Three-in-one oil-cooled electric drive assembly

Abstract

The present invention relates to the technical field of automotive powertrains, and in particular to a three-in-one oil-cooled electric drive assembly; comprising a reduction gearbox, a motor, a controller, and an integrated housing; the reduction gearbox and the motor are respectively mounted on two adjacent sides of the integrated housing; the integrated housing is provided with a mounting recess; the controller is mounted in the mounting recess; the integrated housing is provided with a cooling oil channel; the cooling oil channel is in communication with the reduction gearbox, the motor, the controller, and the integrated housing; one end of the cooling oil channel is in communication with an oil pump, and the other end of the cooling oil channel is in communication with a first main oil passage, a second main oil passage, and a third main oil passage. This enables a configuration in which the controller, the motor, and the reduction gearbox share a common oil passage, and thereby increases the heat dissipation efficiency of the controller, prevents complex and intersecting cooling paths, and reduces overall electric drive assembly size.

Description

Three-in-one oil-cooled electric drive assembly TECHNICAL FIELD

[0001] The application belongs to the technical field of automobile power assemblies, and particularly relates to a three-in-one oil-cooled electric drive assembly. BACKGROUND

[0002] The electric drive three-in-one assembly is an important technology in new energy vehicles, which is a comprehensive component composed of a motor, a reducer and a controller. The power transmission is realized through the motor and the reducer, and the output of the motor is controlled and adjusted through the controller, so as to improve the electric drive efficiency and reduce the energy consumption. The function of the electric drive three-in-one assembly is to convert electric energy into mechanical energy to drive the new energy vehicle to run. The controller is the brain of the electric drive system, which controls and adjusts the output of the motor to ensure the stable and efficient operation of the electric drive system.

[0003] The traditional three-in-one electric drive assembly integrates the motor controller, the motor and the reducer, reduces the overall volume of the product, and makes the product small and light. At present, the mainstream electric drive assembly mainly adopts a water-cooled motor controller and an oil-cooled motor and reducer. Among them, the motor controller adopts a water-cooled plate structure to cool the IGBT module, and the motor and the reducer adopt an oil channel structure to cool the oil flow heat dissipation, so as to finally realize the heat dissipation requirement of the three-in-one electric drive assembly. SUMMARY

[0004] In view of the above problems, the application provides a three-in-one oil-cooled electric drive assembly, which comprises a reducer, a motor, a controller and an integrated shell. The reducer and the motor are respectively installed on two adjacent sides of the integrated shell. An installation groove is formed in the integrated shell. The controller is installed in the installation groove.

[0005] A cooling oil channel is formed in the integrated shell. The cooling oil channel is communicated with the reducer, the motor, the controller and the integrated shell. One end of the cooling oil channel is communicated with an oil pump, and the other end of the cooling oil channel is communicated with a first main oil channel, a second main oil channel and a third main oil channel. The first main oil channel is formed in the integrated shell at a position corresponding to the reducer. The second main oil channel is formed in the integrated shell at a position corresponding to the motor. The third main oil channel is formed in the installation groove. The first main oil channel is communicated with an oil passage in the reducer, the second main oil channel and the third main oil channel. The second main oil channel is communicated with an oil passage in the motor. The third main oil channel is communicated with an oil passage in the controller.

[0006] A machine oil return channel is formed in the motor away from the reducer. One end of the machine oil return channel is communicated with the first main oil channel, the second main oil channel and the third main oil channel, and the other end of the machine oil return channel is communicated with the oil pump.

[0007] Further, a first recess is arranged in the mounting groove; a first branch oil inlet is arranged at one end of the first recess close to the third main oil channel; a first branch oil outlet is arranged at the other end of the first recess away from the third main oil channel; a first copper bar assembly is arranged in the first recess; a first branch oil path is arranged in the first copper bar assembly; the third main oil channel is communicated with the first branch oil inlet; the first branch oil inlet is communicated with the first branch oil outlet through the first branch oil path; the first branch oil inlet is arranged at one end of the first recess close to the third main oil channel; and the first branch oil outlet is arranged at the other end of the first recess away from the third main oil channel.

