Integrated system for electric drive, power system, electric vehicle, and carbon fiber fixing method

Abstract

The present application relates to the technical field of electric drive systems, and discloses an integrated system for electric drive, a power system, an electric vehicle, and a carbon fiber fixing method. The integrated system comprises a housing, a position sensor, and a conductive member. A rotating shaft and a bearing are provided in the housing. The position sensor comprises a circuit board and an induction rotor, the circuit board is integrated with an induction coil, and the induction rotor is connected to the rotating shaft. The conductive member is fixed to the circuit board and is electrically connected to the circuit board, an end surface of the conductive member is in contact with the bearing, and a shaft current is sequentially conducted to the circuit board and the housing by means of the conductive member. The present application achieves the integration of a position sensing function and an electrocorrosion inhibition function, such that the system has the advantages of occupying a smaller axial position of a motor, saving material costs, having a simple mounting process, being able to satisfy use in different environments, etc.

Description

Electric drive integrated system, power system, electric vehicle and carbon fiber fixing method

[0001] This application claims priority to Chinese Patent Application No. 202411949614.4, filed on December 27, 2024, entitled "Integrated System for Electric Drive and Electric Vehicle", the entire contents of which are incorporated herein by reference.

[0002] This application claims priority to Chinese Patent Application No. 202411949620.X, filed on December 27, 2024, entitled "Integrated System for Electric Drive and Electric Vehicle", the entire contents of which are incorporated herein by reference.

[0003] This application claims priority to Chinese Patent Application No. 202511588304.9, filed on October 31, 2025, entitled "Electric Motor and Method for Fixing Carbon Fiber to Circuit Board", the entire contents of which are incorporated herein by reference.

[0004] This application claims priority to Chinese patent application filed on November 5, 2025, with application number 202511609042.X and entitled "Integrated Structure and Power System for Bearing Anti-Electro-Electro-Corrosion and Eddy Current Sensing", the entire contents of which are incorporated herein by reference. Technical Field

[0005] This application relates to the field of electric drive system technology, and in particular to an electric drive integrated system, a power system, an electric vehicle, and a method for fixing carbon fiber. Background Technology

[0006] In related technologies, electric drive systems include at least a drive motor and a motor controller. Currently, to acquire the rotational speed of the drive motor, a position sensor is installed on one end face of the drive motor; to suppress electro-corrosion of the motor bearings, a conductive ring is installed on the other end face of the drive motor to form a conductive bypass. The problem with current electric drive systems is that the position sensor and the conductive ring are installed independently, each occupying a certain axial space on the drive motor. Therefore, sufficient installation space needs to be reserved for each, resulting in a large axial space requirement for the drive motor, and consequently, a large overall motor size. Summary of the Invention

[0007] The main objective of this application is to provide an electric drive integrated system, a power system, an electric vehicle, and a method for fixing carbon fiber, aiming to solve the technical problem in related technologies where the conductive ring and position sensor of the electric drive system are installed independently, occupying a large amount of axial space of the drive motor.

[0008] To achieve the above objectives, this application proposes an electric drive integrated system, comprising:

[0009] The housing contains a rotating shaft and bearings.

[0010] The position sensor includes a circuit board and a sensing rotor, wherein the circuit board integrates a sensing coil and the sensing rotor is connected to a rotating shaft;

[0011] The conductive component is fixed to the circuit board and electrically connected to the circuit board. The end face of the conductive component is in contact with the bearing, and the shaft current is conducted sequentially to the circuit board and the housing through the conductive component.

[0012] In one embodiment, the circuit board is electrically connected to the housing, and the housing is grounded.

[0013] In one embodiment, it further includes:

[0014] The resistor-capacitor module is fixed to the circuit board. One end of the resistor-capacitor module is connected to a conductive component, and the other end of the resistor-capacitor module is electrically connected to the circuit board.

[0015] In one embodiment, the resistor-capacitor module and the induction coil are located on different sides of the circuit board.

[0016] In one embodiment, it further includes:

[0017] A thermistor is fixed to a circuit board and electrically connected to it. The thermistor is used to detect the temperature of the motor coolant.

[0018] In one embodiment, it further includes:

[0019] Motor controller, the motor controller communicates with the circuit board.

[0020] In one embodiment, a signal processing module is provided on the circuit board;

[0021] The signal processing module is connected to the circuit board and communicates with the motor controller.

[0022] In one embodiment, the circuit board is sleeved on the outside of the rotating shaft and cooperates with the induction rotor to generate a magnetic field, or it is disposed on one side of the induction rotor and cooperates with the induction rotor to generate a magnetic field.

[0023] In one embodiment, the induction rotor is the rotor of a rotary transformer or the rotor of an eddy current sensor.

[0024] In one embodiment, a rotor core and a stator core are further provided inside the housing;

[0025] The rotor core is sleeved on the rotating shaft and located inside the stator core. The bearing is sleeved at the end of the rotating shaft and located inside the stator core. The circuit board is sleeved on the rotating shaft and located axially between the bearing and the rotor core.

[0026] In one embodiment, a rotor core and a stator core are further provided inside the housing;

[0027] The rotor core is sleeved on the rotating shaft and located inside the stator core. The bearing is sleeved on the rotating shaft and located inside the stator core. The circuit board is sleeved on the end of the rotating shaft and located axially outside the stator core.

[0028] In one embodiment, an electric drive integrated system further includes:

[0029] The motor includes a housing;

[0030] Motor control unit;

[0031] A temperature sensor is fixed to a circuit board and electrically connected to the circuit board.

[0032] The signal lines of the temperature sensor and the position sensor are integrated on the circuit board and transmitted to the motor control unit through the circuit board.

[0033] In one embodiment, it further includes:

[0034] The resistor-capacitor module is fixed to the circuit board. One end of the resistor-capacitor module is electrically connected to the rotating shaft, and the other end of the resistor-capacitor module is grounded.

[0035] In one embodiment, the RC module and the temperature sensor are located on different sides of the circuit board.

[0036] In one embodiment, the communication lines of the integrated temperature sensor signal line and the position sensor signal line are connected to the circuit board through an electrical connection mounting hole and communicate with the motor control unit.

[0037] In one embodiment, a signal processing module is provided on the circuit board;

[0038] The signal processing module is connected to the circuit board and communicates with the motor control unit.

[0039] In one embodiment, the circuit board is sleeved on the outside of the rotating shaft and cooperates with the induction rotor to generate a magnetic field, or it is disposed on one side of the induction rotor and cooperates with the induction rotor to generate a magnetic field.

[0040] In one embodiment, the induction rotor is the rotor of a rotary transformer or the rotor of an eddy current sensor.

[0041] In one embodiment, the motor further includes bearings, a rotor core, and a stator core;

[0042] The rotor core is sleeved on the rotating shaft and located inside the stator core. The bearing is sleeved at the end of the rotating shaft and located inside the stator core. The circuit board is sleeved on the rotating shaft and located axially between the bearing and the rotor core.

[0043] In one embodiment, the motor further includes bearings, a rotor core, and a stator core;

[0044] The rotor core is sleeved on the rotating shaft and located inside the stator core. The bearing is sleeved on the rotating shaft and located inside the stator core. The circuit board is sleeved on the end of the rotating shaft and located axially outside the stator core.

[0045] In one embodiment, the housing has a shaft hole and a boss arranged circumferentially along the periphery of the shaft hole; one end of the boss along the axial direction is provided with a target end face, and a slot is formed by opening the target end face along the axial direction of the boss, and the slot communicates with the shaft hole;

[0046] The circuit board is housed inside the casing;

[0047] The conductive component is soldered onto the circuit board, with one end of the conductive component passing through the slot and extending at least partially into the shaft hole;

[0048] The cover abuts against the conductive element along the axial direction.

[0049] In one embodiment, a cover is provided on the target end face of the boss; the cover is provided with a protrusion, which is axially opposite to the slot, and the protrusion can be inserted into the slot and abut against the conductive element.

[0050] In one embodiment, the cover and the boss are connected by welding.

[0051] In one embodiment, the protrusion can engage with the slot;

[0052] And / or, the protrusion and the groove are interference fit.

[0053] In one embodiment, the sides of the protrusion at both ends in the circumferential direction are provided with ribs, and the ribs are interference-fitted with the sidewalls of the groove.

[0054] In one embodiment, the outer peripheral surface of the cover is further provided with a plate portion, which is connected to one radial end of the protrusion. The plate portion and the slot are arranged radially opposite each other. The plate portion can fit against the outer peripheral surface of the boss, and the projection of the plate portion on the outer peripheral surface of the boss covers the projection of the slot on the outer peripheral surface of the boss.

[0055] In one embodiment, the plate body is provided with a guide groove, which is arranged axially opposite to the conductive component, and the guide groove is used to limit the conductive component.

[0056] In one embodiment, the conductive element is made of carbon fiber; the conductive element is tin-plated and then soldered onto the circuit board.

[0057] In one embodiment, a first limiting surface is provided in the slot, a second limiting surface is provided on the side of the protrusion facing the conductive element along the axial direction, and a third limiting surface is provided in the guide groove. The first limiting surface, the second limiting surface and the third limiting surface are all matched with the shape of the outer peripheral surface of the conductive element, and the first limiting surface, the second limiting surface and the third limiting surface are all in contact with the outer peripheral surface of the conductive element.

[0058] In one embodiment, the housing is further provided with a connecting kit, which is conductive;

[0059] The electric drive integrated system also includes a resistor-capacitor module, which includes a body and terminals set at an angle to the body. The body is electrically connected to the connector kit, and the terminals are electrically connected to the circuit board.

[0060] In one embodiment, the connecting kit has a first through hole, and the body has a second through hole, the second through hole being coaxially arranged with the first through hole;

[0061] The main body is located at one end of the connecting kit along the axial direction, and the main body fits into the connecting kit; the housing encapsulates the main body and the connecting kit.

[0062] In one embodiment, the circuit board is provided with conductive holes corresponding to the terminals;

[0063] The terminal includes a root and a pin, and two elastic parts connected between the root and the pin, with the two elastic parts spaced apart from each other; the terminal is inserted into a conductive hole, and the elastic parts are compressed and elastically contracted, and elastically abut against the inner wall of the conductive hole.

[0064] In one embodiment, it includes:

[0065] Motor shaft;

[0066] The circuit board has a shaft hole, and the circuit board is loosely fitted onto the motor shaft through the shaft hole. The circuit board has solder pads arranged around the circumference of the shaft hole.

[0067] The conductive component is made of carbon fiber. One end of the carbon fiber contacts and is soldered to the pad, while the other end of the carbon fiber away from the pad contacts and is connected to the motor shaft to form a shaft current conduction path.

[0068] By applying an electroplated layer to carbon fiber and then soldering it to the pads on a circuit board, one end of the carbon fiber contacts the motor shaft, while the other end is soldered to the circuit board pads. This directly diverts the shaft current generated by the shaft voltage away from the bearing, extending the life of the motor bearing.

[0069] In one embodiment, the carbon fiber surface has a nickel layer and a tin layer, and one end of the carbon fiber having the nickel layer and tin layer is soldered to a pad by tin plating.

[0070] In one embodiment, a grounding conductive loop is provided on the circuit board, and the end of the carbon fiber away from the pad is in contact with the motor shaft. The pad is electrically connected to the grounding conductive loop to ground the shaft current.

[0071] By setting up a grounding conductive loop, a complete grounding closed loop is formed, consisting of "motor shaft → carbon fiber → solder pad → grounding conductive loop", which prevents shaft current from accumulating inside the motor and solves the problems of bearing failure and motor malfunction caused by shaft current.

[0072] In one embodiment, a solder paste layer is provided on the pad, and the solder paste layer has raised structures spaced apart along the length of the carbon fiber.

[0073] By forming a solder paste layer of a fixed shape, the solder paste filling range can be precisely controlled, preventing the molten solder from overflowing and causing the carbon fiber to harden.

[0074] In one embodiment, a metal sleeve is fitted at the end of the carbon fiber that contacts the motor shaft. The inner wall of the metal sleeve is interference-fitted with the carbon fiber, and the outer wall of the metal sleeve is in contact with the surface of the motor shaft.

[0075] In one embodiment, the thickness of the nickel layer is set to 1 μm-3 μm, and the thickness of the tin layer is set to 5 μm-10 μm.

[0076] In one embodiment, carbon fibers are welded onto a circuit board using a welding head. The welding head includes a cavity structure and a barrier structure disposed inside the cavity structure. The shape of the solder paste layer is adapted to the shape formed by the cavity structure and the barrier structure.

[0077] In one embodiment, this application also proposes a method for fixing carbon fibers, the method comprising:

[0078] The carbon fiber is electroplated to form an electroplated layer on its surface;

[0079] Pads are provided along the circumference of the axial hole of the circuit board, wherein the circuit board is loosely fitted onto the motor shaft through the axial hole;

[0080] Align one end of the carbon fiber with the pad on the circuit board, and then weld the carbon fiber onto the pad using a thermoforming process.

[0081] In one embodiment, after electroplating the carbon fiber, a nickel layer and a tin layer are sequentially formed on the surface of the carbon fiber.

[0082] In one embodiment, the step of forming a nickel layer and a tin layer on the surface of the carbon fiber is as follows:

[0083] One end of the pretreated carbon fiber is placed in a nickel plating solution, and a nickel layer is deposited using a chemical plating process, wherein the thickness of the nickel layer is 1μm-3μm.

[0084] The nickel-plated carbon fiber is placed in a tin plating solution, and a tin layer is deposited using an electrodeposition process, wherein the thickness of the tin layer is 5μm-10μm.

[0085] In one embodiment, the welding head used in the thermocompression welding process is provided with a cavity structure and a barrier structure. During the welding process, the welding head places solder paste in the cavity structure.

[0086] In one embodiment, this application provides a power system including the electric drive integrated system as described above.

[0087] In one embodiment, this application also proposes an electric vehicle including the electric drive integrated system as described above.

[0088] One or more technical solutions proposed in this application have at least the following technical effects:

[0089] An integrated electric drive system is proposed, comprising a housing, a position sensor, and conductive components. The housing houses a rotating shaft and a bearing. The position sensor includes a circuit board and an induction rotor. An induction coil is integrated into the circuit board, and the induction rotor is connected to the rotating shaft to generate an excitation magnetic field, thus realizing the position sensor function. The conductive components are fixed to the circuit board and electrically connected to it. The end face of the conductive components contacts the bearing, allowing shaft current to be conducted sequentially through the conductive components to the circuit board and the housing, suppressing bearing galvanic corrosion. This integrates position sensing and galvanic corrosion suppression functions. This integrated system utilizes the commonality of the circuit boards to integrate the conductive ring on the motor and the position sensor, reducing the number of components, saving installation space, and simplifying the installation process. This integrated system offers advantages such as occupying less axial space of the motor, saving material costs, simple installation, and suitability for use in various environments. Attached Figure Description

[0090] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0091] To more clearly illustrate the technical solutions in the embodiments or related technologies of this application, the accompanying drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0092] Figure 1 is a schematic diagram of the front structure of the circuit board in one embodiment of the electric drive integrated system of this application;

[0093] Figure 2 is a schematic diagram of the back structure of the circuit board in one embodiment of the electric drive integrated system of this application;

[0094] Figure 3 is a schematic diagram of the structure of the rotating shaft and the induction rotor in one embodiment of the electric drive integrated system of this application;

[0095] Figure 4 is a schematic diagram of an induction rotor in one embodiment of the electric drive integrated system of this application;

[0096] Figure 5 is a schematic diagram of another structure of the induction rotor in one embodiment of the electric drive integrated system of this application;

[0097] Figure 6 is a schematic diagram of a conductive element in one embodiment of the electric drive integrated system of this application;

[0098] Figure 7 is a schematic diagram of another structure of the conductive element in one embodiment of the electric drive integrated system of this application;

[0099] Figure 8 is a schematic diagram of the back structure of the circuit board in one embodiment of the electric drive integrated system of this application;

[0100] Figure 9 is a schematic diagram of the front structure of the circuit board in one embodiment of the electric drive integrated system of this application;

[0101] Figure 10 is a wiring diagram of the circuit board in one embodiment of the electric drive integrated system of this application;

[0102] Figure 11 is a schematic diagram of an installation position of one embodiment of the electric drive integrated system of this application;

[0103] Figure 12 is a schematic diagram of another installation position of one embodiment of the electric drive integrated system of this application;

[0104] Figure 13 is a perspective view of the electric drive integrated system provided in an embodiment of this application;

[0105] Figure 14 is an exploded view of the electric drive integrated system provided in an embodiment of this application;

[0106] Figure 15 is a magnified view of part A in Figure 14;

[0107] Figure 16 is a perspective view of the cover shown in Figure 14;

[0108] Figure 17 is a magnified view of part B in Figure 16;

[0109] Figure 18 is a top view of the electric drive integrated system shown in Figure 13;

[0110] Figure 19 is a sectional view of section CC in Figure 18;

[0111] Figure 20 is a sectional view of section DD in Figure 19;

[0112] Figure 21 is a magnified view of a portion of point E in Figure 20;

[0113] Figure 22 is a sectional view of section FF in Figure 18;

[0114] Figure 23 is a perspective view of the resistor-capacitor module shown in Figure 14;

[0115] Figure 24 is a schematic diagram of the assembly of the circuit board and carbon fiber in an embodiment of this application;

[0116] Figure 25 is a schematic diagram of the assembly of carbon fiber and solder pads in an embodiment of this application;

[0117] Figure 26 is an assembly diagram of the welding head and the welding pad during the welding process in an embodiment of this application;

[0118] Figure 27 is a schematic diagram of the structure of the welding head in an embodiment of this application.

