Electric drive lubricating and cooling system, and vehicle

Abstract

The present application discloses an electric drive lubricating and cooling system, and a vehicle. The electric drive lubricating and cooling system comprises a housing assembly, a controller, a motor, a speed reducer, oil pumps, and oil coolers; the housing assembly is provided with a motor mounting cavity, a controller mounting cavity, a water-cooling cavity, and a speed reducer mounting cavity and an oil storage cavity that are communicated with each other; a plurality of oil passages and a plurality of water passages are formed in the wall of the housing assembly; the oil pumps, the oil coolers, a stator mounting cavity, and the speed reducer mounting cavity are sequentially communicated with each other by means of the oil passages so as to form an electric drive lubricating and cooling circuit; the oil coolers are communicated with the water-cooling cavity by means of the water passages. A stator iron core and a stator winding are immersed in a circulating oil to be cooled, and thus, the cooling efficiency is high. A lubricating oil and a coolant for cooling the controller both flow by means of the wall of the housing assembly, and the whole electric drive lubricating and cooling system does not need to be additionally provided with an oil pipe and a water pipe, and thus, the electric drive lubricating and cooling system has a more compact structure.

Description

Electric drive lubrication and cooling systems and vehicles

[0001] This application claims priority to Chinese Patent Application No. 202510236922.0, filed on February 28, 2025, entitled "Electric Drive Lubrication and Cooling System and Vehicle", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application belongs to the field of electric drive system technology, and in particular relates to an electric drive lubrication and cooling system and a vehicle. Background Technology

[0003] In current electric drive systems, motors are typically cooled by water or air. Water cooling usually involves installing a cooling water jacket on the outside of the stator or creating cooling water channels inside the motor housing, cooling the stator through heat exchange with the air. Air cooling also cools the stator through heat exchange with the air; however, both of these cooling methods have relatively low cooling efficiency.

[0004] Furthermore, water-cooling solutions require cooling water jackets, which significantly increase the size of the motor, resulting in a larger electric drive system. Therefore, a more efficient and compact electric drive lubrication and cooling system is needed. Summary of the Invention

[0005] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes an electric drive lubrication and cooling system and vehicle, in which the reducer and the stator of the motor all adopt active oil lubrication and cooling, which has high cooling efficiency and a compact overall structure.

[0006] In a first aspect of this application, an electrically driven lubrication and cooling system is provided, comprising:

[0007] The housing assembly includes a motor mounting cavity, a controller mounting cavity, a water cooling cavity, and a connected reducer mounting cavity and oil storage cavity. The housing assembly has several oil channels and several water channels in its walls.

[0008] The controller is located in the controller mounting cavity and exchanges heat with the water-cooling cavity;

[0009] The motor is located in the motor mounting cavity. The stator assembly of the motor includes a stator housing. The stator windings and stator core of the stator assembly are both located in the stator mounting cavity of the stator housing.

[0010] A speed reducer is located in the speed reducer mounting cavity and is connected to the rotor assembly of the motor;

[0011] The oil pump and oil cooler are respectively installed at different locations on the housing assembly;

[0012] The oil pump, the oil cooler, the stator mounting cavity, and the reducer mounting cavity are connected by the...

[0013] The oil passages are connected in sequence to form an electrically driven lubrication and cooling circuit; the oil cooler is connected to the water cooling chamber through the water passage.

[0014] In some embodiments, the motor is two axial flux motors arranged side by side along the axial direction, and both axial flux motors are electrically connected to the controller.

[0015] The reducer consists of two planetary gear sets, which are symmetrically distributed on the outside of the two axial flux motors.

[0016] In some embodiments, the planetary gear shaft of the planetary gear set is provided with a communicating oil guide cavity and an oil guide hole; the planetary gears of the planetary gear set are mounted on the planetary gear shaft via a second bearing, the second bearing being positioned corresponding to the oil guide hole;

[0017] The reducer is provided with an oil collection plate, which is connected to the planet carrier of the planetary gear set; the oil collection plate is provided with the same number of oil outlets as the planetary gear shafts, and the oil outlets extend into the corresponding oil guide chambers to connect the oil guide chambers and the oil collection chambers of the oil collection plate.

[0018] The oil passage includes a first oil passage and a second oil passage. The oil pump is connected to the oil storage chamber through the first oil passage, and the oil collection chamber is connected to the second oil passage.

[0019] In some embodiments, the side plate of the oil collecting tray away from the oil outlet is provided with a plurality of clearance areas, and the side plate of the oil collecting tray on the side where the oil outlet is located is provided with a plurality of mounting holes, each clearance area corresponding to each mounting hole, and the oil collecting tray is mounted on the planetary carrier by screws.

[0020] In some embodiments, a first bearing is provided between the planetary gearbox and the reduction gearbox; the oil passage further includes a third oil passage, a fourth oil passage, a fifth oil passage, and a sixth oil passage, the third oil passage being connected to the mounting space of the first bearing; the oil cooler is connected to the oil pump through the fourth oil passage; the stator housing is provided with an oil inlet and an oil outlet communicating with the stator mounting cavity, the oil cooler is connected to the oil inlet through the fifth oil passage, and the oil outlet is connected to both the second and third oil passages through the sixth oil passage.

[0021] In some embodiments, the housing assembly includes a motor housing, a gearbox, and a controller housing. The gearbox includes a connected reducer housing and an end cover. The gearbox is connected to an end opening of the motor housing and is located close to the rotor assembly. An oil seal is provided between the gearbox and the turntable of the rotor assembly.

[0022] The first oil passage and the third oil passage are both located inside the end cover, the second oil passage is located inside the reducer housing, and the fourth, fifth and sixth oil passages are all located inside the motor housing; the water passage is located inside the motor housing.

[0023] In some embodiments, the oil storage chamber is located at the bottom of the gearbox, and the gearbox wall is provided with an oil filter and a magnet, both of which are located in the first oil passage; the first oil passage has two openings communicating with the outside, and each of the two openings is provided with a plug, with the oil filter and the magnet respectively close to the two openings.

[0024] In some embodiments, the stator core includes a plurality of soft magnetic blocks arranged in a circumferential array, and the stator winding includes a plurality of coil windings spaced apart and evenly distributed along the circumferential direction, with each of the coil windings wound on the plurality of soft magnetic blocks in a one-to-one correspondence.

[0025] The stator housing is provided with a blocking member, which is located between the coil winding and the stator housing, so that the blocking member, the coil winding and the stator housing surround and form a cooling oil channel.

[0026] In some embodiments, the stator housing is annular; the coil windings are spaced apart from both the outer and inner ring portions of the stator housing; the circumferential spacing between adjacent coil windings is communicated through the spacing between the coil windings and the inner ring portion; and a blocking element is located in the spacing between the coil windings and the outer ring portion.

[0027] In some embodiments, a plurality of support blocks are provided on the inner ring of the stator housing. The shape of the end face of the support block matches the end shape of the coil winding. The support block abuts against the corresponding end of the coil winding to radially limit the coil winding.

[0028] In some embodiments, the number of support blocks is less than the number of coil windings, such that the circumferential spacing between adjacent coil windings is connected through the area between the coil windings and the inner ring where no support blocks are provided.

[0029] In some embodiments, the stator housing is provided with a sealing insert, which covers the three-phase copper busbar and is embedded in the copper busbar outlet.

