the basis of interference fit between the rotor core and the rotor sleeve, 8 keys are uniformly distributed on the outer periphery of the rotor core and matched and connected with the rotor sleeve.

[0084] Optionally, the magnetic steel is pasted to the inner wall of the rotor core by using high-strength epoxy glue.

[0085] In order to prevent the magnetic steel and the rotor core from moving axially, a stop boss (i.e., a supporting portion 51) is arranged at the bottom of the rotor sleeve to support the rotor core and the magnetic steel, and the rotor disc is connected and fixed to the rotor sleeve through 16 radially distributed screws, and the rotor core and the magnetic steel are pressed by the bottom of the rotor disc.

[0086] Further, the plastic shaft sleeve 10 is in interference fit with the protective cover 9, and the plastic shaft sleeve 10 is in clearance fit with the rotor sleeve 5.

[0087] Further, the plastic shaft sleeve is made of polytetrafluoroethylene material, which has a small friction coefficient and improves the sealing performance.

[0088] Further, the stator assembly 13 includes a stator core and a stator winding 131, and the stator winding 131 is wound on the stator core, wherein part of the stator winding 131 is connected through a bus bar to form a set of three-phase motor control circuit, and another part of the stator winding 131 is connected through a bus bar to form another set of three-phase motor control circuit, and the two three-phase motor control circuits work relatively independently.

[0089] In the technical solution of the above embodiment, the controller has a double-stator control function, and two independent drive control units are included in one controller. The motor winding is divided into two groups, and each group is connected to form a set of three-phase U / V / W winding. The controller includes two independent drive control units to control two sets of three-phase windings, which are redundantly designed, i.e., one set can work normally when the other set has a problem, thereby improving safety and reliability.

[0090] Specifically, as shown in FIG. 7, the W-phase first winding 100, the V-phase first winding 101, the U-phase first winding 102, the W-phase second winding 103, the V-phase second winding 104, and the U-phase second winding 105 are shown.

[0091] As shown in FIG. 9, two drive control units 22 are arranged in the controller assembly 2, and the two drive control units 22 are respectively connected to the two three-phase motor control circuits, and the two drive control units 22 work relatively independently.

[0092] Further, the two drive control units 22 are integrally arranged on the same circuit board, and the two drive control units 22 are symmetrically arranged about the geometric center line of the circuit board.

[0093] As shown in FIG. 13, two cooling zones 211 are arranged in the controller flow channel structure 21, and the two cooling zones 211 are respectively arranged corresponding to the two drive control units 22, wherein the water inlet hole 212 of the controller flow channel structure 21 is arranged between the two cooling zones 211, so that the cooling liquid entering the controller flow channel structure 21 is divided into two liquid flow paths and enters the two cooling zones 211.

[0094] In the technical solution of the above embodiment, the two drive control units 22 share one controller housing, the cooling water enters the controller housing and is divided into two paths to cool the two drive control units 22 respectively, and then is merged into one path to enter the motor flow channel structure 111 of the motor, and finally flows out to enter the cooling system for cooling and then reenters the controller flow channel structure to form a circulation.

[0095] Further, the two cooling zones 211 are symmetrically arranged about the geometric center line of the controller flow channel structure 21, and the water inlet hole 212 is located on the geometric center line of the controller flow channel structure 21.

[0096] In the technical solution of the above embodiment, the symmetrical arrangement can make the heat of each component in the controller assembly evenly dissipate.

[0097] As shown in FIG. 13, the controller flow channel structure 21 has a water outlet hole 213, and the controller flow channel structure 21 is provided with a flow guide 214 at the water outlet hole 213, which is used to guide the two liquid branches after passing through the two cooling zones 211 into the water outlet hole 213.

[0098] In the technical solution of the above embodiment, the flow guide 214 ensures that the cooling liquid flows along a predetermined path, avoiding backflow or turbulent flow. By reasonably guiding the cooling liquid, the flow guide can improve the cooling efficiency of the cooling zone and ensure that the heat is effectively taken away. The flow guide can reduce the pressure loss when the cooling liquid flows and improve the energy efficiency of the cooling system.

[0099] Specifically, the flow path of the cooling liquid is: the water inlet hole of the controller housing--two paths merging into the water outlet hole 213 of the controller housing (preferably two paths)--the water inlet hole of the motor flow channel structure 111--the water outlet hole of the motor flow channel structure 111--the water inlet hole of the water pump--the water outlet hole of the water pump--the water inlet hole of the heat exchanger--the water outlet hole of the heat exchanger--back to the water inlet hole 212 of the controller housing.

[0100] As shown in FIG. 1, the cooling assembly further includes a water pump 32, which is in communication with the controller flow channel structure 21, and the internal flow channel of the heat exchanger 31 is in communication with the water pump 32.

[0101] As shown in FIG. 7, the stator assembly 13 includes a stator core, slot insulation, flat wire winding, slot wedge, and bus bar. The flat wire winding is connected to the stator core by a downline method and is fixed with a slot wedge, and is welded and connected according to a wiring diagram using three-phase bus bars and a star point bus bar. The winding is divided into two groups, each group forms a set of three-phase U / V / W windings, and after completion, the whole is filled with potting glue to improve the heat dissipation effect and prevent dust and water. The stator assembly after filling with glue is assembled on the stator base by interference fit.