[0119] Reference numerals: 1-Motor; 10-Housing; 11-Shaft; 12-Bearing; 13-Rotor Core; 14-Stator Core; 2-Position Sensor; 20-Circuit Board; 21-Induction Rotor; 211-Resolver; 2111-Terminal Block; 2112-Mounting Component; 212-Eddy Current Sensor; 22-Conductive Component; 221-Conductive Carbon Brush; 222-Conductive Brush; 223-Fastener; 24-Thermistor; 25-Signal Processing Module; 101-Shaft Hole; 110-Boss; 111-Target End Face; 112-Slot; 113-First Limiting Surface; 201-Conductive Hole; 40-Cover; 41-Protrusion; 411-Rib; 412-Second Limiting Surface; 42-Plate Body; 421-Guide Groove; 422-Third Limiting Surface; 50-Connecting kit; 501-First through hole; 60-RC module; 61-Body; 611-Second through hole; 62-Terminal; 621-Root; 622-Pin; 623-Elastic part; X-Radial; Y-Axial; W-Circumferential; 7-Positioning hole; 8-Pad; 9-Carbon fiber; 3-Solder paste layer; 4-Solder head; 44-Cavity structure; 45-Barrier structure; 43-Solder head body.

[0120] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0121] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0122] It should be noted that if the embodiments of this application involve directional indications (such as up, down, left, right, front, back, etc.), these directional indications are only used to explain the relative positional relationships and movement of the components in a specific posture. If the specific posture changes, the directional indications will also change accordingly. Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" can explicitly or implicitly include at least one of those features. Additionally, if "and / or" or "and / or" appears throughout the text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or a solution where A and B are simultaneously satisfied. Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0123] The circuits in this application embodiment are applicable to scenarios with high requirements for shaft current protection, lightweighting, and reliability, such as new energy vehicle drive motors, industrial servo motors, aerospace motors, and new energy power generation equipment.

[0124] In related technologies, an electric drive system includes at least a drive motor and a motor controller. Currently, in order to acquire the rotational speed of the drive motor, a position sensor is installed on one end face of the drive motor. The excitation magnetic field of this position sensor is usually set in a PCB (Printed Circuit Board), which is mounted on the motor shaft.

[0125] To suppress electro-corrosion of motor bearings, a conductive ring is placed on the other end face of the drive motor to form a conductive bypass. This conductive ring is typically mounted on the motor shaft or motor housing. Based on this, a current problem with electric drive systems is that the position sensor and the conductive ring are installed independently, each occupying a certain axial space on the drive motor. Therefore, sufficient installation space needs to be reserved for each, resulting in a large axial space requirement for the drive motor and consequently a large overall motor size. Furthermore, the independent installation process for the position sensor and the conductive ring is complex, making the installation procedure for the drive motor cumbersome.

[0126] To address the aforementioned problems, this application provides an integrated electric drive system. The application and its embodiments will be described below with reference to the accompanying drawings.

[0127] In the first embodiment of the electric drive integrated system of this application, referring to Figures 1 and 2, Figure 1 is a front view of the circuit board in the electric drive integrated system and Figure 2 is a back view of the circuit board in the electric drive integrated system. The integrated system may include a housing 10, a position sensor 2 and a conductive element 22.

[0128] The housing 10 is the housing of the motor 1, and the housing 10 contains a rotating shaft 11 and a bearing 12.

[0129] It should be noted that the inner ring of bearing 12 is connected to the shaft 11, and the outer ring of bearing 12 is connected to the housing 10. The motor 1 may also include a rotor assembly and a stator assembly. The stator assembly has components such as a stator core and stator windings. In addition, the motor 1 may also include components such as splines. The motor structure is a known technical solution in the art and will not be described in detail here.

[0130] The position sensor 2 may include a circuit board 20 and an induction rotor 21, wherein the circuit board 20 integrates an induction coil and the induction rotor 21 is connected to the rotating shaft 11.

[0131] It should be noted that circuit board 20 refers to a circuit board that can cooperate with induction rotor 21 to generate an excitation magnetic field and realize the function of a position sensor. Circuit board 20 integrates an induction coil, and the working principle between the induction coil and induction rotor 21 can vary depending on the type of position sensor formed by circuit board 20 and induction rotor 21. For example, induction rotor 21 can be a metal conductor, serving as a sensor probe. The induction coil of circuit board 20 can include a transmitting coil, a receiving coil, and related electronic components for control coils. When this induction rotor 21 cooperates with circuit board 20, it can realize the position detection or displacement detection function of an eddy current sensor. Alternatively, induction rotor 21 can be a primary coil, serving as the rotor of a rotary transformer, and the induction coil of circuit board 20 can be a secondary coil, serving as the stator of the rotary transformer. When this induction rotor 21 cooperates with circuit board 20, it can realize the position detection or displacement detection function of the rotary transformer.

[0132] For example, as shown in Figure 3, which is a schematic diagram of the structure of the rotating shaft and the sensing rotor in this embodiment, the sensing rotor 21 is connected to the rotating shaft 11 and can be sleeved on the outside of the rotating shaft 11, rotating with the rotating shaft 11. The sensing rotor 21 can be fixed to one end of the rotating shaft 11. The circuit board 20 can be wrapped around the periphery of the sensing rotor 21, or located on one side of the sensing rotor 21 in the axial direction, or fixed inside the housing 10, maintaining a certain sensing distance from the sensing rotor 21. The specific settings can be configured according to actual needs and are not limited here.

[0133] Due to the voltage division effect of parasitic capacitance in the electric drive system, the common-mode voltage causes a voltage drop between the inner and outer rings of bearing 12. When the common-mode voltage exceeds the critical voltage of the bearing oil film, the oil film breaks down, resulting in EDM discharge. This causes ablation and spotting on the surfaces of the inner and outer rings and balls of bearing 12. Prolonged and frequent EDM discharge will cause obvious corrosive marks on the surfaces of the inner and outer rings and balls of bearing 12, indicating bearing electro-corrosion. Bearing electro-corrosion will cause vibration and noise in motor 1, affecting its operation.

[0134] To suppress the electro-corrosion of the bearing 12, the integrated system also includes a conductive element 22, which is fixed to the circuit board 20 and electrically connected to the circuit board 20. The end face of the conductive element 22 contacts the bearing 12, and the shaft current is conducted through the conductive element 22 to the circuit board 20 and the housing 10 in sequence.

[0135] It should be noted that the conductive component 22 can be connected to the bearing 12 through its end face to conduct shaft current to the circuit board 20, or it can be electrically connected to the rotating shaft 11 through its input end and to the circuit board 20 through its output end. Since the rotating shaft 11 is connected to the bearing 12, the conductive component 22 is indirectly connected to the bearing 12 to conduct shaft current to the circuit board 20. Through the cooperation of the conductive component 22 and the circuit board 20, the rotating shaft 11 of the motor 1 is grounded through the conductive component 22 and the circuit board 20, releasing the charge on the rotating shaft 11 to ground, thereby reducing the voltage ratio between the inner and outer rings of the bearing 12, and thus achieving the bearing electro-corrosion suppression function.

[0136] For example, as shown in Figures 1 and 2, the sensing rotor 21 is connected to the rotating shaft 11 and sleeved on one end of the rotating shaft 11. The circuit board 20 is fixed to one side of the sensing rotor 21, specifically it can be fixed on the housing 10. The circuit board 20 can have an induction coil built in it, or the induction coil can be set on the surface of the circuit board 20. The circuit board 20 is wound around the outside of the rotating shaft 11. When the sensing rotor 21 rotates with the rotating shaft 11, the induction coil of the circuit board 20 can form a magnetic field with the sensing rotor 21 to realize the function of the position sensor. It is understood that other electronic components of the position sensor can also be integrated into the circuit board 20, including related electronic components for realizing sensing signal processing and output, which are not specifically limited here. The conductive element 22 can be fixed on the circuit board 20. For example, if the induction rotor 21 is located on the front of the circuit board 20, the conductive element 22 can be located on the back of the circuit board 20. The conductive element 22 can be a conductive carbon brush, a conductive brush, etc. Here, multiple conductive brushes 222 are used as an example. The input end of the conductive brush 222 is electrically connected to the rotating shaft 11, and the output end of the conductive brush 222 is connected to the circuit board 20 to achieve grounding. In addition, shaft holes, positioning holes, etc. can be provided on the circuit board 20 according to actual needs to fix the wiring on the circuit board 20 to the circuit board 20 through fasteners 223, etc.

[0137] Unlike related technologies where the conductive ring and position sensor are set up separately, this example integrates the circuit board of the conductive ring and the circuit board of the position sensor, reducing installation space and simplifying the installation process; it also saves material costs and simplifies the installation process; by utilizing the common features of the circuit boards, the conductive ring and position sensor are integrated into one unit, so that the integrated system has both position sensing function and bearing electro-corrosion suppression function.

[0138] The electric drive integrated system provided in this embodiment includes a housing, a position sensor, and conductive components. The housing houses a rotating shaft and a bearing. The position sensor includes a circuit board and an induction rotor. An induction coil is integrated into the circuit board, and the induction rotor is connected to the rotating shaft to generate an excitation magnetic field, thus realizing the position sensor function. The conductive components are fixed to the circuit board and electrically connected to it. The end face of the conductive components contacts the bearing, allowing shaft current to be conducted sequentially through the conductive components to the circuit board and the housing, suppressing bearing electro-corrosion. This integrates position sensing and electro-corrosion suppression functions. In this integrated system, the commonality of the circuit boards is utilized to integrate the conductive ring on the motor and the position sensor in related technologies, reducing the number of components, saving installation space, and simplifying the installation process. This integrated system offers advantages such as occupying less motor axial space, saving material costs, simple installation, and suitability for use in various environments.

[0139] In one possible implementation, the circuit board 20 is electrically connected to the housing 10, and the housing 10 is grounded.

[0140] It should be noted that an induction coil is installed inside the circuit board 20, and other electronic components can also be installed on it. To ensure circuit integrity, the circuit board 20 needs to be grounded. Specifically, it can be directly electrically connected to the housing 10, and the circuit board 20 is grounded based on the grounding of the housing 10, thereby grounding the conductive component 22 and the induction coil or other electronic components on the circuit board 20.

[0141] In this embodiment, the circuit board is electrically connected to the housing, and the circuit board is directly grounded by the grounding of the housing. The grounding method is simple and does not require other grounding devices, which can simplify the motor structure and save motor space.

[0142] In one feasible implementation, the circuit board 20 is sleeved on the outside of the rotating shaft 11 and cooperates with the induction rotor 21 to generate a magnetic field, or it is disposed on one side of the induction rotor 21 and cooperates with the induction rotor 21 to generate a magnetic field.

[0143] It should be noted that the circuit board 20 can be a ring structure, sleeved on the rotating shaft 11, with a certain sensing distance in the axial direction from the sensing rotor 21, so that the sensing rotor 21 generates a sensing magnetic field through the cooperation between the sensing rotor 21 and the circuit board 20 during rotation, thereby realizing the position detection of the rotating shaft 11; or it can be an arc-shaped structure, set on the sensing rotor 21, located on one side of the sensing rotor 21 in the axial direction, and with a certain sensing distance in the axial direction from the sensing rotor 21, so that the sensing rotor 21 generates a sensing magnetic field through the cooperation between the sensing rotor 21 and the circuit board 20 during rotation, thereby realizing the position detection of the rotating shaft 11.

[0144] In this embodiment, the position detection is achieved by generating a magnetic field through the cooperation of the circuit board and the induction rotor, which enables the system to have a position sensing function. Based on this, the circuit board can be set in various ways to adapt to a variety of application environments.

[0145] In one possible implementation, the sensing rotor 21 is the rotor of the rotary transformer 211, or the rotor of the eddy current sensor 212, or the rotor of other types of position sensors.

[0146] It should be noted that when the induction rotor 21 and the induction coil within the circuit board 20 form a position sensor with a rotary transformer structure, the induction rotor 21 is the rotor of the rotary transformer 211; when the induction rotor 21 and the induction coil within the circuit board 20 form a position sensor with an eddy current sensor structure, the induction rotor 21 is the rotor of the eddy current sensor 212. Correspondingly, the circuit board 20 can be the stator of the rotary transformer 211 or the stator of the eddy current sensor 212, specifically configured to correspond to the induction rotor 21, in order to cooperate with the induction rotor 21 to generate an excitation magnetic field and realize the function of the position sensor.

[0147] For example, as shown in Figure 4, which is a structural schematic diagram of the sensing rotor in this embodiment, the sensing rotor 21 can be wound around the rotating shaft 11, and the circuit board 20 can be fixed to the periphery of the sensing rotor 21 by the mounting assembly 2112. In this example, the sensing rotor 21 and the circuit board 20 constitute a position sensor of a rotary transformer structure. The sensing rotor 21 is the rotor of the rotary transformer 211, and the circuit board 20 is the stator of the rotary transformer 211. The two work together to realize the position sensing function. The circuit board 20 can also be provided with wiring terminals 2111 to output the signal generated by the circuit board 20 to the outside of the motor 1, providing it to the motor controller of the integrated system.

[0148] For example, as shown in Figure 5, another structural schematic diagram of the induction rotor in this embodiment is presented. The induction rotor 21 can be wound around the rotating shaft 11, and the circuit board 20 can be fixed around the rotating shaft 11 and located on one side of the induction rotor 21. In this example, the induction rotor 21 and the circuit board 20 constitute a position sensor of an eddy current sensor structure. The induction rotor 21 is the rotor of the eddy current sensor 212, and the circuit board 20 is the stator of the eddy current sensor 212. The two work together to realize the position sensing function. A signal processing circuit can also be provided on the circuit board 20 to amplify, filter, and demodulate the electrical signal generated by the induction coil of the circuit board 20 to obtain accurate detection results.

[0149] In this embodiment, different types of position sensors can be formed by combining the induction rotor with the circuit board, including position sensors in the form of rotary transformers and eddy current sensors, which can meet the needs of different application environments.

[0150] In one feasible implementation, the conductive element 22 is any one of a conductive ring, a conductive carbon brush, a conductive brush, or a conductive spring.

[0151] It should be noted that the conductive component 22 is made of conductive material, and its specific structure can be selected from any one of conductive rings, conductive carbon brushes, conductive brushes, conductive spring sheets, etc., according to actual needs.

[0152] For example, as shown in Figure 6, which is a structural schematic diagram of a conductive component in this embodiment, the conductive component 22 is a conductive carbon brush 221. The conductive carbon brush 221 can be fixed to one end of the rotating shaft 11 by a screw passing through the electrical connection fixing hole on the circuit board 20, so as to realize the electrical connection between the conductive carbon brush 221 and the circuit board 20. The circuit board 20 can be grounded, for example, by connecting it to the housing 10 by a screw passing through other electrical connection fixing holes on the circuit board 20. The front end of the conductive carbon brush 221 can be electrically connected to the rotating shaft 11, so that the shaft current is led to the circuit board 20 through the conductive carbon brush 221. The shaft current then flows through the circuit board 20 to the ground or the housing 10, and then continues to be grounded through the housing 10.

[0153] For example, as shown in Figure 7, another structural schematic diagram of the conductive component in this embodiment is presented. The conductive component 22 consists of multiple conductive brushes 222, which are directly fixed to the circuit board 20 to achieve electrical connection with the circuit board 20. The circuit board 20 can be grounded, for example, by screws passing through other electrical connection fixing holes on the circuit board 20 to connect it to the housing 10. The front end of the conductive brush 222 can be electrically connected to the rotating shaft 11, leading the rotor current to the circuit board 20 via the conductive brush 222. The current then flows through the circuit board 20 to the ground or the housing.

[0154] In this embodiment, the shaft is grounded through a conductive component to release the charge on the bearing and shaft, thereby suppressing bearing electro-corrosion. The conductive component can be adapted to various specific motor structures, allowing the system to meet the needs of more motor operating environments and exhibiting good adaptability.