[0030] In some embodiments, the stator housing includes two housing components that together form a stator mounting cavity; the two housing components are sealed by a first sealing element.

[0031] In some embodiments, the electrically driven lubrication and cooling system further includes:

[0032] A resolver, mounted on the motor;

[0033] A first oil temperature detection element is disposed on the oil pump or the housing assembly and is used to detect the oil temperature in the oil storage chamber;

[0034] The second oil temperature detection element is located at the oil outlet of the stator assembly and is used to detect the outlet oil temperature of the stator assembly; wherein the resolver, the first oil temperature detection element and the second oil temperature detection element are all electrically connected to the controller.

[0035] In a second aspect of this application, a vehicle is provided, including the aforementioned electric drive lubrication and cooling system.

[0036] An electric drive lubrication and cooling system according to one or more embodiments of this application includes a housing assembly, a controller, a motor, a reducer, an oil pump, and an oil cooler. The housing assembly has a motor mounting cavity, a controller mounting cavity, a water-cooling cavity, and a communicating reducer mounting cavity and an oil reservoir. The housing assembly's walls have several oil channels and several water channels. The controller is located in the controller mounting cavity and exchanges heat with the water-cooling cavity. The motor is located in the motor mounting cavity, and the motor's stator assembly includes a stator housing. The stator windings and stator core of the stator assembly are both located in the stator mounting cavity of the stator housing. The reducer is located in the reducer mounting cavity and is drively connected to the motor's rotor assembly. The oil pump and oil cooler are respectively installed at different positions on the housing assembly. The oil pump, oil cooler, stator mounting cavity, and reducer mounting cavity are sequentially connected through oil channels to form an electric drive lubrication and cooling circuit; the oil cooler is connected to the water-cooling cavity through water channels.

[0037] As can be seen from the above technical solution, the electric drive lubrication and cooling system provided in this application connects the stator mounting cavity and the reducer mounting cavity sequentially through oil passages. The oil used for cooling and lubricating the reducer in the reducer mounting cavity is pumped into the stator mounting cavity. The stator windings and stator core of the stator assembly are both located in the stator mounting cavity of the stator housing, and the stator core and stator windings are immersed in the circulating oil for heat dissipation. Because the stator core and stator windings are directly connected to the circulating oil...

[0038] The circulating oil contact results in high heat dissipation efficiency. When 10L / min of cooling oil is circulated inside the stator housing, the average temperature inside the stator can be maintained at around 85℃, and the maximum temperature is less than 150℃.

[0039] In addition, the lubricating oil and the coolant for cooling the controller both flow through the housing wall of the housing assembly. The entire electric drive lubrication and cooling system does not require additional oil and water pipes, making the electric drive lubrication and cooling system more compact. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 shows a schematic diagram of the structure of an electrically driven lubrication and cooling system in one or more embodiments of this application;

[0042] Figure 2 shows a full cross-sectional view of the electric drive lubrication and cooling system of Figure 1;

[0043] Figure 3 shows a schematic diagram of the assembly structure of the planetary gearbox and the gearbox in the electric drive lubrication and cooling system of Figure 1;

[0044] Figure 4 shows a schematic diagram of the oil collection tray in the electric drive lubrication and cooling system of Figure 1.

[0045] Figure 5 shows a schematic diagram of the oil collection tray in the electric drive lubrication and cooling system of Figure 1.

[0046] Figure 6 shows a full cross-sectional view of the oil collection tray in the electric drive lubrication and cooling system of Figure 1;

[0047] Figure 7 shows a full cross-sectional view of the oil collection tray in the electric drive lubrication and cooling system of Figure 1.

[0048] Figure 8 shows a schematic diagram of the oil circuit of the electric drive lubrication and cooling system in Figure 1.

[0049] Figure 9 shows a schematic diagram of the oil circuit of the electric drive lubrication and cooling system in Figure 1.

[0050] Figure 10 shows a schematic diagram of the oil circuit of the electric drive lubrication and cooling system in Figure 1.

[0051] Figure 11 shows a schematic diagram of the oil circuit of the electric drive lubrication and cooling system in Figure 1.

[0052] Figure 12 shows a schematic diagram of the oil circuit of the electric drive lubrication and cooling system in Figure 1.

[0053] Figure 13 shows a structural block diagram of the cooling and lubrication circuit of the electric drive lubrication and cooling system in Figure 1;

[0054] Figure 14 shows a schematic diagram of the stator assembly of the electric drive lubrication and cooling system in Figure 1. To facilitate the display of the internal structure of the stator bushing, the first rotor bearing and the second rotor bearing are hidden.

[0055] Figure 15 shows an exploded view of the stator assembly of Figure 14;

[0056] Figure 16 shows a full sectional view of the stator assembly of Figure 14;

[0057] Figure 17 shows a schematic diagram of the housing components of the stator assembly in Figure 14;

[0058] Figure 18 shows a schematic diagram of the assembly structure of the stator winding and stator core of the stator assembly in Figure 14.

[0059] Figure 19 shows a schematic diagram of the flow path of the cooling oil in the stator assembly of Figure 14;

[0060] Figure 20 shows a schematic diagram of the cooling oil passages of the stator assembly in Figure 19;

[0061] Figure 21 shows a schematic diagram of the connection structure of the winding coil, connecting wire and blocking element in the stator winding of Figure 14;

[0062] Figure 22 shows a schematic diagram of the sealing insert of the stator assembly in Figure 14;

[0063] Figure 23 shows a schematic diagram of the stator bushing of the stator assembly in Figure 14.

[0064] Explanation of reference numerals in the attached drawings: 1000 - Electric drive lubrication and cooling system; 100 - Axial flux motor; 200 - Housing assembly; 201 - Water channel; 210 - Motor housing; 210a - Motor mounting cavity; 211 - Mounting plate; 212 - Fourth oil channel; 213 - Fifth oil channel; 214 - Sixth oil channel; 220 - Gearbox; 220a - Gearbox mounting cavity; 221 - Gearbox housing; 2211 - Second oil channel; 222 - End cover; 2221 - First oil channel; 2222 - Third oil channel; 2223 - Opening; 2224 - Plug; 2225 - Oil filter; 2226 - Magnet; 230 - Controller housing; 230a - Controller mounting cavity; 230b - Water cooling cavity; 231 - Main body; 232 - Cover plate; 300-Controller; 400-Reducer; 410-Planetary Gear; 411-Sun Gear; 4111-Input Shaft; 4112-Support Stop; 412-Planet Carrier; 4121-Output Shaft; 4122-Flanged Edge; 413-Planetary Gear; 414-Planetary Gear Shaft; 414a-Oil Guide Chamber; 414b-Oil Guide Hole; 415-Ring Gear; 420-First Bearing; 430-Second Bearing; 440-Third Bearing; 450-Oil Collection Plate; 450a-Oil Collection Chamber; 451-Oil Outlet; 452-Oil Baffle Plate; 453-Clearing Area; 454-Mounting Hole; 500-Oil Pump; 600-Oil Cooler; 700-Resolver; 801-First Oil Seal; 802-Second Oil Seal; 110-Stator assembly; 111-Stator housing; 111a-Stator mounting cavity; 111b-Oil inlet; 111c-Oil outlet; 111d-Copper busbar outlet; 111e-Cooling oil passage; 111f-Annular hole; 111g-First sealing groove; 111h-Clamping groove; 111i-Core fixing groove; 1111-Housing component; 1112-Support block; 1113-Inner ring; 1114-Outer ring; 112-Stator winding; 1121-Coil winding; 1122-Connecting wire; 11221-Main body section; 11222-Joint section; 1123-Blocking component; 1124-Three-phase copper busbar; 113-Stator core; 1131-Soft magnetic block; 114-Stator bushing; 1141-Stop step; 1142 - Shaft hole; 1143 - Ring plate; 1144 - Bushing bolt; 116 - Sealing insert; 1161 - Insert body; 1162 - Sealing sleeve; 117 - First seal; 118 - Second seal; 119 - Pressure plate; 120a - First rotor assembly; 120b - Second rotor assembly; 121 - Rotor shaft; 1211 - First shaft section; 122a - First turntable; 122b - Second turntable; 1221 - Internal spline; 123 - Rotor magnet; 124 - Rotor core.