[0008] Further, the third main oil channel is communicated with the second branch oil inlet; the second branch oil inlet is communicated with the second branch oil outlet through a second branch oil path; the second branch oil path passes through the IGBT module; one end of the IGBT module is communicated with the second branch oil inlet, and the other end of the IGBT module is communicated with the second branch oil outlet.

[0009] Further, a sealing groove is arranged at the top of the first recess; the sealing groove is matched with the first copper bar assembly to realize the sealing of the inside of the first recess.

[0010] Further, a first oil return flow channel is arranged at one end of the integrated shell away from the controller; one end of the first oil return flow channel is communicated with the first branch oil outlet; and the first oil return flow channel is communicated with the machine oil return channel.

[0011] Further, the second branch oil outlet is communicated with the middle part of the first oil return flow channel.

[0012] Further, one end of the first oil return flow channel away from the first branch oil outlet is communicated with the second oil return flow channel.

[0013] Further, the first oil return flow channel and the second oil return flow channel are arranged vertically.

[0014] Further, a plurality of oil outlets are arranged on the second oil return flow channel; a first oil passing hole is arranged on the second copper bar assembly and communicated with the oil outlet; a second oil passing hole is arranged on the machine rear end cover; and the first oil passing hole is communicated with the machine oil return channel through the second oil passing hole.

[0015] Further, an oil pump port is arranged on the integrated shell; the oil pump port is communicated with an oil filter through a cooling oil channel; the oil filter is communicated with an oil cooler; and the oil cooler is communicated with the first main oil channel, the second main oil channel and the third main oil channel. Beneficial effects

[0016] The beneficial effects of the present application relative to the prior art are as follows:

[0017] 1. The application sets the first main oil way, the second main oil way and the third main oil way, the second main oil way and the third main oil way communicate with the first main oil way, so that the controller is designed with the motor and the reducer in the oil way, improve the heat dissipation efficiency of the controller, avoid the complex cooling path, reduce the volume of the electric drive assembly.

[0018] 2. In the application, the IGBT (Insulated Gate Bipolar Transistor, Insulated Gate Bipolar Transistor) module is cooled by the second branch oil way, and the chip in the IGBT module is directly cooled, thereby improving the product performance.

[0019] 3. The first branch oil way and the second branch oil way are designed on the first copper bar assembly and the second copper bar assembly, the heat of the direct current copper bar, the film capacitor copper bar and the three-phase copper bar is reduced, and the current density is improved.

[0020] Other features and advantages of the present application will be set forth in the following description, and in part will become apparent to those skilled in the art from the description, or can be learned by practice of the present application. The objects and other advantages of the present application can be achieved and obtained by the structure indicated in the specification, claims and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or prior art description. Obviously, the drawings in the following description are some embodiments of the present application, and those skilled in the art can also obtain other drawings according to these drawings without creative labor.

[0022] Fig. 1 shows the overall schematic diagram in the embodiment of the present application.

[0023] Fig. 2 shows the internal structure schematic diagram in the embodiment of the present application.

[0024] Fig. 3 shows the internal structure schematic diagram in another direction in the embodiment of the present application.

[0025] Fig. 4 shows the schematic diagram of the first branch oil outlet in the embodiment of the present application.

[0026] Fig. 5 shows the structure schematic diagram of the integrated shell bottom in the embodiment of the present application.

[0027] Fig. 6 shows the flow path schematic diagram after cooling oil in the embodiment of the present application.

[0028] Fig. 7 shows the flow path schematic diagram in the cooling process of the cooling oil in the embodiment of the present application.

[0029] Figure 8 shows the flow path of the cooling oil to the three-phase copper bar cooling in the embodiment of the application.

