Integrated E-Drive Housing With Oil-Water Cooling for Low NVH
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Solution Overview
Problem
Existing electric drive systems in new energy vehicles face challenges in reducing vibration and noise levels due to limitations in electromagnetic and structural design, with existing hardware-based noise reduction methods being insufficient.
Innovation Solution
An integrated housing structure comprising a motor housing, reducer housing, and controller housing, with integrated oil and water cooling assemblies, including an oil pumping unit, oil passage, and circulating water channel, to enhance cooling and lubrication efficiency while reducing weight and improving stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple housings (motor housing, reducer housing, controller housing) are integrated into a single structure, then the overall stiffness is improved and vibration noise is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent integrates the motor housing, reducer housing, and controller housing into a single integrated housing structure. This merging of multiple separate housings into one unified structure increases overall stiffness and reduces vibration noise by eliminating gaps and connection points between separate components, while the integration simplifies the total number of parts despite increasing the complexity of the manufacturing process for the integrated structure itself.
2Ease of manufacture
If multiple housings are integrated into a single structure, then the number of parts is reduced and assembly is simplified, but the manufacturing precision requirements increase
Solution Approach 1:
By combining multiple housings into one integrated structure, the patent reduces the total number of parts that need to be assembled, eliminating the need for connection seals and mechanical joints between separate housings. This simplifies the assembly process significantly, although it does increase the manufacturing precision requirements for producing the integrated housing structure itself.
3Temperature
If oil cooling assembly and water cooling assembly are integrated, then the cooling efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent integrates the oil cooling assembly and water cooling assembly into a unified cooling system with shared components and pathways. The oil passage and water passage are both communicated with the heat exchange unit, allowing heat exchange between lubricating oil and cooling water. This integration improves cooling efficiency by enabling heat transfer between the two cooling media while reducing the total number of separate cooling components.
Solution Approach 2:
The heat exchange unit serves as an intermediary between the oil cooling system and water cooling system. It enables thermal energy transfer from the lubricating oil to the cooling water, facilitating efficient heat removal from both systems without requiring direct contact between the oil and water, thus maintaining system separation while achieving thermal coupling.
4Weight of stationary object
If the housing structure is integrated, then the weight is reduced, but the structural design complexity increases
Solution Approach 1:
The patent integrates multiple separate housings into a single unified housing structure, eliminating the weight of connection components, seals, and redundant structural elements that would be required to join separate housings. This weight reduction is achieved despite the increased complexity of designing and manufacturing the integrated structure, as the overall system requires fewer total components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated housing structure significantly reduces vibration and noise, enhances cooling and lubrication efficiency, and improves overall NVH performance by integrating multiple components into a single structure, thereby simplifying manufacturing and assembly processes.
Implementation Method 1
the oil pumping unit is communicated with the oil passage and conveys lubricating oil in the reducer housing to the oil passage
Implementation Method 2
heat exchange between the lubricating oil in the oil passage and the cooling water in the water passage is achieved by means of the heat exchange unit
Implementation Method 3
the water passage comprises a first water passage provided at a bottom and/or a side wall of the controller housing, and a second water passage provided between the motor housing and a motor water jacket
Data Source
AI summary
A housing structure of an electric drive assembly and an electric drive assembly are provided. The housing structure comprises a motor housing, a reducer housing, a controller housing, an oil cooling assembly, and a water cooling assembly. At least two housings of the motor housing, the reducer housing, and the controller housing are in an integrated structure. The oil cooling assembly comprises an oil pumping unit and an oil passage, the oil passage is provided inside the motor housing and inside the reducer housing, the oil pumping unit is communicated with the oil passage and conveys lubricating oil in the reducer housing to the oil passage. The water cooling assembly comprises a water passage which is a circulating water channel provided inside the controller housing and inside the motor housing, and the water passage is connected to a cooling water source of a vehicle. This housing structure can reduce the weight of the electric drive assembly and improve its stiffness, and has advantages of good NVH (Noise, Vibration, and Noise) performance as well as high cooling and lubrication efficiency.