[0065] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0066] To enable those skilled in the art to more clearly understand this application, the technical solutions in 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.

[0067] Furthermore, reference numerals and / or reference letters may be repeated in different examples in this application. Such repetition is for simplification and clarity purposes and does not in itself indicate a relationship between the various embodiments and / or settings discussed. In addition, this application provides examples of various specific processes and materials; however, those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0068] The specific technical solutions of this application will be described in detail below with reference to the accompanying drawings, which are not necessarily drawn to scale. Similar or identical reference numerals may be used to designate the same or similar parts in different drawings. The use of similar or identical reference numerals in different drawings does not mean that all drawings including similar or identical reference numerals constitute a single or the same embodiment. The accompanying drawings illustrate the various embodiments discussed in this application in a generalized manner, by way of example and not limitation.

[0069] Please refer to Figures 1 and 2. A first aspect embodiment of this application provides an electrically driven lubrication and cooling system 1000, including a housing assembly 200, a controller 300, and at least one motor. The controller 300 is electrically connected to the motor, providing three-phase current to the motor's stator assembly and communicating data with the vehicle controller 300 to control the motor's operation and provide feedback on the motor's operating parameters.

[0070] The controller 300 is connected to the housing assembly 200. The controller 300 can be a separate component connected to the housing assembly 200. The controller 300 can also be installed inside the housing assembly 200. The motor is installed in the housing assembly 200, which serves as the motor housing.

[0071] To meet the cooling requirements of the stator assembly 110 in the motor, in some embodiments, the electric drive lubrication and cooling system 1000 further includes an oil pump 500 and an oil cooler 600. The oil pump 500 and oil cooler 600 are respectively installed at different positions on the housing assembly 200, and are connected to the stator housing 111. The oil pump pumps oil into the oil cooler 600, which cools the oil. The oil cooler 600 can cool the oil using either air cooling or water cooling; this application is not limited to either method. The oil inlet of the oil cooler 600 is connected to the oil pump 500, and the oil outlet of the oil cooler 600 is connected to the oil inlet 111b of the stator assembly 110.

[0072] In some embodiments, the electrically driven lubrication and cooling system 1000 further includes a reducer 400, which is connected to the motor drive and is used to reduce the power output by the motor before outputting it externally. The reducer 400 can be a separate reducer 400 connected to the housing assembly 200. The reducer 400 can also be installed inside the housing assembly 200.

[0073] The reducer 400 can be a planetary gear set 410, a gear reduction mechanism, etc., and this application does not impose any restrictions.

[0074] The motor can be a radial motor or an axial flux motor; this application is not limited to either. In some embodiments, the motor is an axial flux motor. The electrically driven lubrication and cooling system 1000 can be a single-motor system or a dual-motor system. Referring to Figure 2, in some embodiments, the electrically driven lubrication and cooling system 1000 adopts a dual-motor system, and both motors are axial flux motors 100. The two axial flux motors 100 are arranged side by side along the axial direction. The electrically driven lubrication and cooling system 1000 then includes two reducers 400, which are respectively connected to the two axial flux motors 100 for transmission, used to reduce the power output from the two axial flux motors 100 before outputting it outwards.

[0075] Please refer to Figures 1 and 2, which show a schematic diagram and a full sectional view of the electrically driven lubrication and cooling system 1000 in some embodiments. The electrically driven lubrication and cooling system 1000 is equipped with two axial flux motors 100 and two single planetary gear reducers. The housing assembly 200 has a controller mounting cavity 230a, a motor mounting cavity 210a, and a reducer mounting cavity 220a. The controller 300 is located in the controller mounting cavity 230a. The two axial flux motors 100 are arranged side by side along the axial direction of the axial flux motors 100 in the motor mounting cavity 210a. The two planetary gears 410 are located in the reducer mounting cavity 220a and are symmetrically distributed on the outside of the two axial flux motors 100, so that the electrically driven lubrication and cooling system 1000 has a generally symmetrical structure. The two planetary gears 410 are respectively connected to the rotor assemblies of the two axial flux motors 100 for transmission, and are used to output the power output by the two axial flux motors 100 after reduction and torque amplification.

[0076] In some embodiments, the housing assembly 200 includes a motor housing 210, a controller housing 2, and two gearboxes 220. The two gearboxes 2 are respectively connected to the openings at both ends of the motor housing 210 and are close to the rotor assembly. The gearboxes 2 and the motor housing 210 together form a motor mounting cavity 210a, the inner cavity of the controller housing 2 forms a controller mounting cavity 230a, and the inner cavity of the gearboxes 2 forms a reducer mounting cavity 220a. Along the axial direction of the axial flux motor 100, the motor housing 210 and the two gearboxes 2 share the same wall, which can significantly reduce the axial dimension of the electric drive lubrication and cooling system 1000.

[0077] The gearbox 2 has an internal oil reservoir (not shown in the figure), which is connected to the gearbox mounting cavity 220a. Oil dripping from the various components installed in the gearbox mounting cavity 220a collects in the oil reservoir. The oil reservoir can be formed in the bottom part of the gearbox mounting cavity 220a, or it can be an oil pan additionally installed at the bottom of the gearbox mounting cavity 220a. This application does not impose any restrictions.

[0078] In some embodiments, the motor housing 210 and the main body 231 of the controller housing 2 are integrally formed, with one chamber of the motor housing 210 serving as the motor mounting cavity 210a and the other chamber serving as the controller mounting cavity 230a. The cover plate 232 of the controller housing 2 is connected to the motor housing 210 to seal the controller mounting cavity 230a. This integration of the motor housing 210 and the controller housing 2 can significantly reduce the size of the electric drive lubrication and cooling system 1000 in the direction perpendicular to the axial direction.

[0079] To further reduce the axial dimension of the electric drive lubrication and cooling system 1000 and improve its power density, please refer to Figure 2. In some embodiments, the rotor shaft 121 of the axial flux motor 100 is provided with a spline groove 1214, and the sun gear 411 of the planetary gear set 410 is provided with an input shaft 4111, which is keyed to the spline groove 1214. The torque output by the rotor shaft 121 is transmitted to the planetary gear set 410 through the sun gear 411. In some embodiments, the first shaft section 1211 of the rotor shaft 121 is hollow, and its inner wall is provided with a spline groove 1214.