[0155] In a second embodiment of the electric drive integrated system of this application, referring to FIG8, FIG8 is a schematic diagram of the back structure of the circuit board in the electric drive integrated system. The integrated system may further include a resistor-capacitor module 60.

[0156] The resistor-capacitor module 60 is fixed to the circuit board 20. One end of the resistor-capacitor module 60 is connected to the conductive component 22, and the other end of the resistor-capacitor module 60 is electrically connected to the circuit board 20.

[0157] It should be noted that, unlike the first embodiment where the input end of the conductive element 22 is electrically connected to the rotating shaft 11 and the output end is directly grounded through the circuit board 20 or grounded through the circuit board 20 to the housing 10, in this embodiment, the input end of the conductive element 22 is still electrically connected to the rotating shaft 11, but its output end is connected to one end of the resistor-capacitor module 60, and the other end of the resistor-capacitor module 60 is then electrically connected to the circuit board 20, so that it is grounded through the circuit board 20 or grounded through the circuit board 20 to the housing 10. Thus, the output end of the conductive element 22 can be grounded through the resistor-capacitor module 60 and the circuit board 20. At this time, the shaft current is conducted sequentially through the conductive element 22 to the resistor-capacitor module 60 and the circuit board 20, or sequentially through the resistor-capacitor module 60, the circuit board 20 and the housing 10 to the ground. At this time, the shaft current is conducted sequentially through the conductive element 22 to the resistor-capacitor module 60, the circuit board 20 and the housing 10.

[0158] In practical applications, the resistor-capacitor module 60 can be fixed to the surface of the circuit board 20. For example, as shown in FIG8, the resistor-capacitor module 60 can be fixed to the side surface of the circuit board 20 where the conductive element 22 is located. The connection between the resistor-capacitor module 60 and the conductive element 22 can be direct or indirect through the circuit board 20. For example, the output wire of the conductive element 22 can be connected to the resistor-capacitor module 60 by passing it through the electrical connection fixing hole on the circuit board 20 with a screw. No specific limitation is made here.

[0159] Understandably, the input terminal of the RC module 60 is electrically connected to the shaft 11 of the motor 1 through the conductive component 22, and the output terminal is connected to the circuit board 20 to be grounded, so that the RC module 60 can be connected in parallel with the bearing 12 in the motor 1. Specifically, it can be connected in parallel with the parasitic capacitance of the bearing 12 to suppress the high-frequency loop current generated on the bearing 12. Together with the conductive component 22, it can achieve a better bearing electro-corrosion suppression effect.

[0160] In one feasible implementation, the resistor-capacitor module 60 and the induction coil are located on different sides of the circuit board 20.

[0161] In practical applications, both the induction coil and the resistor-capacitor module 60 can be fixed on the surface of the circuit board 20. Since the induction coil needs to cooperate with the induction rotor 21 to achieve position detection, it can be specifically fixed on the surface of the circuit board 20 near the induction rotor 21. Correspondingly, the resistor-capacitor module 60 can be specifically fixed on the other surface of the circuit board 20, and the conductive element 22 can also be disposed on the surface of the circuit board 20 where the resistor-capacitor module 60 is located. This is only one example; further configuration is possible as needed.

[0162] Understandably, placing the induction coil and the RC module on different sides of the circuit board can make full use of the remaining space inside the motor, avoid having too many components on one side of the circuit board, which would occupy too much space and require increasing the axial installation space of the motor, thus reducing the axial size of the motor. It can also prevent the electronic components on the circuit board from affecting the magnetic field generated between the induction coil and the induction rotor, thereby avoiding affecting the function of the position sensor and ensuring the accuracy of position detection.

[0163] It should also be noted that the RC module 60 may include a capacitor unit and a first resistor unit connected in series; it may also include a capacitor unit, a first resistor unit, and a reactance unit connected in series; or it may include a capacitor unit, a first resistor unit, a reactance unit, and a second resistor unit, wherein the second resistor unit is connected in parallel with the series-connected capacitor unit and the first resistor unit, or the second resistor unit is connected in parallel with the series-connected capacitor unit, the first resistor unit, and the reactance unit; the specific choice can be made according to actual needs. The capacitor unit includes several electrically connected capacitors, the first resistor unit includes several electrically connected resistors, the reactance unit includes several electrically connected ferrite beads and / or several electrically connected inductors, and the second resistor unit includes several electrically connected resistors.

[0164] The RC module 60, consisting of a series-connected capacitor unit and a first resistor unit, is connected in parallel with the bearing 12 of the motor 1. It can divide the voltage between the inner and outer rings of the bearing 12, adjusting the voltage division ratio to reduce the common-mode voltage between the inner and outer rings. This prevents excessively high voltages from breaking down the oil film and causing EDM discharge, which could lead to electrolytic corrosion of the bearing 12. It also reduces loop current, preventing the influence of differential-mode voltage on the bearing 12, and avoiding electromagnetic interference caused by excessive EMI due to transient high-frequency waves during the charging and discharging of the integrated system. The RC module 60, consisting of the series-connected capacitor unit, first resistor unit, and reactance unit, not only possesses the beneficial effects of the RC module 60, but also, through the high-frequency, high-impedance characteristics of the reactance unit, effectively reduces high-frequency loop current, enabling the integrated system to cope with the larger high-frequency loop current generated by the high dv / dt value characteristics of silicon carbide switching devices. The RC module 60, which is formed by connecting the second resistor unit in parallel with the series-connected capacitor unit and the first resistor unit, and the RC module 60 formed by connecting the second resistor unit in parallel with the series-connected capacitor unit, the first resistor unit and the reactance unit, not only has the beneficial effects of the RC module 60, but also can release common-mode charge and reduce electromagnetic interference caused by high-frequency waves during charging and discharging, further release the charge on the shaft 11 of the motor 1 relative to ground, and help reduce the shaft voltage.

[0165] The electric drive integrated system provided in this embodiment integrates a conductive ring, position sensor, and conductive capacitor module on a circuit board. The motor shaft is grounded via the conductive components and the module. Utilizing the commonalities of the circuit board, the conductive ring, position sensor, and conductive capacitor are integrated into a single unit. This integrated system provides position sensing, suppression of bearing galvanic corrosion through conductive discharge, and further suppression of bearing galvanic corrosion through conductive discharge. This increases system integration, reduces the number of components, saves installation space, and simplifies the installation process. Furthermore, the conductive capacitor module reduces the common-mode voltage between the inner and outer rings of the bearing, preventing EDM discharge caused by excessively high voltages. This results in better suppression of bearing galvanic corrosion. Simultaneously, the conductive capacitor module suppresses high-frequency loop current, preventing shaft current from affecting the bearing and extending bearing life.

[0166] In the third embodiment of the electric drive integrated system of this application, referring to FIG9, FIG9 is a front structural schematic diagram of the circuit board in the electric drive integrated system. The integrated system may also include a thermal device 24.

[0167] Thermistor 24 is fixed to the circuit board and electrically connected to the circuit board 20. Thermistor 24 is used to detect the temperature of the motor coolant.

[0168] It should be noted that the thermistor 24 refers to an NTC (Negative Temperature Coefficient) element, whose resistance decreases as temperature increases, thus enabling temperature detection. In specific applications, the motor 1 can be an oil-cooled motor. The thermistor 24 is located inside the motor 1, immersed in the coolant, and can directly measure the temperature of the coolant to obtain the detected temperature. Then, the back-end signal processor or the terminal or device receiving the detected signal can use software algorithms to calculate the temperature of the stator windings on the motor based on the detected temperature, thereby realizing the motor's temperature detection function. Calculating the temperature of the stator windings on the motor based on the detected motor temperature is a known technical solution in the art and will not be elaborated upon here. For example, as shown in Figure 9, the thermistor 24 can be fixed to the surface of the circuit board 20 where the sensing rotor 21 is located.

[0169] It should also be noted that the thermistor 24 and the circuit board 20 form a temperature sensor, which can realize the temperature detection function of the stator winding on the motor. The thermistor 24 is connected to the circuit board 20, and the output signal of the thermistor 24 can be output to the outside of the motor through the low-voltage signal line of the circuit board 20, so as to the motor controller of the integrated system for processing and temperature calculation; alternatively, the electronic components on the circuit board 20 can process its output signal and then output it to the outside of the motor through the low-voltage signal line, so as to the motor controller of the integrated system for temperature calculation. The specific limitation is not specified here.

[0170] The electric drive integrated system provided in this embodiment detects the temperature of the motor coolant by setting a thermistor on the circuit board, thereby detecting the temperature of the stator windings on the motor. By utilizing the common features of the circuit board, the conductive ring, position sensor, and temperature sensor are integrated into one unit. This integrated system not only has the functions of position sensing and suppressing bearing electro-corrosion through conductive discharge, but also the function of detecting the temperature of the stator windings on the motor through thermistors. On the basis of increasing the system integration, reducing the number of components, saving installation space, and simplifying the installation process, it also realizes more functions through the thermistors, making the integrated system more applicable and further improving the system integration.

[0171] In one feasible implementation, the integrated system may further include a motor controller; the motor controller is communicatively connected to the circuit board 20.

[0172] It should be noted that the motor controller is connected to motor 1, specifically to the wiring terminals or output interface of circuit board 20 in motor 1. This connection can be made via a communication cable to receive position detection signals and / or temperature detection signals output from circuit board 20. The motor controller can also drive and control motor 1, achieving precise control and ensuring the safe, reliable, and efficient operation of the electric vehicle. Furthermore, the integrated system may also include a reducer, etc., without specific limitations here.

[0173] In this embodiment, through the communication connection between the circuit board and the motor controller, the position detection signal generated on the circuit board and the temperature detection signal detected by the thermal device on it are sent to the back-end motor controller in a timely manner so that the motor controller can perform subsequent processing.

[0174] In another feasible embodiment, a signal processing module 25 is provided on the circuit board 20; the signal processing module 25 is connected to the circuit board 20 and communicates with the motor controller.

[0175] It should be noted that the signal processing module 25 can be a microprocessor such as an MCU (Microcontroller Unit), which can process the position detection signal generated on the circuit board 20 and the temperature detection signal generated by the thermal device 24 on the circuit board 20. After processing, the signals are sent to the motor controller at the back end through a set of low-voltage signal lines. That is, there is only one communication connection between the circuit board 20 and the motor controller, and there is no need to set up different or too many signal lines, which simplifies the connection relationship and system installation steps.

[0176] For example, as shown in Figure 10, which is a wiring diagram of the circuit board in this embodiment, the induction rotor 21 is located on one side of the circuit board. A thermistor 24 is provided on the surface of the circuit board. The output line of the thermistor 24 can be directly connected to one input pin of the signal processing module 25. The voltage signal generated by the thermistor 24 detecting the temperature of the coolant is input to the signal processing module 25. The other input pin of the signal processing module 25 can also be connected to the induction coil in the circuit board to receive the induction signal output by the induction coil. Then, in the signal processing module 25, the voltage signal and the induction signal can be amplified, filtered, demodulated and converted respectively (the specific processing is selected according to actual needs) to output the position detection signal and temperature detection signal that can be directly sent to the motor controller.

[0177] In this embodiment, by setting a signal processing module on the circuit board, a signal processor is integrated into the position sensor, making signal processing and signal transmission within the integrated system simpler.

[0178] In the fourth embodiment of the electric drive integrated system of this application, the housing 10 of the motor 1 is further provided with a rotor core 13 and a stator core 14.

[0179] In one feasible embodiment, referring to FIG11, FIG11 is a schematic diagram of an installation position of an electric drive integrated system, the rotor core 13 is sleeved on the rotating shaft 11 and located inside the stator core 14, the bearing 12 is sleeved on the end of the rotating shaft 11 and located inside the stator core 14, and the circuit board 20 of the position sensor 2 is sleeved on the rotating shaft 11 and located axially between the bearing 12 and the rotor core 13.

[0180] It should be noted that the circuit board 20 can be installed at the front end of the motor 1, between the bearing 12 and the rotor core 13. The current on the shaft 11 of the motor 1 can be grounded through the conductive part 22 on it or through the housing 10. The current flow direction is shown in Figure 11.

[0181] In another feasible embodiment, referring to FIG12, FIG12 is a schematic diagram of another installation position of the electric drive integrated system, the rotor core 13 is sleeved on the rotating shaft 11 and located inside the stator core 14, the bearing 12 is sleeved on the rotating shaft 11 and located inside the stator core 14, and the circuit board 20 of the position sensor 2 is sleeved on the end of the rotating shaft 11 and located axially outside the stator core 14.

[0182] It should be noted that the circuit board 20 can be installed at the rear end of the motor 1, outside the stator core 14, and the current on the shaft 11 of the motor 1 can be grounded through the conductive part 22 on it or through the housing 10. The current flow direction is shown in Figure 12.

[0183] The electric drive integrated system provided in this embodiment can specifically install the circuit board of the position sensor at different positions of the motor, which can meet more practical needs and increase the system adaptability.

[0184] To collect the temperature of the drive motor, a temperature sensor is installed on the stator windings of the drive motor. This temperature sensor is typically fixed to the stator windings using clips or similar methods. Therefore, a current problem with electric drive systems is that the position sensor and temperature sensor are installed independently, each requiring a low-voltage signal line to connect to the motor controller. This results in complex wiring between the drive motor and the motor controller, and a cumbersome installation process. Furthermore, current methods of fixing the temperature sensor suffer from poor contact reliability and complex manufacturing processes.

[0185] To address the aforementioned problems, this application provides an integrated electric drive system. The application and its embodiments will be described below with reference to the accompanying drawings.

[0186] In the fifth embodiment of the electric drive integrated system of this application, referring to FIG9, FIG9 is a front structural schematic diagram of the circuit board in the electric drive integrated system. The integrated system may include a motor 1, a motor control unit (not shown in the figure), a position sensor 2 and a temperature sensor.

[0187] The motor 1 may include a housing 10, a rotating shaft 11 and a bearing 12 disposed within the housing 10.

[0188] It should be noted that the inner ring of bearing 12 is connected to the shaft 11, and the outer ring of bearing 12 is connected to the housing 10. The motor 1 may also include a rotor assembly and a stator assembly. The stator assembly has components such as a stator core and stator windings. In addition, the motor 1 may also include components such as splines. The motor structure is a known technical solution in the art and will not be described in detail here.

[0189] The position sensor 2 may include a circuit board 20 and an induction rotor 21, wherein the circuit board 20 integrates an induction coil and the induction rotor 21 is connected to the rotating shaft 11.

[0190] It should be noted that circuit board 20 refers to a circuit board that can cooperate with induction rotor 21 to generate an excitation magnetic field and realize the function of a position sensor. Circuit board 20 integrates induction coils, and the working principle between induction coils and induction rotor 21 can vary depending on the type of position sensor 2 constituted by circuit board 20 and induction rotor 21. For example, induction rotor 21 can be a metal conductor, serving as a sensor probe, and the induction coil of circuit board 20 can include a transmitting coil and a receiving coil, as well as related electronic components for control coils. When induction rotor 21 cooperates with circuit board 20, it can realize the position detection or displacement detection function of an eddy current sensor. In addition, induction rotor 21 can be a primary coil, serving as the rotor of a rotary transformer, and the induction coil of circuit board 20 can be a secondary coil, serving as the stator of a rotary transformer. When induction rotor 21 cooperates with circuit board 20, it can realize the position detection or displacement detection function of a rotary transformer.

[0191] For example, as shown in Figure 3, which is a schematic diagram of the structure of the rotating shaft and the sensing rotor in this embodiment, the sensing rotor 21 is connected to the rotating shaft 11 and can be sleeved on the outside of the rotating shaft 11, rotating with the rotating shaft 11. The sensing rotor 21 can be fixed to one end of the rotating shaft 11. The circuit board 20 can be wrapped around the periphery of the sensing rotor 21, or located on one side of the sensing rotor 21 in the axial direction, or fixed inside the housing 10, maintaining a certain sensing distance from the sensing rotor 21. The specific settings can be configured according to actual needs and are not limited here.

[0192] The temperature sensor is fixed to the circuit board 20 and electrically connected to the circuit board 20.

[0193] It should be noted that the temperature sensor may include a thermistor 24, which is fixed to and electrically connected to the circuit board 20. Thermistor 24 is used to detect the temperature of the motor coolant. Thermistor 24 refers to an NTC (Negative Temperature Coefficient) element, whose resistance decreases as the temperature increases, thereby enabling temperature detection. In specific applications, the motor 1 may be an oil-cooled motor. The thermistor 24 is located inside the motor 1 and immersed in the coolant, allowing direct measurement of the coolant temperature to obtain the detected temperature. Then, the backend signal processor or the terminal or device receiving the detected signal can use a software algorithm to calculate the temperature of the stator windings on the motor based on the detected temperature, thus realizing the motor temperature detection function. Calculating the temperature of the stator windings on the motor based on the detected motor temperature is a known technical solution in the art and will not be elaborated further here. For example, as shown in Figure 9, the thermistor 24 may be fixed to the surface of the circuit board 20 where the sensing rotor 21 is located.