[0030] Figure 9 shows the schematic diagram of the three-phase copper bar oil cooling in the embodiment of the application.

[0031] In the figure, 10, speed reducer; 20, motor; 21, rear end cover of the machine;

[0032] 30, controller; 301, direct current copper bar; 302, thin film capacitor copper bar; 303, IGBT module; 304, second copper bar assembly; 3041, three-phase copper bar; 3042, first oil passage;

[0033] 40, integrated housing; 41, cooling oil channel; 411, first main oil channel; 412, second main oil channel;

[0034] 413, third main oil channel; 4131, first branch oil path; 4132, second branch oil path; 4134, second oil return flow channel; 4135, first recess; 4136, first branch oil inlet channel; 4137, second branch oil inlet channel; 4138, second branch oil outlet channel; 4139, first branch oil outlet channel; 4140, first oil return flow channel; 4141, oil outlet hole; 4142, sealing groove;

[0035] 42, machine oil return channel;

[0036] 50, oil pump port; 60, oil filter; 70, oil cooler. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical scheme and advantages of the embodiments of the application more clear, the technical scheme of the embodiments of the application will be clearly and completely described below with reference to the drawings of the embodiments of the application. Obviously, the described embodiments are part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0038] In the traditional electric drive assembly, the controller is cooled by water cooling. However, water cooling is an indirect cooling method, and the cooling effect is poor, which is difficult to meet the heat dissipation requirements of the controller. At the same time, the water channel structure and the oil channel structure in the traditional electric drive assembly are designed independently, and sufficient wall thickness is required between the water channel and the oil channel to prevent leakage, which leads to a complex heat dissipation structure and a large volume of the electric drive assembly.

[0039] Therefore, the application provides a three-in-one oil-cooled electric drive assembly, as shown in Figure 1, a reducer 10 is installed on the front side of an integrated shell 40, and an electric motor 20 is installed on the left side of the integrated shell 40; the three-in-one oil-cooled electric drive assembly comprises the reducer 10, the electric motor 20, a controller 30 and the integrated shell 40; the reducer 10 and the electric motor 20 are respectively installed on the two sides of the integrated shell 40; the integrated shell 40 is provided with a mounting groove; and the controller 30 is installed in the mounting groove;

[0040] As shown in Figures 2 and 6, the integrated shell 40 is provided with a cooling oil channel 41; the cooling oil channel 41 communicates with the reducer 10, the electric motor 20, the controller 30 and the integrated shell 40; the cooling oil channel 41 communicates with a first main oil channel 411, a second main oil channel 412 and a third main oil channel 413; the first main oil channel 411 communicates with an oil passage in the reducer 10, the second main oil channel 412 and the third main oil channel 413; the second main oil channel 412 communicates with an oil passage in the electric motor 20; and the third main oil channel 413 communicates with an oil passage in the controller 30.

[0041] Referring to Figure 8, the electric motor 20 is provided with a motor oil return channel 42; one end of the motor oil return channel 42 communicates with the first main oil channel 411, the second main oil channel 412 and the third main oil channel 413, and the other end of the motor oil return channel 42 communicates with an oil pump.

[0042] In the implementation process, the cooling oil channel 41 is integrated on the integrated shell 40, so that the use of a hose is avoided, the number of parts is reduced, and the structure is simplified; cooling oil flows from the oil pump to the first main oil channel 411 through the cooling oil channel 41, flows into the oil passage through the first main oil channel 411, lubricates the gears and bearings in the reducer 10, flows to the second main oil channel 412 and the third main oil channel 413 through the first main oil channel 411 respectively, flows into the oil passage in the electric motor 20 through the second main oil channel 412, cools the stator and rotor in the electric motor 20, and since the cooling oil has good insulation, the cooling oil enters the controller 30 through the third main oil channel 413, cools the components in the controller 30, and finally the cooling oil in the first main oil channel 411, the second main oil channel 412 and the third main oil channel 413 flows to the oil pump through the motor oil return channel 42 after work, forming a complete electric drive assembly oil passage cooling loop.