[0080] Since the splined engagement between the input shaft 4111 and the rotor shaft 121 is not visible, they can only be blind-assembled. To avoid interference during assembly, please refer to Figure 2. In some embodiments, a shoulder is provided on the inner wall of the rotor shaft 121, and a support stop 4112 is provided on the input shaft 4111. When the input shaft 4111 moves axially until the support stop 4112 abuts against the shoulder and is axially limited, the spline groove 1214 of the rotor shaft 121 stably meshes with the external spline of the input shaft 4111, and the end of the input shaft 4111 will not interfere with the cavity wall of the rotor shaft 121. In addition, the sliding engagement between the support stop 4112 and the inner wall of the rotor shaft 121 also serves to guide and ensure the coaxiality of the sun gear 411 and the rotor shaft 121.

[0081] Taking an electric drive lubrication and cooling system 1000 equipped with two axial flux motors 100 with an overall outer diameter of 310mm as an example, the outer envelope dimensions of the electric drive lubrication and cooling system 1000 are 380*420*290mm, of which the axial dimension is 420mm and the height is 290mm. The smaller axial dimension allows the electric drive lubrication and cooling system 1000 to be directly mounted between the two wheels along the Y direction (vehicle width direction), and the torque output from the two planetary gear sets 410 drives the two wheels respectively.

[0082] In the planetary gear set 410, the sun gear 411 and the input shaft 4111 can be an integral structure, or they can be connected by a key, bolt, or other means. This application does not impose any limitations on this. In some embodiments, the input shaft 4111 and the sun gear 411 are integrally formed to create a gear shaft. The gear shaft is hollow, which reduces its weight. The hollow shaft also allows lubricating oil to enter, thereby lubricating the meshing point between the spline groove 1214 of the rotor shaft 121 and the external spline of the input shaft 4111, as well as the mating point between the support stop 4112 of the input shaft 4111 and the inner wall of the rotor shaft 121.

[0083] To prevent oil leakage, several oil seals are provided at the connection between the planetary gear set 410 and the gearbox 2. Referring to Figures 2 and 3, in some embodiments, the sun gear 411 of the planetary gear set 410 has an input shaft 4111, and the planet carrier 412 of the planetary gear set 410 has an output shaft 4121. A first bearing 420 is provided between the output shaft 4121 and the gearbox 2. That is, the planetary gear set 410 adopts a structure where the sun gear 411 is the input and the planet carrier 412 is the output. Correspondingly, a first oil seal 801 is provided between the input shaft 4111 and the gearbox 2. A second oil seal 802 is provided between the output shaft 4121 and the gearbox 2, and the second oil seal 802 is located outside the first bearing 4. To prevent lubricating oil from entering the motor mounting cavity 210a, a first oil seal 801 is provided between the gearbox 2 and the turntable of the adjacent rotor assembly.

[0084] In some embodiments, the gearbox 2 includes a gearbox housing 221 and an end cover 222 connected together, a first oil seal 801 is installed between the gearbox housing 221 and the input shaft 4111, and a second oil seal 802 is installed between the end cover 222 and the output shaft 4121.

[0085] Referring to Figure 2, in some embodiments, two axial flux motors 100 are arranged side-by-side along the axial direction with their second rotor assemblies 120b close to each other. The stators of the two resolvers 700 are respectively connected to the motor housing 210, and the rotors of the two resolvers 700 are respectively connected to the two second turntables 122b. Specifically, a mounting plate 211 may be provided inside the motor housing 210, and the stators of the two resolvers 700 are symmetrically mounted on both sides of the mounting plate 211 by bolts. Each of the second turntables 122b of the two axial flux motors 100 is provided with a second mounting part 1223, and the rotor of the resolver 700 is fitted onto the second mounting part 1223 with an interference fit. Each of the first turntables 122a of the two axial flux motors 100 has a first mounting part 1222, which is an annular protrusion. The gearbox 2 is fitted onto the first mounting part 1222, and the first oil seal 801 is installed between the gearbox 2 and the first mounting part 1222. Referring to Figure 2, in some embodiments, the gearbox 2 includes a gearbox housing 221 and an end cover 222 connected together. The gearbox housing 221 is connected to the motor housing 210, and an oil seal is installed between the gearbox housing 221 and the first mounting portion 1222. The planetary carrier 412 of the planetary gear set 410 is provided with an output shaft 4121, and a first bearing 420 is provided between the output shaft 4121 and the end cover 222. To prevent lubricating oil leakage, a second oil seal 802 is provided between the output shaft 4121 and the end cover 222.

[0086] In related technologies, the gearbox portion of a distributed dual-motor electric drive lubrication and cooling system often employs a passive gear-driven oil churning lubrication and cooling method, resulting in significant oil churning losses and low efficiency. However, compared to parallel shaft gear reduction mechanisms, the planetary gear set 410 has a more compact structure, and the gear ring 415 is less prone to oil churning. Therefore, the oil churning lubrication method cannot adequately meet the lubrication requirements of the planetary gear set 410. To address this, the electric drive lubrication and cooling system 1000 provided in this application utilizes an oil collection tray 450 for active oil spray lubrication of the planetary gear set 410.

[0087] Referring to Figures 2 and 3, in some embodiments, the planetary carrier 412 is provided with an oil collection tray 450. The oil collection tray 450 is annular and is fitted onto the end of the planetary carrier 412 away from the output shaft 4121, rotating together with the planetary carrier 412. The oil collection tray 450 has the same number of oil outlets 451 as the planetary gear shafts 414 of the planetary gear set 410, allowing lubricating oil to be input into the oil collection tray 450. The lubricating oil can flow out through each oil outlet 451, flowing to each planetary gear 413 and the corresponding bearing.

[0088] Please refer to Figures 4 and 5, which show schematic diagrams of the oil collection tray 450 in some embodiments. The oil collection tray 450 is provided with a plurality of oil baffles 452, the number of which is the same as the number of oil outlets 451, and the root of each oil baffle 452 is close to the corresponding oil outlet 451. By setting the oil baffles 452, the oil can be collected at the root of the oil baffles 452 in the rotating oil collection tray 450, so that the oil can enter the oil outlet 451.

[0089] Referring to Figure 6, in some embodiments, the oil baffle 452 is radially inclined relative to the oil collection plate 450. Along the rotation direction of the oil collection plate 450, the root of the oil baffle 452 is located in front of the corresponding oil outlet 451, and the free end of the oil baffle 452 is located behind the corresponding oil outlet 451. When the oil collection plate 450 rotates in the direction indicated by the arrow in Figure 6, the oil will rotate relative to the oil collection plate 450 due to inertia. This can be understood as the oil collection plate 450 and the oil rotating in the same direction as the arrow in Figure 6, with the oil collection plate 450 rotating faster than the oil. Therefore, the oil will gradually converge at the root of the oil baffle 452 and flow along the oil baffle 452 towards its free end, eventually entering the oil outlet 451.

[0090] Please refer to Figure 7. In some embodiments, the oil collection tray 450 is mounted on the planetary carrier 412 by screws. To facilitate the installation of screws, the side plate of the oil collection tray 450 away from the oil outlet 451 is provided with several clearance areas 453. The side plate of the oil collection tray 450 on the side where the oil outlet 451 is located is provided with several mounting holes 454. Each clearance area 453 corresponds to each mounting hole 454. During installation, a sleeve can be set in the clearance area 453, and the screw can be installed through the internal space of the sleeve to prevent the screw from accidentally falling into the oil collection chamber 450a.