[0194] The signal lines of the temperature sensor and the position sensor 2 are integrated on the circuit board 20 and transmitted to the motor control unit through the circuit board 20.

[0195] It should be noted that the thermistor 24 and the circuit board 20 form a temperature sensor, enabling temperature detection of the stator windings on the motor. The thermistor 24 is electrically connected to the circuit board 20. Simultaneously, the induction coil is integrated into the circuit board 20 and is also electrically connected to it. Here, the output signal lines of the thermistor 24 and the induction coil can be integrated to form an integrated low-voltage signal line, which is connected to the motor control unit. In this integrated system, the output signals of the thermistor 24 and the induction coil can be output to the outside of the motor via the integrated low-voltage signal line through the circuit board 20, providing the signal to the motor control unit for processing and temperature calculation. Alternatively, the electronic components on the circuit board 20 can process the output signals of the thermistor 24 and the induction coil before outputting them to the outside of the motor via the integrated low-voltage signal line, providing the signal to the motor control unit for temperature calculation; no specific limitation is made here. The integrated low-voltage signal line can be a single communication line that uses different frequency bands to send different output signals, or it can be an integrated line with multiple transmission channels that uses different channels to send different output signals. No specific limitation is made here.

[0196] For example, as shown in Figures 9 and 3, the induction rotor 21 is connected to the rotating shaft 11 and sleeved on one end of the rotating shaft 11. The circuit board 20 is fixed to one side of the induction rotor 21, specifically it can be fixed to the housing 10. The circuit board 20 can have an induction coil built in it, or the induction coil can be set on the surface of the circuit board 20. The circuit board 20 is wound around the outside of the rotating shaft 11. When the induction rotor 21 rotates with the rotating shaft 11, the induction coil of the circuit board 20 can form a magnetic field with the induction rotor 21, realizing the function of a position sensor. It is understood that other electronic components of the position sensor can also be integrated into the circuit board 20, including related electronic components for realizing sensing signal processing and output, which are not specifically limited here. The thermal device 24 is fixed on the circuit board 20 and can be located on the front or back of the circuit board 20, depending on the actual needs. In addition, the circuit board 20 can also be provided with shaft holes, positioning holes, etc., as needed, to fix the wiring on the circuit board 20 to the circuit board 20 through fasteners 223, etc.

[0197] Unlike related technologies where temperature and position sensors are set up separately, this example fixes the temperature sensor on the circuit board of the position sensor, using the existing signal lines of the position sensor to transmit the temperature sensor's signal, eliminating the need for additional signal lines. Furthermore, integrating temperature and position detection functions onto a single circuit board reduces installation space, simplifies the installation process, saves material costs, and streamlines the installation workflow. By placing a thermistor on the circuit board to detect the temperature of the motor coolant, the temperature of the stator windings on the motor is monitored. Utilizing the commonalities of the circuit boards, the temperature and position sensors are integrated into a single system, providing both position and temperature detection capabilities.

[0198] The electric drive integrated system provided in this embodiment includes a motor, a motor control unit, a position sensor, and a temperature sensor. The motor includes a rotating shaft, and the position sensor includes a circuit board and an induction rotor. The circuit board integrates an induction coil, and the induction rotor is connected to the rotating shaft to generate an excitation magnetic field, thus realizing the function of the position sensor. A temperature sensor is also fixed to the circuit board and electrically connected to it, realizing the function of the temperature sensor. This achieves the integration of position sensing and temperature sensing functions. In this system, the position sensor and temperature sensor on the motor are integrated using the common features of the circuit boards. The signal lines of the temperature sensor and the position sensor are integrated on the circuit board and transmitted to the motor control unit through the circuit board. Only one communication line is needed between the motor and the motor control unit, achieving the integration of two signal lines, reducing the number of components and wiring complexity. Compared to a temperature sensor fixed on the stator winding, the temperature sensor in this integrated system has better installation stability, fewer wiring, and simpler installation, increasing the system's reliability and meeting the needs of use in different environments.

[0199] In one possible implementation, the circuit board 20 is electrically connected to the housing 10, and the housing 10 is grounded.

[0200] It should be noted that an induction coil is installed inside the circuit board 20, and other electronic components can also be installed on it. To ensure circuit integrity, the circuit board 20 needs to be grounded. Specifically, it can be directly electrically connected to the housing 10, and the circuit board 20 is grounded based on the grounding of the housing 10, thereby grounding the induction coil or other electronic components on the circuit board 20.

[0201] In this embodiment, the circuit board is electrically connected to the housing, and the circuit board is directly grounded by the grounding of the housing. The grounding method is simple and does not require other grounding devices, which can simplify the motor structure and save motor space.

[0202] In one feasible implementation, the communication line between the signal line of the integrated temperature sensor and the signal line of the position sensor 2 can be connected to the circuit board 20 through an electrical connection fixing hole and communicate with the motor control unit.

[0203] It should be noted that the motor control unit is connected to motor 1, specifically to the wiring terminals or output interface of circuit board 20 in motor 1. This connection can be made via a communication cable to receive position detection signals and / or temperature detection signals output from circuit board 20. The motor control unit can also drive and control motor 1, achieving precise control and ensuring the safe, reliable, and efficient operation of the electric vehicle. Furthermore, the electric drive integrated system may also include a reducer, etc., without specific limitations here.

[0204] In this embodiment, the signal lines of the temperature sensor and the position sensor are integrated together through the communication connection between the circuit board and the motor control unit. They can be directly connected to the motor control unit through a single hole. This not only allows the position detection signal generated on the circuit board and the temperature detection signal detected by the thermal device on it to be sent to the back-end motor control unit in a timely manner for subsequent processing by the motor control unit, but also reduces the complexity of the housing.

[0205] In another feasible embodiment, a signal processing module 25 is provided on the circuit board 20; the signal processing module 25 is connected to the circuit board 20 and communicates with the motor control unit.

[0206] It should be noted that the signal processing module 25 can be a microprocessor such as an MCU (Microcontroller Unit), which can process the position detection signal generated on the circuit board 20 and the temperature detection signal generated by the thermal device 24 on the circuit board 20, and then send them to the motor control unit at the back end through a set of low-voltage signal lines. That is, there is only one communication connection between the circuit board 20 and the motor control unit, and there is no need to set up different or too many signal lines, which simplifies the connection relationship and system installation steps.

[0207] For example, as shown in Figure 10, which is a wiring diagram of the circuit board in this embodiment, the induction rotor 21 is located on one side of the circuit board. A thermistor 24 is provided on the surface of the circuit board. The output line of the thermistor 24 can be directly connected to one input pin of the signal processing module 25. The voltage signal generated by the thermistor 24 detecting the temperature of the coolant is input to the signal processing module 25. The other input pin of the signal processing module 25 can also be connected to the induction coil in the circuit board to receive the induction signal output by the induction coil. Then, in the signal processing module 25, the voltage signal and the induction signal can be amplified, filtered, demodulated and converted respectively (the specific processing is selected according to actual needs) to output the position detection signal and temperature detection signal that can be directly sent to the motor control unit.

[0208] In this embodiment, by setting a signal processing module on the circuit board, a signal processor is integrated into the position sensor, making signal processing and signal transmission within the integrated system simpler.

[0209] In one feasible implementation, the circuit board 20 is sleeved on the outside of the rotating shaft 11 and cooperates with the induction rotor 21 to generate a magnetic field, or it is disposed on one side of the induction rotor 21 and cooperates with the induction rotor 21 to generate a magnetic field.

[0210] It should be noted that the circuit board 20 can be a ring structure, sleeved on the rotating shaft 11, with a certain sensing distance in the axial direction from the sensing rotor 21, so that the sensing rotor 21 generates a sensing magnetic field through the cooperation between the sensing rotor 21 and the circuit board 20 during rotation, thereby realizing the position detection of the rotating shaft 11; or it can be an arc-shaped structure, set on the sensing rotor 21, located on one side of the sensing rotor 21 in the axial direction, and with a certain sensing distance in the axial direction from the sensing rotor 21, so that the sensing rotor 21 generates a sensing magnetic field through the cooperation between the sensing rotor 21 and the circuit board 20 during rotation, thereby realizing the position detection of the rotating shaft 11.

[0211] In this embodiment, the position detection is achieved by generating a magnetic field through the cooperation of the circuit board and the induction rotor, which enables the system to have a position sensing function. Based on this, the circuit board can be set in various ways to adapt to a variety of application environments.

[0212] In one possible implementation, the sensing rotor 21 is the rotor of the rotary transformer 211, or the rotor of the eddy current sensor 212, or the rotor of other types of position sensors.

[0213] It should be noted that when the induction rotor 21 and the induction coil within the circuit board 20 form a position sensor with a rotary transformer structure, the induction rotor 21 is the rotor of the rotary transformer 211; when the induction rotor 21 and the induction coil within the circuit board 20 form a position sensor with an eddy current sensor structure, the induction rotor 21 is the rotor of the eddy current sensor 212. Correspondingly, the circuit board 20 can be the stator of the rotary transformer 211 or the stator of the eddy current sensor 212, specifically configured to correspond to the induction rotor 21, in order to cooperate with the induction rotor 21 to generate an excitation magnetic field and realize the function of the position sensor.

[0214] For example, as shown in Figure 4, which is a structural schematic diagram of the sensing rotor in this embodiment, the sensing rotor 21 can be wound around the rotating shaft 11, and the circuit board 20 can be fixed to the periphery of the sensing rotor 21 by the mounting assembly 2112. In this example, the sensing rotor 21 and the circuit board 20 constitute a position sensor of a rotary transformer structure. The sensing rotor 21 is the rotor of the rotary transformer 211, and the circuit board 20 is the stator of the rotary transformer 211. The two work together to realize the position sensing function. The circuit board 20 can also be provided with wiring terminals 2111 to output the signal generated by the circuit board 20 to the outside of the motor 1, providing it to the motor control unit of the integrated system.

[0215] For example, as shown in Figure 5, another structural schematic diagram of the induction rotor in this embodiment is presented. The induction rotor 21 can be wound around the rotating shaft 11, and the circuit board 20 can be fixed around the rotating shaft 11 and located on one side of the induction rotor 21. In this example, the induction rotor 21 and the circuit board 20 constitute a position sensor of an eddy current sensor structure. The induction rotor 21 is the rotor of the eddy current sensor 212, and the circuit board 20 is the stator of the eddy current sensor 212. The two work together to realize the position sensing function. A signal processing circuit can also be provided on the circuit board 20 to amplify, filter, and demodulate the electrical signal generated by the induction coil of the circuit board 20 to obtain accurate detection results.

[0216] In this embodiment, different types of position sensors can be formed by combining the induction rotor with the circuit board, including position sensors in the form of rotary transformers and eddy current sensors, which can meet the needs of different application environments.

[0217] In the sixth embodiment of the electric drive integrated system of this application, referring to FIG8, FIG8 is a schematic diagram of the back structure of the circuit board in the electric drive integrated system. The integrated system may further include a resistor-capacitor module 60.

[0218] The resistor-capacitor module 60 is fixed to the circuit board 20. One end of the resistor-capacitor module 60 is electrically connected to the rotating shaft 11, and the other end of the resistor-capacitor module 60 is electrically grounded.

[0219] Due to the voltage division effect of parasitic capacitance in the electric drive system, the common-mode voltage causes a voltage drop between the inner and outer rings of bearing 12. When the common-mode voltage exceeds the critical voltage of the bearing oil film, the oil film breaks down, resulting in EDM discharge. This causes ablation and spotting on the surfaces of the inner and outer rings and balls of bearing 12. Prolonged and frequent EDM discharge will cause obvious corrosive marks on the surfaces of the inner and outer rings and balls of bearing 12, indicating bearing electro-corrosion. Bearing electro-corrosion will cause vibration and noise in motor 1, affecting its operation.

[0220] To suppress the electro-corrosion of the bearing 12, the integrated system may also include a resistor-capacitor module 60. One end of the resistor-capacitor module 60 is electrically connected to the shaft 11, and the other end is grounded. This allows the shaft 11 of the motor 1 to be grounded through the resistor-capacitor module 60 and the circuit board 20, or through the resistor-capacitor module 60, the circuit board 20, and the housing 10 in sequence, so as to release the charge on the shaft 11 to ground and reduce the voltage ratio between the inner and outer rings of the bearing 12, thereby achieving the function of suppressing bearing electro-corrosion.

[0221] It should be noted that the specific methods for grounding the other end of the resistor-capacitor module 60 include: the other end of the resistor-capacitor module 60 is connected to the circuit board 20 and grounded through the circuit board 20; the other end of the resistor-capacitor module 60 is electrically connected to the housing 10 and grounded through the housing 10; the other end of the resistor-capacitor module 60 is electrically connected to the housing 10 through the circuit board 20 and grounded through the circuit board 20 and the housing 10.

[0222] In practical applications, the resistor-capacitor module 60 can be fixed to the surface of the circuit board 20. For example, as shown in Figure 8, the resistor-capacitor module 60 can be fixed to either side of the circuit board 20. This module is electrically connected to the rotating shaft 11, either directly or via the circuit board 20. For instance, the input terminal of the circuit board 20 can be electrically connected to the rotating shaft 11, and the output terminal can be connected to one end of the resistor-capacitor module 60. Alternatively, it can be connected to the circuit board 20 via a conductive element 22. For example, the output wire of the conductive element 22 can be connected to the resistor-capacitor module 60 by passing a screw through the electrical connection fixing hole on the circuit board 20. No specific limitations are made here.

[0223] Understandably, the input terminal of the RC module 60 is electrically connected to the rotating shaft 11 of the motor 1, and the output terminal is grounded, so that the RC module 60 can be connected in parallel with the bearing 12 in the motor 1. Specifically, it can be connected in parallel with the parasitic capacitance of the bearing 12 to suppress the high-frequency loop current generated on the bearing 12, thereby realizing the bearing electro-corrosion suppression function.

[0224] In one feasible implementation, the RC module 60 and the temperature sensor are located on different sides of the circuit board 20.

[0225] In one specific example, the RC module 60 and the induction coil are located on different sides of the circuit board 20, while the temperature sensor and the induction coil are located on the same side of the circuit board 20.

[0226] In practical applications, both the induction coil and the RC module 60 can be fixed on the surface of the circuit board 20. Since the induction coil needs to cooperate with the induction rotor 21 to achieve position detection, it can be specifically fixed on the surface of the circuit board 20 near the induction rotor 21. The thermal device 24 can be disposed on the surface of the circuit board 20 where the induction coil is located. Correspondingly, the RC module 60 can be specifically fixed on the other surface of the circuit board 20. This is only one example; further configuration is possible as needed.

[0227] Understandably, placing the temperature sensor and the RC module on different sides of the circuit board can make full use of the remaining space inside the motor, avoid having too many components on one side of the circuit board, which would occupy too much space and require increasing the axial installation space of the motor, thus reducing the axial size of the motor. It can also prevent the electronic components on the circuit board from affecting the magnetic field generated between the induction coil and the induction rotor, thereby avoiding affecting the function of the position sensor and ensuring the accuracy of position detection.

[0228] It should also be noted that the RC module 60 may include a capacitor unit and a first resistor unit connected in series; it may also include a capacitor unit, a first resistor unit, and a reactance unit connected in series; or it may include a capacitor unit, a first resistor unit, a reactance unit, and a second resistor unit, wherein the second resistor unit is connected in parallel with the series-connected capacitor unit and the first resistor unit, or the second resistor unit is connected in parallel with the series-connected capacitor unit, the first resistor unit, and the reactance unit; the specific choice can be made according to actual needs. The capacitor unit includes several electrically connected capacitors, the first resistor unit includes several electrically connected resistors, the reactance unit includes several electrically connected ferrite beads and / or several electrically connected inductors, and the second resistor unit includes several electrically connected resistors.

[0229] The RC module 60, consisting of a series-connected capacitor unit and a first resistor unit, is connected in parallel with the bearing 12 of the motor 1. It can divide the voltage between the inner and outer rings of the bearing 12, adjusting the voltage division ratio to reduce the common-mode voltage between the inner and outer rings. This prevents excessively high voltages from breaking down the oil film and causing EDM discharge, which could lead to electrolytic corrosion of the bearing 12. It also reduces loop current, preventing the influence of differential-mode voltage on the bearing 12, and avoiding electromagnetic interference caused by excessive EMI due to transient high-frequency waves during the charging and discharging of the integrated system. The RC module 60, consisting of the series-connected capacitor unit, first resistor unit, and reactance unit, not only possesses the beneficial effects of the RC module 60, but also, through the high-frequency, high-impedance characteristics of the reactance unit, effectively reduces high-frequency loop current, enabling the integrated system to cope with the larger high-frequency loop current generated by the high dv / dt value characteristics of silicon carbide switching devices. The RC module 60, which is formed by connecting the second resistor unit in parallel with the series-connected capacitor unit and the first resistor unit, and the RC module 60 formed by connecting the second resistor unit in parallel with the series-connected capacitor unit, the first resistor unit and the reactance unit, not only has the beneficial effects of the RC module 60, but also can release common-mode charge and reduce electromagnetic interference caused by high-frequency waves during charging and discharging, further release the charge on the shaft 11 of the motor 1 relative to ground, and help reduce the shaft voltage.