[0102] As shown in Figure 8, the rotor assembly 12 includes a rotating shaft and front and rear bearings. The rotating shaft and the inner rings of the front and rear bearings are in interference fit, the inner ring of the front bearing is limited by the shaft shoulder and the stop ring, the outer ring of the front bearing is in transition fit with the front bearing seat of the stator base and is fixed by the bearing pressing plate, the inner ring of the rear bearing is limited by the shaft shoulder, and the outer ring of the rear bearing is in transition fit with the rear bearing seat of the stator base and is pre-tightened by the wave washer. In order to reduce the weight, the rotating shaft is designed as a hollow shaft, the top end of the rotating shaft is connected with the magnet sleeve assembly by 8 screws, and 8 rectangular keys are additionally arranged at the top end of the rotating shaft for further improving the reliability of the bearing torque.

[0103] According to another aspect of the present application, there is provided an aircraft having an electric drive system as described above.

[0104] From the above description, it can be seen that the above-mentioned embodiments of the present application achieve the following technical effects:

[0105] A high-performance aviation electric drive system is provided, which highly integrates a motor, a controller and a cooling system together, is small in size and light in weight, optimizes installation space and connection wiring, and realizes high power density.

[0106] The motor and the controller are both cooled by liquid cooling, and the controller cooling channel and the motor cooling channel are integrated into one, realizing a highly integrated design, simplifying the cooling system design, being small in size and light in weight, and realizing high power density.

[0107] For ease of description, spatial relative terms such as "above", "upper", "top", "up", and the like can be used herein to describe the spatial relationship between one device or feature and another device or feature as shown in the drawings. It should be understood that the spatial relative terms are intended to include different orientations of the device in use or operation in addition to the orientation of the device described in the drawings. For example, if the device in the drawings is inverted, the device described as "above" or "on" other devices or structures will be positioned "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below" orientations. The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein are interpreted accordingly.

[0108] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0109] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0110] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electric drive system, characterized by The application relates to a motor assembly (1) comprising a stator base (11) on which a rotor assembly (12) and a stator assembly (13) are mounted, the rotor assembly (12) comprising a rotating shaft (121), the stator assembly (13) being located outside the rotating shaft (121), the stator base (11) being provided with a motor flow channel structure (111) arranged between the rotating shaft (121) and the stator assembly (13); a controller assembly (2) located at the bottom of the motor assembly (1), the controller assembly (2) being connected with the motor assembly (1), the controller assembly (2) comprising a controller housing, the controller housing being provided with a controller flow channel structure (21) in communication with the motor flow channel structure (111); and a cooling assembly (3) connected with the controller assembly (2), the cooling assembly (3) comprising a heat exchanger (31), the internal flow channel of the heat exchanger (31) being in communication with the controller flow channel structure (21), wherein the cooling assembly (3) is used for performing cooling work on at least one of the motor assembly (1) and the controller assembly (2). The stator base (11) is provided with a first annular structure and a second annular structure, the first annular structure forms a stator mounting groove (112) for mounting the stator assembly (13), the stator mounting groove (112) is located outside the rotating shaft (121) along the radial direction of the stator base (11), and the second annular structure is located inside the first annular structure, and the inside of the second annular structure forms the motor flow channel structure (111). The second annular structure is an annular groove with an opening on one side, the side of the annular groove away from the controller assembly (2) has the opening, the motor assembly (1) further comprises a water channel sealing plate (14), the water channel sealing plate (14) is located at the top of the annular groove, the water channel sealing plate (14) is connected with the stator base (11), and the water channel sealing plate (14) is used for sealing the opening so that the sidewall of the annular groove and the water channel sealing plate (14) form the motor flow channel structure (111). The first annular structure and the second annular structure share a sidewall.

2. The electric drive system of claim 1, wherein, The controller assembly (2) is provided with a control circuit board, the controller flow channel structure (21) is located at the bottom of the control circuit board, and the controller flow channel structure (21) is a cavity flow channel arranged in the controller housing.

3. The electric drive system of claim 2, wherein, Along the thickness direction of the controller assembly (2), the controller flow channel structure (21) is a polygon, the controller assembly (2) is a circle, and each vertex of the polygon is arranged in contact with the circle.

4. An electric drive system according to claim 2 or 3, characterised in that, ​ 5. The electric drive system of claim 1, wherein, ​ 6. The electric drive system of claim 1 or 5, wherein, ​ 7. The electric drive system of claim 1, wherein, The cooling assembly (3) is arranged at the bottom of the controller assembly (2), and the central axis of the motor assembly (1), the central axis of the controller assembly (2) and the geometric center line of the cooling assembly (3) are arranged coincidentally.

8. The electric drive system of claim 2, wherein, The motor assembly (1) further comprises a rotor rotating disc (4) and a rotor sleeve (5), the rotor rotating disc (4) is connected with the rotating shaft (121), the rotor rotating disc (4) is located at the top of the stator base (11), the rotor rotating disc (4) is connected with the stator base (11), the rotor sleeve (5) is arranged between the rotor rotating disc (4) and the stator base (11), and the rotor sleeve (5) has a supporting portion (51) for supporting at least one of a magnetic steel and a rotor core.