[0043] The application sets the third main oil channel 413, so that the controller 30 shares the oil channel with the electric motor 20 and the reducer 10, improves the heat dissipation efficiency of the controller 30, and reduces the volume of the electric drive assembly.

[0044] In an embodiment of the present application, as shown in Figures 3 and 7, a first recess 4135 is formed in the mounting groove; a first copper bar assembly is installed in the first recess 4135; the third main oil channel 413 is communicated with a first branch inlet oil channel 4136; the first branch inlet oil channel 4136 is communicated with a first branch outlet oil channel 4139 through a first branch oil passage 4131; the first branch inlet oil channel 4136 is formed in the first recess 4135 close to one end of the third main oil channel 413; as shown in Figure 4, the first branch outlet oil channel 4139 is formed in the first recess 4135 away from the other end of the third main oil channel 413.

[0045] In an embodiment of the present application, a sealing groove 4142 is formed at the top of the first recess 4135; the sealing groove 4142 cooperates with the first copper bar assembly to realize the internal sealing of the first recess 4135.

[0046] In the implementation process, the cooling oil flows into the third main oil channel 413 through the cooling oil channel 41, and then flows into the first recess 4135 through the first branch inlet oil channel 4136; the first copper bar assembly in the first recess 4135 is a direct current copper bar 301 and a film capacitor copper bar 302; the direct current copper bar 301 and the film capacitor copper bar 302 are installed at the top of the first recess 4135, and a sealing ring is arranged in the sealing groove 4142; the cooling oil in the first recess 4135 is sealed through the sealing groove 4142, the sealing ring and the first copper bar assembly; the first branch oil passage 4131 includes the first copper bar assembly; the connecting terminals of the direct current copper bar 301 assembly and the film capacitor copper bar 302 extend into the first recess 4135 and contact the cooling oil; the cooling oil flowing into the first recess 4135 sufficiently cools the connecting terminals of the direct current copper bar 301 assembly and the film capacitor copper bar 302, reduces the heat of the direct current copper bar 301 and the film capacitor copper bar 302, and improves the current density.

[0047] Then, the cooling oil flows into the first return oil channel 4140 through the first branch outlet oil channel 4139; the cooling oil reenters the oil pump through the machine return oil channel 42.

[0048] In an embodiment of the present application, as shown in Figure 7, the third main oil channel 413 is communicated with a second branch inlet oil channel 4137; the second branch inlet oil channel 4137 is communicated with a second branch outlet oil channel 4138 through a second branch oil passage 4132; the second branch oil passage 4132 flows through an IGBT module 303; one end of the IGBT module 303 is communicated with the second branch inlet oil channel 4137, and the other end of the IGBT module 303 is communicated with the second branch outlet oil channel 4138.

[0049] In the implementation process, the first branch oil path 4131 and the second branch oil path 4132 are arranged in parallel and staggered, and the first branch oil path 4131 and the second branch oil path 4132 are arranged perpendicularly to the third main oil channel 413; part of the cooling oil in the third main oil channel 413 flows into the second branch oil path 4132 (the second branch oil path 4132 includes an IGBT module 303 oil path, the IGBT module 303 oil path is arranged in the IGBT module 303, and an oil inlet and an oil outlet are arranged on the IGBT module 303 and are connected with the second branch oil inlet channel 4137 and the second branch oil outlet channel 4138, respectively) through the second branch oil inlet channel 4137, and directly contacts the chip of the IGBT module 303; the IGBT module 303 is fully cooled and radiated, and the product performance is improved; and then the cooling oil flows into the first oil return flow channel 4140 through the second branch oil outlet channel 4138 and is collected with the cooling oil in the first branch oil outlet channel 4139; the IGBT module 303 is provided with an oil path cooling channel through the second branch oil inlet channel 4137, the second branch oil path 4132 and the second branch oil outlet channel 4138.