[0091] Lubricating oil can be fed into the oil collection tray 450 through an externally installed oil pipe, or it can be transported through oil channels opened in the wall of the housing assembly 200. Furthermore, the cooling oil of the stator assembly 110 of the axial flux motor 100 can be mixed with the lubricating oil of the planetary gear set 410. That is, the oil first enters the stator assembly 110 to cool it, and then is transported to the oil collection tray 450 through the oil channels 220c opened in the wall of the housing assembly 200. After lubricating the planetary gear set 410, the oil finally falls into the reducer mounting cavity 220a. The oil pump 500 is connected to the reducer mounting cavity 220a and pumps the oil falling into the reducer mounting cavity 220a to the stator assembly 110.

[0092] The planetary gear shaft 414 of the planetary gear set 410 is provided with a communicating oil guide cavity 414a and an oil guide hole 414b; the planetary gear 413 of the planetary gear set 410 is mounted on the planetary gear shaft 414 via a second bearing 4, the second bearing 4 corresponding to the position of the oil guide hole 414b. The oil collection plate 450 is connected to the planet carrier 412 of the planetary gear set 410; the oil collection plate 450 is provided with the same number of oil outlets 451 as the planetary gear shaft 414, the oil outlets 451 extending into the corresponding oil guide cavity 414a to connect the oil guide cavity 414a and the oil collection cavity 450a of the oil collection plate 450.

[0093] Please refer to Figures 8 to 12. The oil passages in the housing assembly 200 include a first oil passage 2221 and a second oil passage 2211. The oil pump 500 is connected to the oil storage chamber through the first oil passage 2221, and the oil collection chamber 450a of the oil collecting pan 450 is connected to the second oil passage 2211. Also referring to Figures 8 to 12, the oil passages in the housing assembly 200 include a third oil passage 2222, a fourth oil passage 212, a fifth oil passage 213, and a sixth oil passage 214. The third oil passage 2222 is connected to the mounting space of the first bearing 4. The oil cooler 600 is connected to the oil pump 500 through the fourth oil passage 212. The oil cooler 600 is connected to the oil inlet 111b of the stator housing 111 through the fifth oil passage 213, and the oil outlet 111c of the stator housing 111 is connected to both the second oil passage 2211 and the third oil passage 2222 through the sixth oil passage 214.

[0094] In some embodiments, the housing assembly 200 includes a motor housing 210, a gearbox 2, and a controller housing 230. The gearbox 2 includes a gearbox housing 221 and an end cover 222 connected together. The gearbox 2 is connected to the end opening of the motor housing 210 and is close to the first rotor assembly 120a. The first oil passage 2221 and the third oil passage 2222 are both located inside the end cover 222, the second oil passage 2211 is located inside the gearbox housing 221, the fourth oil passage 212 and the sixth oil passage 214 are both located in the motor housing 210 and the gearbox housing 221, and the fifth oil passage 213 is located inside the motor housing 210. Please refer to Figure 8. The oil reservoir is located at the bottom of the gearbox 2. An oil filter 22 and a magnet 2226 are installed in the gearbox wall of the gearbox 2. Both the oil filter 22 and the magnet 2226 are located in the first oil passage 2221. The first oil passage 2221 has two openings 2223 communicating with the outside. Each opening 2223 has a plug 2224. The oil filter 22 and the magnet 2226 are located near the two openings 2223. After the electric drive lubrication and cooling system 1000 has been running for a period of time, the oil filter 2225 and the magnet 2226 need to be cleaned or replaced. The corresponding opening 2223 can be opened by using the plug 2224, allowing the oil filter 22 or the magnet 2226 to be removed for cleaning or replacement.

[0095] Referring to Figure 1, in some embodiments, the housing assembly 200 further includes a water-cooled cavity 230b. The housing assembly 200 has several water channels 201 in its wall, and the oil cooler 600 communicates with the water-cooled cavity 230b through the water channels 201. The controller 300 is located in the controller mounting cavity 230a and exchanges heat with the water-cooled cavity 230b. Specifically, the water-cooled cavity 230b is located on the controller housing 2 and can be a chamber inside the controller housing 2, or it can be a groove inside the controller housing 2 sealed by a cover plate to form the water-cooled cavity 230b. The inlet and outlet of the water channels 201 are located on the motor housing 210, and the water channels 201 are mainly located in the wall of the motor housing 210.

[0096] Referring to Figures 13, 14, 15, and 16, in some embodiments, the stator assembly 110 of the axial flux motor 100 includes a stator housing 111 having a stator mounting cavity 111a, and a stator winding 112 and a stator core 113 located in the stator mounting cavity 111a, with the stator winding 112 wound on the stator core 113. The stator housing 111 is provided with an oil inlet 111b, an oil outlet 111c, and a copper busbar outlet 111d communicating with the stator mounting cavity 111a. The three-phase copper busbars 1124 of the stator winding 112 extend outward through the copper busbar outlet 111d. Cooling oil is circulated into the stator mounting cavity 111a through the oil inlet 111b and the oil outlet 111c, and the stator winding 112 and the stator core 113 are immersed in the circulating oil for heat dissipation.

[0097] Both the stator winding 112 and the stator core 113 can be integral structures. For example, the stator core 113 may be ring-shaped, and the stator winding 112 may be wound on the ring-shaped stator core 113. In some embodiments, the stator winding 112 and the stator core 113 may be separate structures. Referring to Figure 18, the stator core 113 includes a plurality of soft magnetic blocks 1131 arranged in a circumferential array, which are evenly and spaced apart along the circumferential direction. It is understood that the material of the stator core 113 is not limited to soft magnetic materials. Referring to Figures 18 and 19, the stator winding 112 includes a plurality of coil windings 1121 spaced apart and evenly distributed along the circumferential direction, and connecting wires 1122 for connecting the coil windings. The plurality of coil windings 1121 are wound one-to-one on the plurality of soft magnetic blocks 1131.

[0098] Please refer to Figures 18, 19, and 20. The stator housing 111 is provided with several blocking elements 1123. These blocking elements 1123 are located between the coil winding 1121 and the stator housing 111, and are circumferentially spaced apart. This arrangement, along with the coil winding 1121 and the stator housing 111, forms a cooling oil channel 111e. Oil flows into the cooling oil channel 111e from the oil inlet hole 111b, immersing the stator core 113 and stator winding 112 in the stator mounting cavity 111a. After heat exchange with the stator core 113 and stator winding 112, the oil flows out from the oil outlet hole 111c. To avoid interference with the magnetic field, the blocking elements 1123 are made of non-magnetic materials, such as plastics, carbon fibers, rubber, ceramics, or non-magnetic metals.

[0099] The stator housing 111 is annular, with an annular hole 111f for the rotor shaft 121 to pass through and for mounting the rotor bearing. The two housing components 1111 are connected and fixed by bolts on the outer ring portion 1114 of the stator housing 111. To ensure the structural strength of the outer ring portion 1114, the wall thickness of the outer ring portion 1114 is 15mm to 25mm. The coil winding 1121 is spaced from both the outer ring portion 1114 and the inner ring portion 1113 of the stator housing 111. The circumferential spacing between adjacent coil windings 1121 is communicated by the spacing between the coil winding 1121 and the inner ring portion 1113. Referring to Figure 4, in some embodiments, the inner ring portion 1113 of the stator housing 111 is provided with several support blocks 1112. The shape of the end face of the support block 1112 matches the end shape of the coil winding 1121. The support block 1112 abuts against the corresponding end of the coil winding 1121, radially limiting the coil winding 1121.