[0230] The electric drive integrated system provided in this embodiment integrates a resistive-capacitive (RC) module on the circuit board, grounding the motor shaft through the module. Utilizing the commonalities of the circuit board, the position sensor, temperature sensor, and RC module are integrated into a single unit. This integrated system provides position and temperature sensing functions, as well as the ability to suppress bearing electro-corrosion through RC discharge. This increases system integration, reduces the number of components, saves installation space, and simplifies the installation process. Furthermore, the RC module lowers the common-mode voltage between the inner and outer rings of the bearing, preventing EDM discharge caused by excessively high voltages. This effectively suppresses bearing electro-corrosion. Simultaneously, the RC module suppresses high-frequency loop currents, preventing shaft current from affecting the bearing and extending its service life. This integrated system can achieve more functions, broadening its applicability and further improving its overall integration.

[0231] In one feasible implementation, referring to Figures 1 and 2, Figure 1 is a front view of the circuit board in the electric drive integrated system, and Figure 2 is a back view of the circuit board in the electric drive integrated system. The integrated system may also include a conductive element 22. The conductive element 22 is fixed to the circuit board 20 and electrically connected to the resistor-capacitor module 60. The end face of the conductive element 22 contacts the bearing 12, and the shaft current can be conducted to the resistor-capacitor module 60 through the conductive element 22.

[0232] It should be noted that the conductive component 22 can be connected to the bearing 12 through its end face to conduct shaft current to the resistor-capacitor module 60, or it can be electrically connected to the rotating shaft 11 through its input end and connected to one end of the resistor-capacitor module 60 through its output end. Since the rotating shaft 11 is connected to the bearing 12, the connection between the conductive component 22 and the bearing 12 is indirectly realized. At this time, the shaft current is conducted to the resistor-capacitor module 60 for consumption, that is, the bearing electro-corrosion is suppressed.

[0233] It should be noted that the conductive component 22 can be fixed on the circuit board 20. For example, if the induction rotor 21 is located on the front of the circuit board 20, the conductive component 22 can be located on the back of the circuit board 20. The conductive component 22 can be a conductive carbon brush, a conductive brush, etc. Here, multiple conductive brushes 222 are used as an example. The input end of the conductive brush 222 is electrically connected to the rotating shaft 11, and the output end of the conductive brush 222 is connected to the input end of the resistor-capacitor module 60. The output end of the resistor-capacitor module 60 is grounded.

[0234] In practical applications, the conductive element 22 can be set on the side surface of the circuit board 20 where the resistor-capacitor module 60 is located. The connection between the resistor-capacitor module 60 and the conductive element 22 can be direct or indirect through the circuit board 20. For example, the output line of the conductive element 22 can be connected to the resistor-capacitor module 60 by passing the screw through the electrical connection fixing hole on the circuit board 20. No specific limitation is made here.

[0235] Understandably, the shaft 11 of motor 1 is grounded through the conductive element 22 and the RC module 60, releasing the charge on the shaft 11 to ground and reducing the voltage ratio between the inner and outer rings of bearing 12. In other words, the conductive element 22 and the RC module 60 work together to further suppress bearing electro-corrosion. Therefore, integrating the conductive element 22 and the RC module 60 onto the position sensor's circuit board allows for better suppression of bearing electro-corrosion while still achieving position detection.

[0236] In this embodiment, by setting an RC module and conductive components on the circuit board, the motor shaft is grounded through the conductive components and the RC module. Utilizing the commonalities of the circuit board, the position sensor, temperature sensor, conductive ring, and RC module are integrated into a single unit. This allows the system to possess position and temperature sensing functions, as well as the ability to suppress bearing galvanic corrosion through conductive and RC discharge, resulting in better bearing galvanic corrosion suppression. Simultaneously, by integrating the conductive ring and position sensor on the motor in related technologies using the commonalities of the circuit board, the number of components is reduced, installation space is saved, and the installation process is simplified. This gives the system advantages such as occupying less axial space on the motor, saving material costs, simple installation, and applicability to various environments.

[0237] In one feasible implementation, the conductive element 22 is any one of a conductive ring, a conductive carbon brush, a conductive brush, or a conductive spring.

[0238] It should be noted that the conductive component 22 is made of conductive material, and its specific structure can be selected from any one of conductive rings, conductive carbon brushes, conductive brushes, conductive spring sheets, etc., according to actual needs.

[0239] For example, as shown in Figure 6, which is a structural schematic diagram of a conductive component in this embodiment, the conductive component 22 is a conductive carbon brush 221. The conductive carbon brush 221 can be fixed to one end of the rotating shaft 11 by a screw passing through the electrical connection fixing hole on the circuit board 20, so as to realize the electrical connection between the conductive carbon brush 221 and the circuit board 20, or to realize the electrical connection between the conductive carbon brush 221 and the resistor-capacitor module 60 on the circuit board 20. The circuit board 20 can be grounded, for example, by connecting it to the housing 10 by a screw passing through other electrical connection fixing holes on the circuit board 20. The front end of the conductive carbon brush 221 can be electrically connected to the rotating shaft 11, so that the shaft current is led to the circuit board 20 through the conductive carbon brush 221. The shaft current then flows through the circuit board 20 to the ground or the housing 10, and then continues to be grounded through the housing 10, or flows through the circuit board 20 to the resistor-capacitor module 60.

[0240] For example, as shown in Figure 7, another structural schematic diagram of the conductive component in this embodiment is presented. The conductive component 22 consists of multiple conductive brushes 222, which are directly fixed to the circuit board 20 to achieve electrical connection with the circuit board 20 or to the resistor-capacitor module 60 on the circuit board 20. The circuit board 20 can be grounded, for example, by connecting it to the housing 10 through screws passing through other electrical connection fixing holes on the circuit board 20. The front end of the conductive brush 222 can be electrically connected to the rotating shaft 11, leading the rotor current to the circuit board 20 via the conductive brush 222. The current then flows through the circuit board 20 to the ground or the housing, or through the circuit board 20 to the resistor-capacitor module 60.

[0241] In this embodiment, the shaft is grounded through conductive components and a resistor-capacitor module to release the charge on the bearing and shaft, thereby suppressing bearing electro-corrosion. The conductive components can be adapted to various specific motor structures, allowing the system to meet the needs of more motor operating environments and exhibiting good adaptability.

[0242] In the seventh embodiment of the electric drive integrated system of this application, the motor 1 further includes a bearing 12, a rotor core 13 and a stator core 14, all of which are disposed within the housing 10.

[0243] In one feasible embodiment, referring to FIG11, FIG11 is a schematic diagram of an installation position of an electric drive integrated system, the rotor core 13 is sleeved on the rotating shaft 11 and located inside the stator core 14, the bearing 12 is sleeved on the end of the rotating shaft 11 and located inside the stator core 14, and the circuit board 20 of the position sensor 2 is sleeved on the rotating shaft 11 and located axially between the bearing 12 and the rotor core 13.

[0244] It should be noted that the circuit board 20 can be installed at the front end of the motor 1, between the bearing 12 and the rotor core 13. The current on the shaft 11 of the motor 1 can be grounded through the conductive parts 22 and / or the resistor-capacitor module 60, or grounded through the housing 10. The current flow direction is shown in Figure 11.

[0245] In another feasible embodiment, referring to FIG12, FIG12 is a schematic diagram of another installation position of the electric drive integrated system, the rotor core 13 is sleeved on the rotating shaft 11 and located inside the stator core 14, the bearing 12 is sleeved on the rotating shaft 11 and located inside the stator core 14, and the circuit board 20 of the position sensor 2 is sleeved on the end of the rotating shaft 11 and located axially outside the stator core 14.

[0246] It should be noted that the circuit board 20 can be installed at the rear end of the motor 1, outside the stator core 14. The current on the shaft 11 of the motor 1 can be grounded through the conductive parts 22 and / or the resistor-capacitor module 60, or grounded through the housing 10. The current flow direction is shown in Figure 12.

[0247] The electric drive integrated system provided in this embodiment allows the position sensor circuit board to be installed at different locations on the motor, meeting more practical needs and increasing system adaptability. This application also proposes an electric vehicle.

[0248] In one embodiment of the electric vehicle of this application, the electric vehicle includes the electric drive integrated system as described above.

[0249] It should be noted that the specific structure of the electric drive integrated system refers to the above embodiments. Since the electric vehicle adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0250] In related technologies, taking the conductive component made of carbon fiber as an example, some solutions use screws or other fastening methods to fix the carbon fiber to the position sensor, thereby integrating two different modules together; other solutions fix the carbon fiber crimp terminals to the upper circuit board, and integrate the carbon fiber and the position sensor into one module by welding the upper fixing plate to the lower circuit board.

[0251] However, the above solution involves a complex fastening method for conductive components and position sensors, requires many accessories, is difficult to assemble, and has a high cost.

[0252] It should be noted that the position sensor in this application can be divided into a rotary transformer and an eddy current sensor. The conductive components include conductive elements and resistive-capacitive modules.

[0253] To address the aforementioned technical problems, the electric drive integrated system provided in this application includes: a housing having a shaft hole and a boss arranged circumferentially along the periphery of the shaft hole; one end of the boss has a target end face along the axial direction, and the boss forms a slot along the axial direction from the target end face, the slot communicating with the shaft hole; a circuit board disposed within the housing; a conductive element, one end of which is soldered to the circuit board, and the other end passing through the slot and extending at least partially into the shaft hole; a cover covering the target end face of the boss; the cover having a protrusion arranged axially opposite to the slot, and the protrusion being able to be inserted into the slot and abut against the conductive element.

[0254] The electric drive integrated system provided in this application, by creating a slot on the boss of the housing that communicates with the shaft hole, allows one end of the conductive component to pass through the slot and at least partially extend into the shaft hole to contact the motor shaft, thereby conducting shaft current from the motor shaft to the circuit board through the conductive component. The slot can limit the conductive component, and the cover can abut against the conductive component along the axial direction to guide and fix the conductive component, thereby ensuring that the conductive component does not move due to operation at the designated position, ensuring effective contact between the conductive component and the motor shaft. It eliminates the need for fixing plates, screws, and other connecting parts, reducing component development costs, and simplifies the assembly process and reduces assembly difficulty by eliminating the need for additional fastening steps. By directly soldering the conductive component to the circuit board, the functions of the conductive component and the position sensor can be integrated into a single-layer circuit board, eliminating the need for a multi-layer circuit board structure. This eliminates the need for traditional fixing steps (such as crimp terminals and screws), reducing component development costs, reducing the number of components, simplifying the assembly process, reducing assembly difficulty, and improving the integration degree between the conductive component and the position sensor.

[0255] To make the above-mentioned objectives, features, and advantages of the embodiments of this application more apparent and understandable, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0256] It should be noted that the conductive element 22 and the resistor-capacitor module 60 in the corresponding embodiments of Figures 1-12 have the same function as the conductive element 22 and the resistor-capacitor module 60 in the corresponding embodiments of Figures 13-23, but there are differences in the specific implementation method, which is as follows.

[0257] Please refer to Figures 13-23. This application provides an electric drive integrated system, including:

[0258] The housing 10, as shown in Figure 13, has a shaft hole 101 and a boss 110 arranged circumferentially along the periphery of the shaft hole 101; as shown in Figure 14, one end of the boss 110 along the axial direction Y is provided with a target end face 111, and the boss 110 is formed by opening a slot 112 from the target end face 111 along the axial direction Y, and the slot 112 communicates with the shaft hole 101.

[0259] The circuit board 20, as shown in Figure 13, is disposed inside the housing 10;

[0260] The conductive element 22, as shown in Figure 13, is soldered onto the circuit board 20. One end of the conductive element 22 passes through the slot 112 and extends at least partially into the shaft hole 101.

[0261] The cover 40 abuts against the conductive element 22 along the axial direction Y.

[0262] It should be noted that, referring to Figure 15, with the shaft hole 101 as a reference, the axial direction Y refers to the direction of the central axis of the shaft hole 101; referring to Figure 19, the radial direction X refers to the radial direction of the shaft hole 101, that is, the direction from the central axis of the shaft hole 101 to the radius of the circumference, and the radial direction X is perpendicular to the axial direction Y; referring to Figure 15, the circumferential direction W refers to the circumferential direction around the central axis of the shaft hole 101. A printed circuit board is also called a circuit board or PCB.

[0263] The electric drive integrated system provided in this application, by opening a slot 112 on the boss 110 of the housing 10 that communicates with the shaft hole 101, allows one end of the conductive element 22 to pass through the slot 112 and at least partially extend into the shaft hole 101 to contact the motor shaft, thereby conducting shaft current from the motor shaft to the circuit board 20 through the conductive element 22; the slot 112 can limit the conductive element 22, and the cover 40 can abut against the conductive element 22 along the axial direction Y to guide and fix the conductive element 22, thereby ensuring that the conductive element 22 does not move due to operation in the designated position, and ensuring the contact between the conductive element 22 and the motor shaft. Effective contact eliminates the need for fixing plates, screws, and other connectors, reducing component development costs and simplifying the assembly process by eliminating the need for additional fastening steps. By directly soldering the conductive component 22 onto the circuit board 20, the functions of the conductive component and the position sensor can be integrated into a single-layer circuit board 20, eliminating the need for a multi-layer circuit board structure. This eliminates the need for crimping or fastening steps of traditional fasteners (such as crimp terminals and screws), reducing component development costs, decreasing the number of components, simplifying the assembly process, reducing assembly difficulty, and improving the integration of the conductive component and the position sensor.

[0264] Furthermore, as shown in Figures 13 and 14, there are multiple conductive elements 22. Multiple slots 112 are provided on the boss 110. The multiple slots 112 are spaced apart along the circumferential direction W. The cover 40 abuts against the conductive elements 22 along the axial direction Y. This allows multiple conductive elements 22 to be guided and fixed at the same time, without the need to fix each conductive element 22 individually. Moreover, no additional fastening steps are required, which simplifies the assembly process and reduces the assembly difficulty.

[0265] Furthermore, the circuit board 20 is at least partially located on the side of the boss 110 away from the shaft hole 101, thereby providing the conductive component 22 with a soldering area closer to the boss 110, making the overall structure more compact.

[0266] In one possible implementation, the cover 40 covers the target end face 111 of the boss 110; as shown in Figure 16, the cover 40 is provided with a protrusion 41, the protrusion 41 and the slot 112 are arranged opposite to each other along the axial direction Y, and the protrusion 41 can be inserted into the slot 112 and abut against the conductive element 22.

[0267] In this embodiment, the protrusion 41 abuts against the conductive element 22. When the cover 40 is connected to the boss 110, the conductive element 22 can be guided and fixed by the cooperation of the slot 112 and the protrusion 41, thereby ensuring that the conductive element 22 does not move due to work in the designated position, and ensuring effective contact between the conductive element 22 and the motor shaft. There is no need for fixing plates, screws and other connecting parts, which reduces the development cost of parts. Moreover, there is no need for additional fastening steps, which simplifies the assembly process and reduces the assembly difficulty.

[0268] Furthermore, the cover 40 is provided with multiple protrusions 41, and multiple slots 112 are arranged opposite to the multiple protrusions 41 along the axial direction Y. During assembly, when the cover 40 is connected to the boss 110, each protrusion 41 is inserted into the corresponding slot 112. Through the cooperation of multiple slots 112 and multiple protrusions 41, multiple conductive parts 22 can be guided and fixed at the same time. It is not necessary to fix multiple conductive parts 22 one by one, and no additional fastening steps are required, which simplifies the assembly process and reduces the assembly difficulty.

[0269] In one possible implementation, the cover 40 and the boss 110 are connected by welding.

[0270] In this embodiment, the cover 40 and the boss 110 are connected by welding. After the cover 40 and the boss 110 are connected, the conductive component 22 can be guided and fixed by the cooperation of the slot 112 and the protrusion 41, thereby ensuring that the conductive component 22 does not move due to work in the designated position. There is no need for fixing plates, screws and other connecting parts, which reduces the development cost of parts. Moreover, there is no need for additional fastening steps, which simplifies the assembly process and reduces the assembly difficulty.

[0271] Furthermore, both the cover 40 and the shell 10 can be made of plastic.

[0272] Furthermore, the cover 40 and the shell 10 can be connected by ultrasonic welding or laser welding.