[0050] In an embodiment of the present application, as shown in FIGS. 5 and 7, the first oil return flow channel 4140 is arranged at one end of the integrated shell 40 away from the controller 30; one end of the first oil return flow channel 4140 is connected with the first branch oil outlet channel 4139; and the first oil return flow channel 4140 is connected with the machine oil return channel 42. The first oil return flow channel 4140 is arranged at the bottom of the integrated shell 40.

[0051] In an embodiment of the present application, as shown in FIG. 7, the second branch oil outlet channel 4138 is connected with the middle part of the first oil return flow channel 4140.

[0052] In an embodiment of the present application, one end of the first oil return flow channel 4140 away from the first branch oil outlet channel 4139 is connected with the second oil return flow channel 4134.

[0053] In an embodiment of the present application, as shown in FIG. 5, the first oil return flow channel 4140 is arranged perpendicularly to the second oil return flow channel 4134.

[0054] In an embodiment of the present application, as shown in FIGS. 8 and 9, a plurality of oil outlet holes 4141 are arranged on the second oil return flow channel 4134; a first oil passing hole 3042 is arranged on the second copper bar assembly 304 and is connected with the oil outlet hole 4141; and a second oil passing hole is arranged on the rear end cover 21 of the machine; the first oil passing hole 3042 is connected with the machine oil return channel 42 through the second oil passing hole.

[0055] In the implementation process, the cooling oil in the first branch oil path 4131 and the second branch oil path 4132 flows through the first oil return flow channel 4140 and the second oil return flow channel 4134; after flowing through the second oil return flow channel 4134, the cooling oil flows out from the first oil outlet hole 4141; the cooling oil flows into the second copper bar assembly 304 through the first oil outlet hole 4141, and cools and dissipates heat for the three-phase copper bar 3041; and then flows into the motor oil return channel 42 at the bottom of the motor 20 from the second oil passing hole on the rear end cover 21 of the motor, and finally flows into the oil pump.

[0056] In an embodiment of the present application, as shown in FIG. 6, the integrated housing 40 is provided with an oil pump port 50; the oil pump port 50 is in communication with an oil filter 60 through a cooling oil channel 41; the oil filter 60 is in communication with an oil cooler 70; and the oil cooler 70 is in communication with a first main oil channel 411, a second main oil channel 412 and a third main oil channel 413. The oil pump port 50 is also arranged at the bottom of the integrated housing 40.

[0057] In the implementation process, after the cooling oil works in the oil paths inside the speed reducer 10, the motor 20 and the controller 30, the cooling oil flows into the oil pump through the motor oil return channel 42 and the oil pump port 50; then flows into the oil filter 60 through the cooling oil channel 41, and the cooling oil is filtered by the oil filter 60 to remove the impurities in the cooling oil after the cooling work; then flows through the oil cooler 70, because the cooling oil will absorb heat after the cooling work and thus the temperature will rise, so the temperature needs to be lowered before the cooling oil enters the first main oil channel 411, the second main oil channel 412 and the third main oil channel 413 again for the second cooling work; thus a complete three-in-one oil-cooled electric drive assembly oil path cooling loop is formed, and the working effect of the cooling oil is ensured.