[0100] In some embodiments, the number of support blocks 1112 is less than the number of coil windings 1121, such that the circumferential gap between adjacent coil windings 1121 is connected through the area between the coil winding 1121 and the inner ring portion 1113 where no support block 1112 is provided. As one implementation, a support block 1112 can be provided every other coil winding 1121. By providing support blocks 1112, the coil windings 1121 can be supported radially, and the oil flow along the gap between the coil windings 1121 and the inner ring portion 1113 can be prevented from forming a circulation, forcing the oil into the circumferential gap between adjacent coil windings 1121.

[0101] In some embodiments, the gap between the outer ring portion 1114 of the coil winding 1121 and the stator housing 111 is greater than the gap between the inner ring portion 1113 of the coil winding 1121 and the stator housing 111. In this case, the oil will mainly flow within the gap between the coil winding 1121 and the outer ring portion 1114, making it difficult for it to actively enter the circumferential gap between adjacent coil windings 1121 and the gap between the coil winding 1121 and the inner ring portion 1113. By providing a blocking member 1123 between the coil winding 1121 and the outer ring portion 1114... In the interval of part 1114, the circumferential interval between the blocking member 1123 and the adjacent coil winding 1121 is staggered, which forces the oil to flow to the circumferential interval between the adjacent coil windings 1121 and the interval between the coil winding 1121 and the inner ring part 1113, thereby forming the S-shaped circulating cooling circuit shown in the figure. The heat dissipation area is larger and the cooling effect is better. When 10L / min of cooling oil is circulated inside the stator housing, the average temperature inside the stator can be maintained at about 85°C and the maximum temperature is less than 150°C.

[0102] In addition to preventing oil from flowing along the annular gap between the coil winding 1121 and the stator housing 111, the blocking member 1123 can also assist in fixing the connecting wire 1122. Referring to Figure 21, in some embodiments, the connecting wire 1122 passes through the blocking member 1123, and the blocking member 1123 fixes the connecting wire 1122. Referring to Figure 21, in some embodiments, both the coil winding 1121 and the connecting wire 1122 are flat wires. To facilitate the connection of the connecting wire 1122 to the blocking member 1123 and the coil winding 1121, in some embodiments, the connecting wire 1122 includes a main body section 11221 and a connector section 11222. The main body section 11221 is straight or curved and passes through the blocking member 1123. The connector section 11222 is welded to the coil winding 1121, and the connector section 11222 is typically a bent structure.

[0103] To facilitate the installation of the three-phase copper busbar 1124 and accommodate its thermal expansion and contraction, the size of the busbar outlet 111d must be larger than that of the three-phase copper busbar 1124. This results in a tiny gap between the outlet 111d and the busbar, creating a leakage point. Because this gap is too small to be sealed with conventional sealants, only adhesive can be used. However, the oil has a certain pressure and a high temperature, making it difficult for the sealant to maintain the appropriate durability for the environment at the installation site of the three-phase copper busbar 1124.

[0104] To address the aforementioned issues, please refer to Figures 15 and 19. In some embodiments, a sealing insert 116 is provided in the stator housing 111. The sealing insert 116 covers the three-phase copper busbar 1124 and is embedded in the copper busbar outlet 111d. The sealing insert 116 is made of an elastic material (e.g., rubber, silicone, etc.) and can deform elastically under pressure. Therefore, it can seal the minute gaps between the stator housing 111 and the three-phase copper busbar 1124, resulting in higher sealing reliability of the stator assembly 110.

[0105] To facilitate the installation of the stator core 113 and the stator winding 112, the stator housing 111 adopts a split structure. Please refer to Figures 15 and 16. In some embodiments, the stator housing 111 includes two housing components 1111, which together form a stator mounting cavity 111a. The oil inlet 111b, oil outlet 111c, and copper busbar outlet 111d can be respectively located on different housing components 1111, or they can be formed by the two housing components 1111 together. The two housing components 1111 can have the same structure, equivalent to dividing the housing component 1111 in half; the two housing components 1111 can also have different structures, for example, one is an annular groove and the other is an annular cover plate. More structural forms of the housing components 1111 are not exhaustively listed here.

[0106] Referring to Figure 16, the two housing components 1111 are sealed by a first seal 117, which provides an outer ring seal for the stator housing 111. A sealing insert 116 is located outside the first seal 117. The first seal 117 forms the first seal at the copper busbar outlet 111d, and the sealing insert 116 forms the second seal at the same outlet. This unique sealing design ensures that even with a high internal pressure of 2.5 bar, the leakage pressure drop of the stator cooling system remains less than the industry standard of 135 Pa / min, resulting in higher reliability.

[0107] The copper bus outlet 111d can be a single, integral opening, with the U, V, and W phase copper busbars 1124 all located within it; alternatively, the copper bus outlet 111d can have three openings, with the U, V, and W phase copper busbars 1124 each located in one of the three openings. Referring to Figure 17, the copper bus outlet 111d is located on one of the housing components 1111, and includes three openings. The other housing component 1111 has a first sealing groove 111g for assembling the first sealing element 117. The sealing insert 116 is clamped and fixed by the two housing components 1111. It is understood that the sealing insert 116 is made of an elastic material, such as rubber or silicone, and can be made of the same material as the first sealing element 117.

[0108] Please refer to Figure 22, which shows a schematic diagram of the sealing insert 116 in some embodiments. The sealing insert 116 includes a connected insert body 1161 and three sealing sleeves 1162. A three-phase copper busbar 1124 is interference-fitted with each of the three sealing sleeves 1162. The insert body 1161 is connected to two housing components 1111 respectively, which can be fixed by adhesive or bolt connection. Each housing component 1111 is provided with three clamping grooves 111h, and the three sealing sleeves 1162 are respectively located in the three clamping grooves 111h and clamped and fixed by the two housing components 1111.

[0109] Referring to Figure 15, considering that the sealing insert 116 is made of soft rubber, the connection is prone to cracking if directly connected to the bolt. Therefore, in some embodiments, a pressure plate 119 is provided on the outer side of the sealing insert 116. The pressure plate 119 is made of metal or a high-strength non-metallic plate, such as resin. The insert body 1161 is clamped between the pressure plate 119 and the stator housing 111. Bolts pass through the insert body 1161 and the pressure plate 119, and are screwed to the two housing components 1111 respectively, thereby clamping and fixing the insert body 1161.

[0110] In some embodiments, the stator housing 111 is made of a non-magnetic material, which does not obstruct the magnetic circuit. Specifically, the non-magnetic material can be a non-metallic material, such as carbon fiber, phenolic resin, or Teflon; or a non-magnetic metallic material, such as stainless steel, aluminum alloy, or titanium alloy. The stator housing 111 primarily protects the internal stator core 113 and stator windings 112, requiring a tensile strength of at least 1500 MPa and a stiffness of at least 20000 N / mm. Furthermore, when this stator assembly 110 is used in an axial flux motor, to minimize the air gap between the stator and rotor, the wall thickness at the thinnest point of the stator housing 111 should not exceed 1 mm. In some embodiments, the stator housing 111 is made of carbon fiber, and the wall thickness at the thinnest point (at the core fixing slot 111i) of the carbon fiber stator housing 111 is only 0.5 mm to 0.7 mm. The high-strength carbon fiber material gives the stator housing 111 extremely high rigidity and strength, enabling it to withstand torques of over 600 N·m and compressive forces of over 10,000 N without being damaged.