9. The electric drive system of claim 8, wherein, One end of the rotor sleeve (5) close to the rotor rotating disc (4) abuts against the rotor rotating disc (4) through a first step surface (52).

10. The electric drive system according to claim 8 or 9, characterized in that The other end of the rotor sleeve (5) away from the rotor rotating disc (4) is formed with a plurality of first matching protrusions, the plurality of first matching protrusions are arranged at intervals along the radial direction of the rotor sleeve (5), and a first matching groove is formed between adjacent first matching protrusions. One end of the stator base (11) close to the rotor sleeve (5) is provided with a plurality of second matching protrusions, the plurality of second matching protrusions are arranged at intervals along the radial direction of the stator base (11), and a second matching groove is formed between adjacent second matching protrusions. The plurality of first matching protrusions and the plurality of second matching protrusions are arranged in a staggered manner, the plurality of first matching protrusions and the plurality of second matching grooves are matched correspondingly, and the plurality of second matching protrusions and the plurality of first matching grooves are matched correspondingly, so that a labyrinth sealing structure (8) is formed between the rotor sleeve (5) and the stator base (11).

11. The electric drive system of claim 8 or 9, wherein, The motor assembly (1) further comprises a protective cover (9) located outside the stator base (11), and an inner side wall of the first annular structure and the protective cover (9) jointly form the stator mounting groove (112). The other end of the rotor sleeve (5) away from the rotor rotating disc (4) is formed with a plurality of first matching protrusions, the plurality of first matching protrusions are arranged at intervals along the radial direction of the rotor sleeve (5), and a first matching groove is formed between adjacent first matching protrusions. One end of the protective cover (9) close to the rotor sleeve (5) is provided with a plurality of second matching protrusions, the plurality of second matching protrusions are arranged at intervals along the radial direction of the protective cover (9), and a second matching groove is formed between adjacent second matching protrusions. The plurality of first matching protrusions and the plurality of second matching protrusions are arranged in a staggered manner, the plurality of first matching protrusions and the plurality of second matching grooves are matched correspondingly, and the plurality of second matching protrusions and the plurality of first matching grooves are matched correspondingly, so that a labyrinth sealing structure (8) is formed between the protective cover (9) and the rotor sleeve (5).

12. The electric drive system of claim 11, wherein, The end of the protective cover (9) close to the rotor sleeve (5) is further formed with a second stepped surface (53), the supporting part (51) is matched with the second stepped surface (53), and the plastic shaft sleeve (10) is arranged between the supporting part (51) and the second stepped surface (53).

13. The electric drive system of claim 12, wherein, The plastic shaft sleeve (10) is matched with the protective cover (9) in an interference fit, and the plastic shaft sleeve (10) is matched with the rotor sleeve (5) in a clearance fit.

14. The electric drive system of claim 1, wherein, The stator assembly (13) comprises a stator core and a stator winding (131), and the stator winding (131) is wound on the stator core, wherein part of the stator winding (131) is connected by bus bars to form a set of three-phase motor control circuits, and another part of the stator winding (131) is connected by bus bars to form another set of three-phase motor control circuits, and the two sets of three-phase motor control circuits work relatively independently.

15. The electric drive system of claim 14, wherein, The controller assembly (2) is provided with two drive control units (22), the two drive control units (22) are respectively connected with the two sets of three-phase motor control circuits, and the two drive control units (22) work relatively independently.

16. The electric drive system of claim 15, wherein, The two drive control units (22) are integrally arranged on the same circuit board, and the two drive control units (22) are symmetrically arranged about the geometric center line of the circuit board.

17. The electric drive system of claim 15 or 16, wherein, The controller flow channel structure (21) is provided with two cooling zones (211), the two cooling zones (211) are respectively arranged corresponding to the two drive control units (22), wherein the water inlet hole (212) of the controller flow channel structure (21) is arranged between the two cooling zones (211), so that the cooling liquid entering the controller flow channel structure (21) is divided into two liquid flow paths and enters the two cooling zones (211) respectively.

18. The electric drive system of claim 17, wherein, The two cooling zones (211) are symmetrically arranged about the geometric center line of the controller flow channel structure (21), and the water inlet hole (212) is located on the geometric center line of the controller flow channel structure (21).

19. The electric drive system of claim 17, wherein, The controller flow channel structure (21) has a water outlet hole (213), and the controller flow channel structure (21) is provided with a flow guide piece (214) at the water outlet hole (213), and the flow guide piece (214) is used for guiding two liquid branches after passing through the two cooling zones (211) into the water outlet hole (213).

20. The electric drive system of claim 1, wherein, The cooling assembly (3) further comprises a water pump (32), the water pump (32) is in communication with the controller flow channel structure (21), and the internal flow channel of the heat exchanger (31) is in communication with the water pump (32).

21. An aircraft having an electric drive system, characterized in that The electric drive system is the electric drive system of any one of claims 1-20.

Images