[0058] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that the technical solutions recorded in the foregoing embodiments can be modified, or some technical features can be replaced by equivalent features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A three-in-one oil-cooled electric drive assembly, characterized in that, Including reducer (10), motor (20), controller (30) and integrated shell (40);The reducer (10) and motor (20) are respectively installed on the two sides adjacent to integrated shell (40);The integrated shell (40) is provided with mounting groove; The integrated shell (40) is provided with cooling oil channel (41);The cooling oil channel (41) is communicated with reducer (10), motor (20), controller (30) and integrated shell (40);The cooling oil channel (41) is communicated with oil pump at one end, and the other end of the cooling oil channel (41) is communicated with first main oil channel (411), second main oil channel (412) and third main oil channel (413);The first main oil channel (411) is arranged at the position corresponding to the reducer (10) of the integrated shell (40);The second main oil channel (412) is arranged at the position corresponding to the motor (20) of the integrated shell (40);The third main oil channel (413) is arranged in the mounting groove;The first main oil channel (411) is communicated with the oil circuit in the reducer (10), the second main oil channel (412) and the third main oil channel (413);The second main oil channel (412) is communicated with the oil circuit in the motor (20);The third main oil channel (413) is communicated with the oil circuit in the controller (30); The motor (20) is provided with motor oil return channel (42) at the end away from the reducer (10);The motor oil return channel (42) is communicated with the first main oil channel (411), the second main oil channel (412) and the third main oil channel (413) at one end, and is communicated with the oil pump at the other end.

2. The three-in-one oil-cooled electric drive assembly of claim 1, wherein, A first branch oil channel (4131) is arranged in the first branch oil channel (4136) and the first branch oil channel (4139) in the one recess (4135);The third main oil channel (413) is communicated with the first branch oil channel (4136);The first branch oil channel (4136) is communicated with the first branch oil channel (4139) through the first branch oil channel (4131);The first branch oil channel (4136) is arranged at the end close to the third main oil channel (413) in the one recess (4135);The first branch oil channel (4139) is arranged at the end away from the third main oil channel (413) in the one recess (4135).

3. The three-in-one oil-cooled electric drive assembly of claim 2, wherein, The third main oil passage (413) communicates with the second branch oil inlet passage (4137); the second branch oil inlet passage (4137) communicates with the second branch oil outlet passage (4138) through the second branch oil path (4132); the second branch oil path (4132) flows through the IGBT module (303); one end of the IGBT module (303) communicates with the second branch oil inlet passage (4137), and the other end of the IGBT module (303) communicates with the second branch oil outlet passage (4138).

4. The three-in-one oil-cooled electric drive assembly of claim 3, wherein, The top of the first recess (4135) is provided with a sealing groove (4142); the sealing groove (4142) cooperates with the first copper bar assembly to realize the internal sealing of the first recess (4135).

5. The three-in-one oil-cooled electric drive assembly of claim 4, wherein, The integrated shell (40) is provided with a first oil return flow channel (4140) at one end away from the controller (30); one end of the first oil return flow channel (4140) communicates with the first branch oil outlet passage (4139); the first oil return flow channel (4140) communicates with the motor oil return passage (42).

6. The three-in-one oil-cooled electric drive assembly of claim 5, wherein, The second branch oil outlet passage (4138) communicates with the middle part of the first oil return flow channel (4140).

7. The three-in-one oil-cooled electric drive assembly of claim 6, wherein, The first oil return flow channel (4140) communicates with the second oil return flow channel (4134) at one end away from the first branch oil outlet passage (4139).

8. The three-in-one oil-cooled electric drive assembly of claim 7, wherein, The first oil return flow channel (4140) and the second oil return flow channel (4134) are arranged vertically.

9. The three-in-one oil-cooled electric drive assembly of claim 8, wherein, A plurality of oil outlet holes (4141) are arranged on the second oil return flow channel (4134); a first oil passing hole (3042) that communicates with the oil outlet hole (4141) is arranged on the second copper bar assembly (304); a second oil passing hole is arranged on the motor rear end cover (21); the first oil passing hole (3042) communicates with the motor oil return passage (42) through the second oil passing hole.

10. The three-in-one oil-cooled electric drive assembly of claim 9, wherein, The integrated shell (40) is provided with an oil pump port (50); the oil pump port (50) communicates with the oil filter (60) through the cooling oil passage (41); the oil filter (60) communicates with the oil cooler (70); the oil cooler (70) communicates with the first main oil passage (411), the second main oil passage (412) and the third main oil passage (413).

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