[0111] Referring to Figures 15 and 16, in some embodiments, since the stator housing 111 is made of a non-metallic material, to strengthen the structure of the stator housing 111, the stator assembly 110 further includes one or more stator bushings 114, all of which are metal bushings. The stator housing 111 is annular, and the stator bushings 114 are embedded in the annular holes 111f of the stator housing 111. The inner cavity of the stator bushings 114 forms the shaft hole 1142 of the stator assembly 110. The inner cavity wall of the stator bushings 114 is provided with a stop step 1141, and one end of the rotor bearing is axially limited by the stop step 1141 of the stator bushing 114, as shown in Figure 16.

[0112] In some embodiments, the two stator bushings 114 are respectively interference-fitted with the two housing components 1111, so that no leakage occurs between the stator bushings 114 and the corresponding housing components 1111. The two stator bushings 114 are sealed by a second seal 118. A sealing groove can be provided on either of the two stator bushings 114, or sealing grooves can be provided on the opposite end faces of the two stator bushings 114. The second seal 118 is embedded in the sealing groove and is clamped and deformed by the two stator bushings 114.

[0113] The clamping force between the two stator bushings 114 can be provided by the bolts connecting the two housing components 1111. Considering that the bolts connecting the two housing components 1111 are distributed on the outer periphery of the stator housing 111, and that both stator bushings 114 are located in the annular holes 111f of the stator housing 111, the constraint force received is limited. Therefore, referring to Figure 23, in some embodiments, the two stator bushings 114 are fixedly connected by bushing bolts 1144. Annular plates 1143 can be provided in both stator bushings 114 for connecting the bushing bolts 1144. After the two stator bushings 114 are locked by the bushing bolts 1144, they jointly clamp the second sealing element 118, achieving an inner ring seal of the stator housing 111.

[0114] Understandably, in some embodiments, the stator housing 111 is made of a non-magnetic metallic material with a certain strength. The stator housing 111 is then generally annular, with its inner annular hole forming a shaft hole. A stop step is provided on the hole wall of the inner annular hole of the metallic stator housing 111 to axially limit the bearing. The inner annularities of the two housing components 1111 of the metallic stator housing 111 are sealed by a second sealing element 118, achieving an inner annular seal for the stator housing 111.

[0115] To limit the tangential movement of the stator core 113, referring to Figure 17, in some embodiments, the stator housing 111 is provided with a plurality of core fixing slots 111i communicating with the stator mounting cavity 111a. The end of the stator core 113 is embedded in the core fixing slot 111i and abuts against the stator housing 111, thereby limiting the axial, tangential, and radial movement of the stator core 113. It is understood that the axial dimension of the stator core 113 is larger than that of the stator winding 112, such that at least one end of the stator core 113 is exposed relative to the stator winding 112, and the exposed portion of the stator core 113 extends into the core fixing slot 111i. The area between the iron core fixing slots 111i abuts against the stator winding 112, that is, the slot wall of the iron core fixing slot 111i abuts against the coil winding 1121. The stator housing 111 and the stator iron core 113 together limit the stator winding 112 in the axial, tangential and radial directions.

[0116] In some embodiments, the core fixing groove 111i is formed in a recessed area in the stator housing 111. The core fixing groove 111i is located at least on the axial inner wall of the stator housing 111 on the side near the rotor of the axial flux motor. It can not only limit the stator core 113, but also reduce the thickness of the barrier between the rotor magnet and the stator core 113 in the axial flux motor, thereby reducing the influence of the stator housing 111 on the magnetic circuit.

[0117] The number, shape, and distribution of the core fixing slots 111i are the same as those of the soft magnetic blocks 1131. The core fixing slots 111i and the soft magnetic blocks 1131 can be fitted with either an interference fit or a clearance fit. To further fix the soft magnetic blocks 1131, adhesive can be applied to the core fixing slots 111i, and the adhesive can be used to glue and fix each soft magnetic block 1131 to the stator housing 111.

[0118] In some embodiments, the electrically driven lubrication and cooling system 1000 further includes two oil temperature detection elements: a first oil temperature detection element, mounted on the oil pump 500 or housing assembly 200, for detecting the oil temperature in the oil reservoir; and a second oil temperature detection element, located at the oil outlet 111c of the stator assembly 110, for detecting the outlet oil temperature of the stator assembly 110. The resolver 700, the first oil temperature detection element, and the second oil temperature detection element are all electrically connected to the controller. As one implementation, the first oil temperature detection element is integrated into the PCB circuit board of the electronic oil pump for monitoring the oil temperature T0 in the oil reservoir, and the second oil temperature detection element is located at the oil outlet 111c of the stator assembly 110 for monitoring the oil temperature T1 after stator cooling.

[0119] According to the different operating conditions of the electric drive lubrication and cooling system 1000, the controller 300 estimates the motor power based on the thermal model, estimates the heat generated by the stator assembly 110, and then, combined with the oil outlet temperature T0 of the oil pump 500, further estimates the stator outlet oil temperature T2. Based on the difference between the oil temperature T1 monitored by the sensor and the estimated oil temperature T2 after the stator is cooled, the closed-loop input is sent to the controller 300. According to the established electric drive thermal model, the speed of the oil pump 500 is changed in real time, and the flow rate of lubricating oil entering the stator assembly 110 and the inner cavity of the gearbox 2 is adjusted to realize the system cooling and lubrication function.

[0120] Furthermore, in some embodiments, an oil level of a certain height H can be set in the reducer mounting cavity 220a of the reduction gearbox 2, and the height of the oil pump 500's suction port can be set higher than the lowest point of the oil storage cavity of the reduction gearbox 2, that is, the height difference between the oil pump 500's suction port and the lowest point of the oil storage cavity of the reduction gearbox 2 is H. When the temperature of the stator assembly 110 is low and no lubricating oil is needed for cooling, in order to reduce the power loss of the oil pump 500, when the oil pump 500's suction port is lower than the lowest oil level in the inner cavity of the reduction gearbox 2 (at this time, the oil pump has poor oil suction or cannot suck up oil), the oil pump 500 is controlled to stop. At this time, several gears and bearings in the reduction gearbox 2 drive the lubricating oil in their inner cavities to perform splash lubrication through the planetary gear 413 and planet carrier 412 to ensure the normal operation of the planetary gear set 410. In a second aspect embodiment of this application, a vehicle is provided, which includes the electric drive lubrication and cooling system of any of the first aspects embodiments described above. The vehicle can be a pure electric vehicle or a hybrid vehicle, and this application is not limited thereto.

[0121] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0122] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0123] It should be noted that all directional indications in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0124] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0125] Furthermore, the use of terms such as "first" and "second" in this application is 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" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0126] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0127] 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.