[0273] In one possible implementation, the protrusion 41 can be engaged within the slot 112;

[0274] And / or, the protrusion 41 and the groove 112 are interference fit.

[0275] In this embodiment, the cover 40 and the boss 110 are connected by a snap-fit ​​between the protrusion 41 and the slot 112, and / or, the cover 40 and the boss 110 are connected by an interference fit between the protrusion 41 and the slot 112. After the cover 40 and the boss 110 are connected, the cooperation between the slot 112 and the protrusion 41 can guide and fix the conductive component 22, thereby ensuring that the conductive component 22 does not move due to operation in the designated position. There is no need for fixing plates, screws, or other connecting parts, which reduces the development cost of components. Moreover, no additional fastening steps are required, which simplifies the assembly process and reduces the assembly difficulty. In addition, during the assembly process, the circuit board 20 needs to be potted with glue. The interference fit between the protrusion 41 and the slot 112 can ensure an effective seal between the cover 40 and the boss 110, effectively preventing the glue after potting on the circuit board 20 from overflowing into the shaft hole 101 along the extension direction of the conductive component 22, and avoiding the overflowing glue from affecting the normal operation of the motor shaft.

[0276] In one possible implementation, as shown in Figures 17, 20 and 21, the protrusion 41 is provided with ribs 411 on both sides of the two ends of the circumferential W, and the ribs 411 are interference fit with the side wall of the groove 112.

[0277] In this embodiment, by providing ribs 411 on the sides of both ends of the protrusion 41 along the circumferential W direction, during assembly, the protrusion 41 is inserted into the slot 112 along the axial Y direction. The ribs 411 and the sidewall of the slot 112 are interference-fitted. On the one hand, this can ensure the connection strength and reliability between the cover 40 and the boss 110. On the other hand, it can ensure a reliable seal between the cover 40 and the boss 110, effectively preventing glue from overflowing into the shaft hole 101 along the extension direction of the conductive component 22.

[0278] Furthermore, as shown in Figure 17, the rib 411 is provided along the extension direction of the protrusion 41, and the rib 411 extends continuously from the starting position of the protrusion 41 along the axial Y to the ending position of the protrusion 41 along the axial Y, thereby avoiding gaps between the rib 411 and the sidewall of the groove 112, and effectively preventing glue from overflowing into the shaft hole 101 along the extension direction of the conductive part 22.

[0279] In one possible implementation, as shown in Figures 16 and 17, the outer peripheral surface of the cover 40 is further provided with a plate portion 42. The plate portion 42 is connected to one radial X end of the protrusion 41. The plate portion 42 and the slot 112 are arranged opposite each other in the radial X direction, as shown in Figure 21. The plate portion 42 can fit against the outer peripheral surface of the boss 110, and the projection of the plate portion 42 on the outer peripheral surface of the boss 110 covers the projection of the slot 112 on the outer peripheral surface of the boss 110.

[0280] In this embodiment, by providing a plate portion 42 on the outer peripheral surface of the cover 40, during assembly, the protrusion 41 is inserted into the slot 112 along the axial direction Y. The protrusion 41 and the slot 112 are interference-fitted, thereby ensuring a reliable seal between the cover 40 and the boss 110, effectively preventing glue from overflowing into the shaft hole 101 along the extension direction of the conductive element 22. At the same time, the plate portion 42 can fit against the outer peripheral surface of the boss 110, and the projection of the plate portion 42 on the outer peripheral surface of the boss 110 covers the projection of the slot 112 on the outer peripheral surface of the boss 110, further enhancing the blocking effect on glue, thereby effectively preventing glue from overflowing into the shaft hole 101 along the extension direction of the conductive element 22.

[0281] Furthermore, the cover 40, the protrusion 41, and the plate portion 42 are integrally formed structures.

[0282] In one possible implementation, as shown in Figure 17, the plate body 42 is provided with a guide groove 421, which is disposed opposite to the conductive element 22 along the axial direction Y. The guide groove 421 is used to limit the conductive element 22.

[0283] In this embodiment, by providing a guide groove 421 on the plate body 42, and inserting the protrusion 41 into the slot 112 along the axial Y direction, the guide groove 421, together with the slot 112 and the protrusion 41, can guide and fix the conductive component 22, thereby ensuring that the conductive component 22 does not move due to operation at the designated position, ensuring effective contact between the conductive component 22 and the motor shaft, and eliminating the need for fixing plates, screws and other connecting parts, reducing the development cost of parts, and eliminating the need for additional fastening steps, simplifying the assembly process and reducing the assembly difficulty.

[0284] In one possible implementation, the conductive element 22 is made of carbon fiber; the conductive element 22 is tin-plated and then soldered onto the circuit board 20.

[0285] In this embodiment, the conductive component 22, which is formed by carbon fiber into a column structure, is used to achieve conductivity by contacting the motor shaft with the carbon fiber. This can form a low-impedance grounding path, prevent bearing electro-corrosion, and the carbon fiber can be woven or molded into a flexible conductive brush to adapt to the rotational vibration of the shaft, ensuring continuous contact and avoiding poor contact caused by mechanical wear of rigid metal contacts. The carbon fiber is pretreated by tin plating, which can enhance the welding strength with the circuit board pads.

[0286] In one possible implementation, as shown in Figure 15, a first limiting surface 113 is provided in the slot 112. As shown in Figure 17, a second limiting surface 412 is provided on the side of the protrusion 41 facing the conductive element 22 along the axial direction Y. A third limiting surface 422 is provided in the guide groove 421. The first limiting surface 113, the second limiting surface 412 and the third limiting surface 422 are all matched with the shape of the outer peripheral surface of the conductive element 22, and the first limiting surface 113, the second limiting surface 412 and the third limiting surface 422 are all in contact with the outer peripheral surface of the conductive element 22.

[0287] In this embodiment, by providing a first limiting surface 113 matching the shape of the outer peripheral surface of the conductive element 22 in the slot 112, providing a second limiting surface 412 matching the shape of the outer peripheral surface of the conductive element 22 on the protrusion 41, and providing a third limiting surface 422 matching the shape of the outer peripheral surface of the conductive element 22 in the guide groove 421, during assembly, the first limiting surface 113, the second limiting surface 412, and the third limiting surface 422 are all in contact with the outer peripheral surface of the conductive element 22, thereby fixing the conductive element 22 made of carbon fiber onto the circuit board 20 in a preset columnar structure. This not only ensures that the conductive element 22 is fixed in the set structural shape, but also prevents glue from overflowing into the shaft hole 101 along the extension direction of the conductive element 22.

[0288] In one possible implementation, as shown in Figures 14 and 22, the housing 10 is further provided with a connecting kit 50, which is conductive;

[0289] The electric drive integrated system also includes a resistor-capacitor module 60, which includes a body 61 and terminals 62 that are angled to the body 61. The body 61 is electrically connected to the connector kit 50, and the terminals 62 are electrically connected to the circuit board 20.

[0290] In this embodiment, the connecting kit 50 on the housing 10 can be threadedly connected to a screw, and the connecting kit 50 is conductive; the body 61 of the resistor-capacitor module 60 is electrically connected to the connecting kit 50, and the terminal 62 of the resistor-capacitor module 60 is electrically connected to the circuit board 20. The current can be conducted through the following path: conductive part 22 (contacting the motor shaft) - circuit board 20 - terminal 62 - body 61 - connecting kit 50 - screw - system grounding terminal, thereby discharging the shaft current generated during the rotation of the motor shaft through this grounding path, avoiding electrolytic damage to the bearing caused by the shaft current, and extending the equipment life.

[0291] Furthermore, the connecting kit 50 can be made of metal.

[0292] Furthermore, the resistor-capacitor module 60 can be made of metal.

[0293] In one possible implementation, as shown in Figure 22, the connecting kit 50 is provided with a first through hole 501, and the body 61 is provided with a second through hole 611, with the second through hole 611 being coaxially arranged with the first through hole 501.

[0294] The main body 61 is located at one end of the connecting kit 50 along the Y axis, and the main body 61 is in contact with the connecting kit 50; the housing 10 is plastic-coated with the main body 61 and the connecting kit 50.

[0295] In this embodiment, the housing 10 can be integrally injection molded with the body 61 and connecting kit 50 of the resistor-capacitor module 60, so that the housing 10 encapsulates the body 61 and connecting kit 50, thereby fixing the body 61 and connecting kit 50 to the housing 10. The body 61 and connecting kit 50 are in close contact, which can realize the electrical connection between the resistor-capacitor module 60 and the connecting kit 50. The second through hole 611 and the first through hole 501 are coaxially arranged. During assembly, the screw can pass through the second through hole 611 and the first through hole 501 at the same time, which can ensure the electrical connection between the screw and the connecting kit 50 and the resistor-capacitor module 60, thereby forming a grounding path of "conductive component 22 (contacting motor shaft) - circuit board 20 - terminal 62 - body 61 - connecting kit 50 - screw - system grounding terminal". The shaft current generated during the rotation of the motor shaft is then discharged through this grounding path, avoiding the shaft current from causing electrolytic corrosion damage to the bearing and extending the equipment life.

[0296] In one possible implementation, as shown in Figure 22, the circuit board 20 is provided with a conductive hole 201 corresponding to the terminal 62;

[0297] Please refer to Figure 23. The terminal 62 includes a root portion 621 and a pin portion 622, as well as two elastic portions 623 connected between the root portion 621 and the pin portion 622. The two elastic portions 623 are arranged at intervals relative to each other. The terminal 62 is inserted into the conductive hole 201, and the elastic portion 623 is compressed and elastically contracts, and elastically abuts against the inner wall of the conductive hole 201.

[0298] In this embodiment, terminal 62 adopts a fisheye terminal structure. Two elastic portions 623 are provided between the root 621 and the pin portion 622 of terminal 62. During assembly, terminal 62 can be directly inserted into conductive hole 201. During this process, the elastic portion 623 is compressed and elastically contracts, and elastically abuts against the inner wall of conductive hole 201, so that terminal 62 and circuit board 20 maintain close contact. This not only ensures the electrical connection between terminal 62 and circuit board 20 and avoids grounding failure due to poor contact, but also avoids complex processes such as welding (requiring high temperature and precision equipment) or crimping (requiring special tools). The elastic portion 623 of terminal 62 can automatically compensate for the positional deviation between resistor-capacitor module 60, circuit board 20 and connecting kit 50. Even if terminal 62 and conductive hole 201 are not completely aligned, they can maintain close contact through elastic deformation, avoiding grounding failure due to poor contact, thereby reducing assembly difficulty and grounding cost.

[0299] Furthermore, the resistor-capacitor module 60 can be made of copper sheet, with the second through hole 611 and the elastic part 623 formed by stamping.

[0300] In the powertrain system, during the operation of the motor, the shaft current generated by the rotation of the motor shaft needs to be grounded. Current shaft current grounding solutions typically use carbon fiber as a medium.

[0301] In related technologies, carbon fibers must first be fixed into a module before they can be used. Carbon fibers cannot be directly used in circuit connections. This assembly process is highly complex, and the cost of the cluster fixer terminal crimping process and the materials themselves is high.

[0302] Based on the above, this application also proposes an electric drive integrated system, in which carbon fiber in the electric drive integrated system is electroplated and then directly soldered onto a circuit board, reducing assembly difficulty and overall machine cost.

[0303] The electric drive integrated system proposed in this application includes a motor housing, a motor rotor, a motor stator, and a motor shaft. The motor rotor and motor shaft are interference-fitted, and the motor stator is fixed to the inner wall of the motor housing. The two are clearance-fitted to form an air gap.

[0304] The motor shaft has a stepped shaft structure and is chrome-plated to improve wear resistance and rust prevention. The end of the motor shaft away from the load is provided with an assembly section for mounting the circuit board 20. The diameter of the assembly section is designed according to the motor power.

[0305] Referring to Figures 24 and 25, the electric drive integrated system also includes a circuit board 20 and a carbon fiber 9, with the carbon fiber 9 soldered onto the circuit board 20.

[0306] Circuit board 20 is a printed circuit board (PCB). As the core carrier for shaft current output, circuit board 20 can simultaneously integrate the motor control circuit, realizing the integration of grounding and control functions.

[0307] The circuit board 20 has a shaft hole 101, and the circuit board 20 is loosely fitted onto the motor shaft through the shaft hole 101. The circuit board 20 has pads 8 arranged around the shaft hole 101.

[0308] The circuit board 20 is also provided with multiple positioning holes 7, which can be used to connect with the motor housing and limit the axial displacement of the circuit board 20.

[0309] One end of the carbon fiber 9 contacts and is soldered to the pad 8, while the other end of the carbon fiber 9 away from the pad 8 contacts and connects to the motor shaft to form a shaft current conduction path.

[0310] The carbon fiber 9 is provided with an electroplated layer. The electroplated layer improves the welding reliability of the carbon fiber 9.

[0311] In some embodiments, the electroplating layer is configured as a nickel layer and a tin layer, one end of the carbon fiber 9 with the nickel layer and tin layer is soldered to the pad 8 by tin plating, and the end of the carbon fiber 9 away from the pad 8 is connected to the motor shaft.

[0312] In some embodiments, the entire surface of the carbon fiber 9 can be electroplated to form a nickel and tin layer. The electroplated carbon fiber can then be cut into small segments and soldered onto the pads 8.

[0313] It is known that electroplating can also be performed on one end of carbon fiber 9 to form a nickel layer and a tin layer on one end of carbon fiber 9.

[0314] By setting a nickel layer and a tin layer on the carbon fiber 9, the welding performance of the carbon fiber 9 can be improved, and a pad 8 is set in the non-interference area of ​​the circuit board 20 to weld the carbon fiber 9 to the pad 8 of the circuit board 20.

[0315] Carbon fiber 9 is directly soldered to the surface pad 8 of circuit board 20. One end of carbon fiber 9 is in contact with the motor shaft, and the other end of carbon fiber 9 is soldered to the pad 8 on circuit board 20 through nickel and tin layers. This directly diverts the shaft current generated by the shaft voltage away from the bearing and allows it to be absorbed by electronic components on the circuit board or transferred to the housing through a grounding device, thereby reducing the shaft current and extending the life of the motor bearing.

[0316] Compared with the technical solution in related technologies that uses carbon fiber 9 fixers to press together carbon fiber 9 bundles and then install the fixers, the above technical solution directly welds the carbon fiber 9 onto the circuit board 20, which eliminates the need for fixing components, reduces component development, and simplifies assembly and reduces costs.

[0317] In this embodiment, carbon fiber 9 includes a carbon fiber body, a nickel layer, and a tin layer. The carbon fiber body is made of high-strength, highly conductive carbon fiber bundles, for example, T700 or T800 grade.

[0318] It is known that T700 grade carbon fiber has a single filament diameter of 7μm, a bundle of 12K (12,000 single filaments), a diameter of 0.5-0.8mm, a tensile strength ≥4900MPa, and a volume resistivity ≤1.7×10-3Ω·cm. It is suitable for industrial servo motors and new energy vehicle motors.

[0319] T800 grade carbon fiber: The single filament diameter is 7μm, the number of bundled filaments is 6K (6000 single filaments), the diameter is 0.3-0.5mm, the tensile strength is ≥5400MPa, and the volume resistivity is ≤1.5×10-3Ω·cm. It is suitable for lightweight applications such as aerospace motors.

[0320] It should be noted that this is merely an example, and those skilled in the art can choose the type of carbon fiber according to their needs.

[0321] The length of the carbon fiber body is set according to the internal space of the motor. One end is the welding end, which needs to reserve a certain length for electroplating nickel and tin layers. The other end is the contact end, which is used to fit the metal sleeve.

[0322] In some possible implementations, the thickness of the nickel layer is set to 1 μm-3 μm, and the thickness of the tin layer is set to 5 μm-10 μm.

[0323] By setting a nickel layer of 1μm-3μm, a continuous, dense, and uniform conductive substrate can be formed, which improves the conductivity of carbon fiber 9, blocks the atomic diffusion between carbon fiber 9 and the tin layer, avoids the formation of brittle carbon-tin compounds, and enhances the bonding force of subsequent tin layers.

[0324] When the nickel layer is greater than 3μm, it will increase the interfacial contact resistance (thick nickel layers are prone to grain boundary defects, which increases the resistance), which is not conducive to the conduction of shaft current.

[0325] By adding a tin layer, the soldering wettability is improved and the soldering temperature is reduced to meet the temperature resistance requirements of the circuit board 20.

[0326] When the tin layer is less than 5μm, it may not be possible to form a fully molten tin layer on the nickel layer surface, resulting in reduced solder wettability.

[0327] When the tin layer is larger than 10μm, the tin layer is too thick, which may result in a larger size of the welded component, affecting the subsequent welding of carbon fibers.