[0128] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

[0129] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

Claims

1. An electrically driven lubrication and cooling system, characterized in that, include: The housing assembly (200) is provided with a motor mounting cavity (210a), a controller mounting cavity (230a), a water cooling cavity (230b), and a connected reducer mounting cavity (220a) and an oil reservoir. The housing assembly (200) has a plurality of oil passages and a plurality of water passages (201) in its box wall. The controller (300) is located in the controller mounting cavity (230a) and exchanges heat with the water-cooling cavity (230b); The motor is located in the motor mounting cavity (210a). The stator assembly (110) of the motor includes a stator housing (111). The stator winding (112) and stator core (113) of the stator assembly (110) are both located in the stator mounting cavity (111a) of the stator housing (111). A reducer (400) is located in the reducer mounting cavity (220a) and connected to the rotor assembly of the motor; an oil pump (500) and an oil cooler (600) are respectively installed at different positions on the housing assembly (200); wherein the oil pump (500), the oil cooler (600), the stator mounting cavity (111a) and the reducer mounting cavity (220a) are connected in sequence through the oil passage to form an electric drive lubrication and cooling circuit; the oil cooler (600) is connected to the water cooling cavity (230b) through the water passage (201).

2. The electrically driven lubrication and cooling system according to claim 1, characterized in that, The motor consists of two axial flux motors (100) arranged side by side along the axial direction, and both axial flux motors (100) are electrically connected to the controller (300); The reducer (400) consists of two planetary gear sets (410), which are symmetrically distributed on the outside of the two axial flux motors (100).

3. The electrically driven lubrication and cooling system according to claim 2, characterized in that, The planetary gear shaft (414) of the planetary gear set (410) is provided with a communicating oil guide cavity (414a) and an oil guide hole (414b); the planetary gear (413) of the planetary gear set (410) is mounted on the planetary gear shaft (414) through a second bearing (430), and the second bearing (430) corresponds to the position of the oil guide hole (414b); The reducer (400) is provided with an oil collection plate (450), which is connected to the planet carrier (412) of the planetary gear set (410); the oil collection plate (450) is provided with an oil outlet (451) in the same number as the planetary gear shaft (414), and the oil outlet (451) extends into the corresponding oil guide cavity (414a) to connect the oil guide cavity (414a) and the oil collection cavity (450a) of the oil collection plate (450); The oil passage includes a first oil passage (2221) and a second oil passage (2211). The oil pump (500) is connected to the oil storage chamber through the first oil passage (2221), and the oil collecting chamber (450a) is connected to the second oil passage (2211).

4. The electrically driven lubrication and cooling system according to claim 3, characterized in that, The oil collecting plate (450) has several clearance areas (453) on the side plate away from the oil outlet (451). The oil collecting plate (450) has several mounting holes (454) on the side plate where the oil outlet (451) is located. Each clearance area (454) corresponds to each mounting hole (454). The oil collecting plate (450) is mounted on the planetary carrier (412) by screws.

5. The electrically driven lubrication and cooling system according to claim 3, characterized in that, A first bearing (420) is provided between the planetary gearbox (410) and the gearbox; the oil passage also includes a third oil passage (2222), a fourth oil passage (212), a fifth oil passage (213) and a sixth oil passage (214), the third oil passage (2222) is connected to the installation space of the first bearing (420); the oil cooler (600) is connected to the oil pump (500) through the fourth oil passage (212); the stator housing (111) is provided with an oil inlet (111b) and an oil outlet (111c) connected to the stator mounting cavity (111a), the oil cooler (600) is connected to the oil inlet (111b) through the fifth oil passage (213), and the oil outlet (111c) is connected to both the second oil passage (2211) and the third oil passage (2222) through the sixth oil passage (214).

6. The electrically driven lubrication and cooling system according to claim 5, characterized in that, The housing assembly (200) includes a motor housing, a gearbox (220), and a controller housing (230). The gearbox (220) includes a connected reducer housing (221) and an end cover (222). The gearbox (220) is connected to the end opening (2223) of the motor housing (210) and is close to the rotor assembly. An oil seal is provided between the gearbox (220) and the turntable of the rotor assembly. The first oil passage (2221) and the third oil passage (2222) are both located inside the end cover (222), the second oil passage (2211) is located inside the reducer housing (221), the fourth oil passage (212), the fifth oil passage (213) and the sixth oil passage (214) are all located inside the motor housing (210); the water passage (201) is located inside the motor housing (210).

7. The electrically driven lubrication and cooling system according to claim 6, characterized in that, An oil storage chamber is located at the bottom of the gearbox (220). An oil filter (2225) and a magnet (2226) are provided in the wall of the gearbox (220). The oil filter (2225) and the magnet (2226) are both located in the first oil passage (2221). The first oil passage (2221) has two openings (2223) that communicate with the outside. A plug (2224) is provided in each of the two openings (2223). The oil filter (2225) and the magnet (2226) are respectively close to the two openings (2223).

8. The electrically driven lubrication and cooling system according to any one of claims 1-7, characterized in that, The stator core (113) includes a plurality of soft magnetic blocks (1131) arranged in a circular array, and the stator winding (112) includes a plurality of coil windings (1121) spaced apart and evenly distributed along the circumferential direction, with the plurality of coil windings (1121) wound one-to-one on the plurality of soft magnetic blocks (1131). The stator housing (111) is provided with a blocking member (1123), which is located between the coil winding (1121) and the stator housing (111) so that the blocking member (1123), the coil winding (1121) and the stator housing (111) surround and form a cooling oil passage (111e).

9. The electrically driven lubrication and cooling system according to claim 7, characterized in that, The stator housing (111) is annular; the coil winding (1121) is spaced from both the outer ring (1114) and the inner ring (1113) of the stator housing (111); the circumferential spacing between adjacent coil windings (1121) is communicated through the spacing between the coil winding (1121) and the inner ring (1113); the blocking member (1123) is located in the spacing between the coil winding (1121) and the outer ring (1114).

10. The electrically driven lubrication and cooling system according to claim 8, characterized in that, The inner ring (1113) of the stator housing (111) is provided with a plurality of support blocks (1112). The shape of the end face of the support block (1112) matches the end shape of the coil winding (1121). The support block (1112) abuts against the corresponding end of the coil winding (1121) to radially limit the coil winding (1121).

11. The electrically driven lubrication and cooling system according to claim 10, characterized in that, The number of support blocks (1112) is less than the number of coil windings (1121), such that the circumferential spacing between adjacent coil windings (1121) is connected through the area between the coil windings (1121) and the inner ring (1113) where no support blocks (1112) are provided.

12. The electrically driven lubrication and cooling system according to claim 11, characterized in that, The stator housing (111) is provided with a sealing insert (116), which covers the three-phase copper busbar (1124) and is embedded in the copper busbar outlet (111d).

13. The electrically driven lubrication and cooling system according to claim 12, characterized in that, The stator housing (111) includes two housing components (1111), which together form a stator mounting cavity (111a); the two housing components (1111) are sealed by a first sealing member (117).

14. The electrically driven lubrication and cooling system according to any one of claims 1-7, characterized in that, Also includes: A resolver (700) is mounted on the motor; The first oil temperature detection element is installed on the oil pump (500) or the housing assembly (200) for detecting the oil temperature in the oil storage chamber; The second oil temperature detection element is located at the oil outlet of the stator assembly (110) and is used to detect the outlet oil temperature of the stator assembly (110); wherein the resolver (700), the first oil temperature detection element and the second oil temperature detection element are all electrically connected to the controller (300).

15. A vehicle, characterized in that, The electric drive lubrication and cooling system (1000) includes any one of claims 1-14.

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