[0328] In some possible implementations, a grounding conductive loop is provided on the circuit board 20, and the end of the carbon fiber 9 away from the pad 8 is in contact with the motor shaft. The pad 8 is electrically connected to the grounding conductive loop to ground the shaft current.

[0329] Multiple solder pads 8 are evenly arranged along the circumference of the shaft hole 101 for soldering to the carbon fiber 9. For example, the solder pads 8 are made of electrolytic copper foil, and the size of the solder pads 8 is required to ensure sufficient soldering area and reduce contact resistance.

[0330] The circuit board 20 has a grounding conductive loop etched on it. The material is the same as that of the pad 8. One end of the grounding conductive loop is electrically connected to the pad 8, and the other end extends to the grounding terminal at the edge of the circuit board 20. The grounding terminal is connected to the motor housing through a grounding wire to form a closed loop for shaft current grounding.

[0331] By setting up a grounding conductive loop, a complete grounding closed loop is formed, consisting of motor shaft → carbon fiber 9 → solder pad 8 → grounding conductive loop. This prevents shaft current from accumulating inside the motor and solves the problems of bearing failure and motor malfunction caused by shaft current.

[0332] In some implementations, the grounding conductive loop of circuit board 20 is gold-plated to improve corrosion resistance and make it suitable for extreme corrosive environments.

[0333] It should be noted that the carbon fiber 9 can be grounded through the motor housing to form a closed-loop grounding system for the shaft current of the motor shaft, carbon fiber, circuit board 20, and motor housing. Alternatively, it can be grounded through a grounding point on the circuit board 20 to form the same closed-loop grounding system. Those skilled in the art can set the grounding location as needed, as long as it satisfies the requirement of grounding the shaft current.

[0334] The surface of pad 8 is treated with an organic solderability protection treatment, which can effectively prevent the pad 8 from oxidizing and maintain the solderability of the pad 8.

[0335] In some possible implementations, in order to improve the contact reliability between the carbon fiber 9 and the motor shaft, a metal sleeve is provided at the end of the carbon fiber 9 that contacts the motor shaft. The inner wall of the metal sleeve is interference-fitted with the carbon fiber 9 to ensure that there is no gap between the metal sleeve and the carbon fiber 9, and the outer wall of the metal sleeve is in contact with the surface of the motor shaft.

[0336] For example, the metal sleeve is made of brass to balance conductivity and mechanical strength.

[0337] The surface of the motor shaft assembly section is precision ground to a surface roughness of less than 0.8 μm to ensure a tight fit with the metal sleeve at the end of the carbon fiber 9 and reduce contact resistance.

[0338] The outer wall of the metal sleeve is polished, and the inside has axial rough texture to further enhance the mechanical connection strength with carbon fiber 9. The outer wall can be selectively tin-plated to reduce the contact resistance with the motor shaft.

[0339] In some implementations, coating the carbon fiber body and the metal sleeve with silver-based conductive adhesive can reduce contact resistance while enhancing mechanical connection strength.

[0340] This application also proposes an electric vehicle. In one embodiment of the electric vehicle of this application, the electric vehicle includes the electric drive integrated system as described above.

[0341] It should be noted that the specific structure of the electric drive integrated system refers to the above embodiments. Since the electric vehicle adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0342] This application also provides a power system, including the electric drive integrated system as described above.

[0343] Given that the power system in this embodiment includes the electric drive integrated system described in any of the above embodiments, the structure and beneficial effects of the power system including the electric drive integrated system will not be described in detail here.

[0344] In some possible implementations, this application proposes a soldering head 4 with solder paste on the solder pads 8. The soldering head 4 is used to perform thermocompression soldering of the carbon fiber 9 and the circuit board 20, and can control the melting range of the solder paste to prevent molten solder from overflowing.

[0345] Referring to Figures 26 and 27, the welding head 4 includes a welding head body 43, a cavity structure 44, and a barrier structure 45.

[0346] The welding head body 43 is made of high temperature resistant alloy, and the lower end face of the welding head 4 is provided with a cavity structure 44, which is used to accommodate the solder paste and the welding end of the carbon fiber 9.

[0347] The barrier structure 45 is disposed inside the cavity structure 44. The barrier structure 45 is used to guide the flow of molten solder phase at the center of the solder pad 8, while preventing the molten solder from spreading along the length of the carbon fiber 9 to the non-soldering area.

[0348] In some embodiments, the cavity structure 44 is 1.5 to 2 times the size of the solder paste to ensure that there is enough space to fill the cavity after the solder paste melts, preventing it from overflowing.

[0349] The barrier structures 45 are spaced apart along the length direction of the cavity structure 44 (the length direction of the carbon fiber 9), and the barrier structures 45 extend along the length direction perpendicular to the carbon fiber 9. This forms a lateral barrier to the spread of molten tin along the carbon fiber 9.

[0350] Multiple barrier structures 45 are configured, for example, three. The three barrier structures 45 form a stepped structure.

[0351] The solder head 4 has a barrier structure 45 that prevents solder from overflowing. This structure allows the solder to be soldered onto the pad 8 in the desired shape, effectively preventing the solder from overflowing along the direction of the carbon fiber 9. This prevents the carbon fiber 9 from hardening and becoming brittle in non-soldering areas due to solder spread, thus ensuring that the function of the carbon fiber 9 is not damaged.

[0352] In this embodiment, referring to FIG27, the lower surface of all the barrier structures 45 is lower than the lower surface of the cavity structure 44, so that the sidewalls of the barrier structures 45 and the cavity structure 44 form a stepped structure. This achieves the blocking of solder paste during the soldering process, preventing excess solder from overflowing along the direction of the carbon fiber 9.

[0353] The welding head 4 has a heating channel and a pressurizing channel inside, which are used to control the temperature and pressure of thermocompression welding. The heating channel can be heated by high-temperature oil or electric heating wire, and the pressurizing channel can be connected to a cylinder.

[0354] In some embodiments, a micro-channel is added to the cavity structure 44 of the solder head 4 to guide the molten solder to fill more evenly and reduce the void rate of the solder joint.

[0355] A polytetrafluoroethylene coating (5-10 μm thick) is applied to the surface of the solder head 4 to prevent molten solder from sticking together and extend the maintenance cycle of the solder head 4.

[0356] Carbon fiber 9 is soldered onto circuit board 20 via soldering head 4, and the shape of solder paste layer 3 and cavity structure 44 are adapted to the shape of trapezoidal barrier.

[0357] The cavity enclosed by the cavity structure 44 can be square or circular, and the shape of the solder paste layer 3 can be set to square or circular.

[0358] Referring to Figure 25, the overall outline of the solder paste layer 3 after soldering is square. Referring to Figure 27, the cavity structure 44 encloses a square space.

[0359] In some possible implementations, the solder paste layer 3 after soldering has raised structures spaced along the length of the carbon fiber 9.

[0360] By forming a solder paste layer 3 with a fixed shape, the solder paste filling range can be precisely controlled to prevent the solder liquid from overflowing and causing the carbon fiber 9 to harden.

[0361] Solder paste is used to control the shape and amount of solder. Solder paste during the hot-pressing process is filled into the cavity structure 44 of the contact area between the soldering head 4 and the carbon fiber 9 by hot-pressing the cavity structure 44.

[0362] The cavity structure 44 is larger than the solder paste, and the cavity structure 44 is designed with a barrier structure 45 to effectively prevent excess solder from overflowing along the direction of the carbon fiber 9, and to prevent the carbon fiber 9 from hardening and becoming brittle due to the overflow of solder, thus affecting its functionality.

[0363] Referring to Figure 25, the effect after welding is shown. The barrier structure inside the welding head 4 guides the solder into the cavity structure 44, so that the solder welds the carbon fiber 9 onto the pad 8 in the desired shape, which can effectively prevent the problem of solder overflow.

[0364] Referring to Figure 24, the structure of solder paste layer 3 in Figure 24 is different from that in Figure 25.

[0365] It should be noted that the technical solution in this application embodiment does not limit the specific structure of the solder paste layer 3. It is only necessary that the solder paste layer 3 after soldering has raised structures spaced along the length of the carbon fiber 9 to effectively prevent excess solder from overflowing outward along the direction of the carbon fiber 9, and to prevent the carbon fiber 9 from hardening and becoming brittle due to the overflow of solder, thus affecting its function.

[0366] This application also proposes a method for fixing carbon fiber 9 to a circuit board 20.

[0367] The core of this fixing method is to modify the welding end of the carbon fiber 9 with a double-layer plating of "chemical nickel plating + electrodeposition tin", and then use the welding head 4 with cavity structure 44 and barrier structure 45 for thermo-pressure welding to achieve direct welding of carbon fiber 9 to circuit board 20, eliminating the need for traditional fixing devices and controlling the overflow of molten tin. This method is suitable for mass production and is compatible with automated production lines.

[0368] In this embodiment, the method for fixing the carbon fiber 9 to the circuit board 20 includes:

[0369] Carbon fiber 9 is electroplated to form an electroplated layer on its surface.

[0370] In some embodiments, after electroplating, a nickel layer and a tin layer are sequentially formed on the surface of carbon fiber 9 to improve the soldering stability of subsequent tin plating.

[0371] Pads 8 are arranged circumferentially along the axial hole 101 of the circuit board 20.

[0372] One end of the carbon fiber 9 is aligned with the pad 8 of the circuit board 20 and welded using a thermo-press welding process. The circuit board 20 is loosely fitted onto the motor shaft through the shaft hole 101.

[0373] Start welding head 4 and set welding parameters, for example, temperature 240-260℃ (preferably 250℃), pressure 0.5-1MPa (preferably 0.8MPa), and time 5-10s (preferably 8s).

[0374] The cavity structure 44 of the welding head 4 is covered with solder paste layer 3, and the barrier structure 45 guides the molten solder to fill. The molten solder forms an intermetallic compound with the solder layer of carbon fiber 9 and the aluminum foil of the solder pad 8, thus achieving reliable welding.

[0375] Before electroplating carbon fiber 9, the welding ends can be ultrasonically cleaned first, followed by electroless nickel plating and electrodeposition of tin, and then metal sleeves can be press-fitted onto the contact ends of carbon fiber 9. This completes the preparation for welding carbon fiber 9.

[0376] The purpose of pretreatment of carbon fiber 9 is to remove oil and impurities from the surface of carbon fiber 9, so as to provide a clean substrate for subsequent coating.

[0377] The cleaning solution used for the ultrasonic cleaning described above can be an alkaline mixture. After cleaning, the carbon fiber 9 is rinsed in deionized water to remove residual cleaning solution, and then dried to avoid coating bubbles.

[0378] The circuit board 20 is loosely fitted onto the assembly section of the motor shaft through the shaft hole 101. The circumferential position of the circuit board 20 is adjusted to avoid interference. The circuit board 20 is then connected to the motor housing through the positioning hole 7 via a plastic bracket to fix the axial position of the circuit board 20 and ensure that the circuit board 20 can rotate flexibly.

[0379] In some embodiments, after welding is completed, the contact end of the carbon fiber 9 is adjusted so that the metal sleeve fits into the assembly section of the motor shaft, forming a contact path between the motor shaft, the metal sleeve, and the carbon fiber 9.

[0380] The grounding terminal on circuit board 20 is connected to the motor housing through a grounding wire to complete the shaft current grounding closed loop.

[0381] By using the above-described method of fixing carbon fiber 9 to circuit board 20, the shaft current extraction rate is improved, and the contact resistance between carbon fiber 9 and motor shaft is reduced. Compared with the fixing methods of carbon fiber 9 in related technologies, the fixing method in this embodiment reduces assembly steps, improves production efficiency, reduces costs, and also helps to achieve motor weight reduction.

[0382] In one possible implementation, the steps of forming a nickel layer and a tin layer on the surface of the carbon fiber 9 are as follows:

[0383] One end of the pretreated carbon fiber 9 is placed in a nickel plating solution, and a nickel layer is deposited using a chemical plating process, wherein the thickness of the nickel layer is 1μm-3μm.

[0384] The nickel-plated carbon fiber 9 was placed in a tin plating solution, and a tin layer was deposited using an electrodeposition process, wherein the thickness of the tin layer was 5μm-10μm.

[0385] The purpose of nickel and tin plating is to address the surface inertness of carbon fiber 9 and achieve reliable welding.

[0386] In this embodiment, the nickel plating process is as follows:

[0387] 1. Preparation of nickel plating solution: Add deionized water to the nickel plating tank, and then add the following reagents in sequence: nickel sulfate (NiSO4·6H2O), sodium hypophosphite (NaH2PO2·H2O), sodium citrate (Na3C6H5O7·2H2O) and ammonia (NH3·H2O, 25% concentration).

[0388] Nickel sulfate (NiSO4·6H2O) is used to provide nickel ions. Sodium hypophosphite (NaH2PO2·H2O) acts as a reducing agent to remove Ni ions. 2+ The reduction is carried out to Ni. Sodium citrate (Na3C6H5O7·2H2O) acts as a complexing agent to prevent Ni(OH)2 precipitation; ammonia (NH3·H2O, 25% concentration) is used to adjust the pH of the plating solution to 8.5-9.0. Too low a pH will result in a slow reduction reaction, while too high a pH will result in a loose nickel layer.

[0389] 2. Nickel plating process control:

[0390] Immerse the pretreated carbon fiber 9 weld ends (exemplary, 5-10 mm in length) into the nickel plating solution, ensuring that the plating area is completely submerged, and protect the non-plating areas with high-temperature resistant tape.

[0391] Set the nickel plating parameters as follows: temperature 40-60℃ (50℃ for example), stirring speed 50-100rpm (to ensure uniform plating solution), and deposition time 10-15min (to ensure a nickel layer thickness of 1-3μm by real-time monitoring with a film thickness gauge).

[0392] 3. Post-treatment: Remove the nickel-plated carbon fiber 9 from the nickel plating solution, rinse it three times with deionized water (for example, 2 minutes each time), and then put it in an oven to dry (for example, at 80°C for 5 minutes) to avoid oxidation of the nickel layer.

[0393] It should be noted that the above data are for illustrative purposes only, and those skilled in the art may adjust them as needed.

[0394] In this embodiment, the tin plating process is as follows:

[0395] 1. Preparation of tin plating solution: Add deionized water to the electrodeposition tank, and then add the following reagents in sequence: stannous methanesulfonate (Sn(CH3SO3)2), methanesulfonic acid (CH3SO3H) and phenolic additives (such as hydroquinone).

[0396] Stannous methanesulfonate (Sn(CH3SO3)2) is used to provide tin ions. Methanesulfonic acid (CH3SO3H) is used to adjust the pH value and prevent the hydrolysis of tin ions. Phenolic additives (such as hydroquinone) are used to refine the tin layer grains and prevent dendrite growth.

[0397] 2. Electrodeposition process control:

[0398] Nickel-plated carbon fiber 9 was used as the cathode, and a pure tin plate (99.99% purity) was used as the anode, and connected to a DC power supply.

[0399] Set the electrodeposition parameters: current density 0.2-0.5 A / dm³ 2 (Preferred 0.3A / dm) 2 Excessive current density can lead to a rough tin layer. The temperature should be 40-50℃ (45℃ for example), and the deposition time should be 5-10 min (monitored by a film thickness gauge to ensure that the tin layer thickness is 5μm-10μm).

[0400] 3. Post-processing:

[0401] Remove the electrodeposited carbon fiber 9, rinse it three times with deionized water (exemplary, 2 min each time), dry it in an oven (exemplary, temperature 80°C, time 5 min), and then wipe the coating surface with alcohol to remove residual organic matter.

[0402] After coating modification, the wetting angle of the weld end of carbon fiber 9 is reduced, and the weldability is significantly improved; the bonding strength between the nickel layer and carbon fiber 9 is increased by ≥0.5 N / mm. 2 The bonding strength between the tin layer and the nickel layer is ≥0.8 N / mm. 2 This meets the welding requirements.

[0403] It should be noted that the above data are for illustrative purposes only, and those skilled in the art may adjust them as needed.

[0404] The above nickel and tin plating processes are merely examples, and those skilled in the art can adjust the specific nickel and tin plating methods according to their needs.

[0405] In some possible implementations, replacing DC electrodeposition with pulse electrodeposition can refine the tin layer grains, reduce coating uniformity deviations, and further reduce contact resistance.

[0406] In some possible implementations, the pads 8 are first subjected to an organic solderability protection treatment before welding the carbon fiber 9.

[0407] As mentioned above, Organic Solderability Preservatives (OSP) is a surface treatment technology for the pads 8 of the circuit board 20 in this technical solution. Its core function is to form a thin and uniform organic protective film on the surface of the pads 8 to achieve specific technical functions. The specific definition and function are as follows:

[0408] Organic solderability protection treatment refers to coating an organic compound protective film onto the surface of the pads 8 of the circuit board 20 of the motor through a specific process. The thickness of this film layer needs to be adapted to the subsequent soldering process and does not affect the conductivity and soldering compatibility of the pads 8. It is specifically used to solve the oxidation problem of the pads 8 of the circuit board 20 during storage and assembly.

[0409] The main functions of organic solderability protection treatment are as follows: preventing pad oxidation and ensuring the stability of soldering quality.

[0410] By performing an organic solderability protection treatment, the problem of easy oxidation of the solder pads 8 on the circuit board 20 in the related technology is effectively solved, which leads to the inability of the tin layer to effectively bond with the solder pads 8 during soldering, resulting in problems such as cold solder joints and insufficient solder joint strength. The organic protective film formed by the organic solderability protection treatment can isolate the direct contact between air and moisture and the surface of the solder pads 8, prevent the solder pads 8 from oxidizing, and ensure that even after the motor assembly cycle (exemplarily, storage for 1-3 months), the solder pads 8 still have good solderability, adapting to the soldering requirements of the nickel-plated tin layer of the carbon fiber 9.

[0411] This patented technology utilizes thermocompression welding (temperature 240-260℃, pressure 0.5-1MPa) to weld carbon fiber 9 to pad 8. The organic protective film formed by the organic solderability protection treatment will evaporate or decompose along with the flux at the high temperature of thermocompression welding, leaving no residue that would affect the bonding between the molten solder and the pad 8. Instead, through its characteristic of protecting first and then ensuring compatibility with soldering, it ensures a stable metallic bond between the molten solder layer and the pad 8.

[0412] In some possible implementations, the welding head 4 used in the thermocompression welding process is provided with a cavity structure 44 and a barrier structure 45. During the welding process, the welding head 4 places solder paste in the cavity structure 44.

[0413] During the soldering process, the solder paste melts and forms an intermetallic compound with the tin layer of the carbon fiber 9 and the copper foil of the solder pad 8 through the hot pressing action of the solder head 4.

[0414] First, perform fixture positioning: Fix the circuit board 20 onto the welding fixture, and adjust the fixture position so that the solder pad 8 is directly below the welding head 4. Align the welding end of the carbon fiber 9 with the solder pad 8, ensuring that the axial deviation between the carbon fiber 9 and the center of the solder pad 8 is less than a preset value, for example, 0.2mm.

[0415] Then, preheat soldering head 4: Activate the heating channel of soldering head 4 and raise the temperature to 240-260℃ (preferably 250℃, the melting temperature of Sn63Pb37 solder paste), hold for 5 minutes, and ensure uniform temperature. It should be noted that uniform temperature here refers to a temperature fluctuation limit of 2℃.

[0416] In hot-press welding using welding head 4: control the welding head 4 to descend so that the cavity structure 44 is covered with solder paste, the blocking structure 45 contacts the solder paste, and then start the pressurization channel.

[0417] During this process, the solder paste melts and fills the cavity structure 44 under the guidance of the barrier structure 45 to form the solder paste layer 3. The solder paste layer 3 reacts with the tin layer of the carbon fiber 9 and the aluminum foil of the pad 8 to form an intermetallic compound.

[0418] Finally, cooling and demolding are carried out: After the welding time is over, heating is stopped, the pressure is kept constant, and when the temperature drops below 150℃, the welding head 4 is raised to complete the demolding.

[0419] The above welding method results in a high solder joint fill rate (greater than 90% according to X-ray inspection), a high welding strength (greater than 0.8 N / mm2 according to tensile test), reduced solder overflow, and no solder coverage in the non-welding areas of carbon fiber 9.

[0420] In some implementations, the welded components can be inspected after welding. Inspection methods include visual inspection, X-ray inspection, tensile testing, and contact resistance testing to ensure quality requirements for mass production.

[0421] The electric drive integrated system and carbon fiber fixing method provided in this application embodiment require only three steps compared to related technologies, which require four steps: "carbon fiber 9 pretreatment, pressing and fixing, module installation, and installation on circuit board 20": "pretreatment, plating modification, and hot pressing welding." This eliminates the need for fixing-related steps and improves production efficiency.

[0422] In this embodiment, a nickel layer and a tin layer are provided on the carbon fiber 9 to weld the carbon fiber 9 to the pad 8 of the circuit board 20. One end of the carbon fiber 9 is in contact with the motor shaft, and the other end of the carbon fiber 9 is welded to the pad 8 of the circuit board 20 through the nickel-tin layer, forming a shaft current conduction path of "motor shaft → carbon fiber 9 → pad 8 → circuit board 20". This directly diverts the shaft current generated by the shaft voltage away from the bearing, avoids the breakdown of the bearing oil film and causes electrolytic corrosion, and extends the life of the motor bearing.

[0423] This application, through the core innovation of "carbon fiber 9 coating modification + direct welding," provides a method for fixing the motor and carbon fiber 9 to the circuit board 20, solving the problems of "complex process, high cost, low reliability, and solder overflow" in traditional shaft current grounding schemes. Specifically:

[0424] In the motor structure, a stable shaft current grounding closed loop is formed by the nickel-tin plating layer of carbon fiber 9, the circumferential pads 8 of circuit board 20 and grounding circuit, and the welding head 4 with cavity structure 44 and barrier structure 45. The shaft current output rate is improved and the contact resistance fluctuation rate is reduced.

[0425] In the fixed method, the process is simplified and the cost is reduced by following the steps of pretreatment → plating modification → circuit board preparation → thermoforming → inspection, which improves the welding strength and makes it suitable for mass production. It should be noted that the above examples are only for understanding this application and do not constitute a limitation on the stator assembly or motor of this application. Many simple modifications based on this technical concept are within the scope of protection of this application.

[0426] The above are only some embodiments of this application and do not limit the patent scope of this application. All equivalent structural transformations made under the technical concept of this application and using the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included in the patent protection scope of this application.

Claims

An electrically driven integrated system, characterized in that The application relates to a position sensor for an electric motor. The position sensor comprises a shell, a rotating shaft and a bearing arranged in the shell, a position sensor comprising a circuit board and an induction rotor, wherein the circuit board is integrated with an induction coil, and the induction rotor is connected with the rotating shaft. An electrically conductive part is fixed to the circuit board and electrically connected with the circuit board, and the end surface of the electrically conductive part is in contact with the bearing, and the shaft current is conducted to the circuit board, the shell and the electrically conductive part in sequence. Further comprising: The electric drive integrated system according to claim 1, characterized in that, A resistance-capacitance module is fixed to the circuit board, one end of the resistance-capacitance module is connected with the electrically conductive part, and the other end of the resistance-capacitance module is electrically connected with the circuit board. The resistance-capacitance module and the induction coil are arranged on different sides of the circuit board. The electric drive integrated system according to claim 2, characterized in that, Further comprising: The electric drive integrated system according to claim 1, characterized in that, A temperature sensor is fixed to the circuit board and electrically connected with the circuit board, and the temperature sensor is used for detecting the temperature of motor coolant. Further comprising: The electric drive integrated system according to claim 4, characterized in that A motor controller is in communication connection with the circuit board. A signal processing module is arranged on the circuit board. The electric drive integrated system according to claim 5, characterized in that The signal processing module is connected with the circuit board and in communication connection with the motor controller. The circuit board is arranged outside the rotating shaft and cooperates with the induction rotor to generate a magnetic field, or is arranged on one side of the induction rotor and cooperates with the induction rotor to generate a magnetic field. The electric drive integrated system according to claim 1, characterized in that, The induction rotor is a rotor of a resolver or a rotor of an eddy current sensor. The electric drive integration system according to claim 1, characterized in that The shell further comprises a rotor core and a stator core. The electric drive integration system according to any one of claims 1 to 8, characterized in that The rotor core is arranged on the rotating shaft and located inside the stator core, the bearing is arranged on the end of the rotating shaft and located inside the stator core, and the circuit board is arranged on the rotating shaft and located between the bearing and the rotor core in the axial direction. The shell further comprises a rotor core and a stator core. The electric drive integration system according to any one of claims 1 to 8, characterized in that The rotor core is arranged on the rotating shaft and located inside the stator core, the bearing is arranged on the rotating shaft and located inside the stator core, and the circuit board is arranged on the end of the rotating shaft and located outside the stator core in the axial direction. Further comprising: The electric drive integration system according to any one of claims 1 to 9, characterized in that A motor comprising the shell; A motor control unit; A temperature sensor is fixed to the circuit board and electrically connected with the circuit board; The signal line of the temperature sensor and the signal line of the position sensor are integrated on the circuit board and transmitted to the motor control unit through the circuit board. Further comprising: The electric drive integration system according to claim 11, characterized in that A resistance-capacitance module is fixed to the circuit board, one end of the resistance-capacitance module is electrically connected with the rotating shaft, and the other end of the resistance-capacitance module is grounded. The resistance-capacitance module and the temperature sensor are arranged on different sides of the circuit board. The electric drive integration system according to claim 12, characterized in that The communication line integrated with the signal line of the temperature sensor and the signal line of the position sensor is connected to the circuit board through an electric connection fixing hole and is in communication connection with the motor control unit. The electric drive integration system according to claim 11, characterized in that A signal processing module is arranged on the circuit board. The electric drive integrated system according to claim 14, characterized in that The signal processing module is connected with the circuit board and in communication connection with the motor control unit. ​ The electric drive integration system according to claim 11, characterized in that The circuit board is sleeved on the rotating shaft and located outside the induction rotor, and generates a magnetic field in cooperation with the induction rotor. The electric drive integration system according to claim 11, characterized in that The induction rotor is a rotor of a resolver or a rotor of an eddy current sensor. The electric drive integration system according to any one of claims 11 to 17, characterized in that The motor further comprises a bearing, a rotor core and a stator core. The rotor core is sleeved on the rotating shaft and located inside the stator core, the bearing is sleeved on the end of the rotating shaft and located inside the stator core, and the circuit board is sleeved on the rotating shaft and located axially between the bearing and the rotor core. The electric drive integration system according to any one of claims 11 to 17, characterized in that The motor further comprises a rotor core and a stator core. The rotor core is sleeved on the rotating shaft and located inside the stator core, the bearing is sleeved on the rotating shaft and located inside the stator core, and the circuit board is sleeved on the end of the rotating shaft and located axially outside the stator core. The electric drive integrated system according to any one of claims 1 to 19, characterized in that The shell has a shaft hole and a boss arranged along the circumferential direction of the shaft hole; one end of the boss in the axial direction is provided with a target end face, and a notch is formed in the boss in the axial direction from the target end face, and the notch is in communication with the shaft hole; The circuit board is arranged in the shell; The electric drive integrated system further comprises: The conductive part is welded on the circuit board, one end of the conductive part passes through the notch and extends at least partially into the shaft hole; The cover abuts against the conductive part in the axial direction. The electric drive integrated system according to claim 20, wherein The cover is arranged on the target end face of the boss; the cover is provided with a protrusion, the protrusion is arranged opposite to the notch in the axial direction, and the protrusion can be inserted into the notch and abut against the conductive part. The electric drive integrated system according to claim 21, wherein, The cover and the boss are connected by welding. The electric drive integrated system according to claim 21, wherein, The protrusion can be clamped in the notch. The protrusion and the notch are in interference fit. The electric drive integrated system according to claim 23, wherein, The protrusion is provided with a protruding rib on the side surface of the circumferential direction, and the protruding rib is in interference fit with the side wall of the notch. The electric drive integrated system according to claim 21, wherein, The outer circumferential surface of the cover is further provided with a plate body part, the plate body part is connected with one end of the protrusion in the radial direction, the plate body part is arranged opposite to the notch in the radial direction, the plate body part can be attached to the outer circumferential surface of the boss, and the projection of the plate body part on the outer circumferential surface of the boss covers the projection of the notch on the outer circumferential surface of the boss. The electric drive integrated system according to claim 25, characterized in that The plate body part is provided with a guide groove, the guide groove is arranged opposite to the conductive part in the axial direction, and the guide groove is used for limiting the conductive part. The electric drive integrated system according to claim 26, wherein, The conductive part is carbon fiber; the conductive part is tinned and then welded on the circuit board. The electric drive integrated system according to claim 27, characterized in that The notch is provided with a first limiting surface, one side of the protrusion in the axial direction towards the conductive part is provided with a second limiting surface, and the guide groove is provided with a third limiting surface; the first limiting surface, the second limiting surface and the third limiting surface are matched with the shape of the outer circumferential surface of the conductive part, and the first limiting surface, the second limiting surface and the third limiting surface are attached to the outer circumferential surface of the conductive part. The electric drive integrated system according to any one of claims 20 to 28, characterized in that The shell is further provided with a connecting sleeve, and the connecting sleeve has electrical conductivity. The electric drive integrated system further comprises a resistance-capacitance module, the resistance-capacitance module comprises a body and a terminal arranged at an angle with the body, the body is electrically connected with the connecting sleeve, and the terminal is electrically connected with the circuit board. The electric drive integrated system according to claim 29, wherein, The connecting sleeve is provided with a first through hole, and the body is provided with a second through hole coaxially arranged with the first through hole. The body is arranged at one end of the connecting sleeve along an axial direction, and the body is attached to the connecting sleeve; and the shell is plasticized with the body and the connecting sleeve. The electric drive integrated system according to claim 29, wherein, The circuit board is provided with a conductive hole corresponding to the terminal; The terminal comprises a root portion and a pin portion, and two elastic portions connected between the root portion and the pin portion, the two elastic portions are arranged opposite to each other; the terminal is inserted into the conductive hole, and the elastic portions are elastically contracted by being extruded and elastically abut against the inner wall of the conductive hole. The electric drive integrated system according to any one of claims 1 to 31, characterized in that, Comprise: A motor shaft; The circuit board is provided with a shaft hole, the circuit board is sleeved on the motor shaft through the shaft hole, and the circuit board is provided with a welding pad along the shaft hole in a circumferential direction; The conductive member is a carbon fiber, one end of the carbon fiber is in contact with the welding pad and is welded on the welding pad, and the other end of the carbon fiber away from the welding pad is in contact with the motor shaft to form a shaft current conduction path. The electric drive integrated system according to claim 32, characterized in that The surface of the carbon fiber has a nickel layer and a tin layer, and one end of the carbon fiber is welded on the welding pad by tin plating. The electric drive integration system according to claim 32 or 33, characterized in that The circuit board is provided with a grounding conductive loop, the other end of the carbon fiber away from the welding pad is in contact with the motor shaft, and the welding pad is electrically connected with the grounding conductive loop to ground the shaft current. The electric drive integrated system according to claim 32 or 33, characterized in that The welding pad is provided with a tin paste layer, and the tin paste layer is formed with a protruding structure along the length direction of the carbon fiber. The electric drive integrated system according to claim 32 or 33, characterized in that The end of the carbon fiber in contact with the motor shaft is sleeved with a metal sleeve, the inner wall of the metal sleeve is in interference fit with the carbon fiber, and the outer wall of the metal sleeve is attached to the surface of the motor shaft. The electric drive integrated system according to claim 33, wherein The thickness of the nickel layer is 1-3 μm, and the thickness of the tin layer is 5-10 μm. The electric drive integrated system according to claim 35, wherein, The carbon fiber is welded on the circuit board through a welding head, the welding head comprises a cavity structure and a blocking structure arranged inside the cavity structure, and the shape of the tin paste layer is adapted to the shape formed by the cavity structure and the blocking structure. A method of fixing carbon fibers, characterized by, Comprise: Electroplating treatment is performed on the carbon fiber to form an electroplated layer on the surface of the carbon fiber; A welding pad is arranged along the shaft hole of the circuit board in a circumferential direction, and the circuit board is sleeved on the motor shaft through the shaft hole; One end of the carbon fiber is aligned with the welding pad of the circuit board, and the carbon fiber is welded on the welding pad by using a hot-press welding process. The method of claim 39, wherein After the electroplating treatment is performed on the carbon fiber, a nickel layer and a tin layer are sequentially formed on the surface of the carbon fiber. The method of fixing carbon fibers according to claim 39 or 40, characterized in that, The steps of forming the nickel layer and the tin layer on the surface of the carbon fiber are: One end of the carbon fiber after the pretreatment is placed in a nickel plating solution, and the nickel layer is deposited by using a chemical plating process, wherein the thickness of the nickel layer is 1-3 μm; The same end of the carbon fiber after the nickel plating is placed in a tin plating solution, and the tin layer is deposited by using an electrodeposition process, wherein the thickness of the tin layer is 5-10 μm. The method of fixing carbon fibers according to claim 39 or 40, characterized in that, The welding head used in the hot press welding process is provided with a cavity structure and a blocking structure arranged in the cavity structure, and during the welding process, the welding head places the solder paste in the cavity structure. A power system characterized by An electric drive integrated system comprising any one of the above claims 1 to 38. An electric vehicle characterized by comprising: An electric drive integrated system comprising any one of the above claims 1 to 38.

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