CN111591120A - An electric drive integrated system - Google Patents

Abstract

The present invention provides an electric drive integrated system, comprising: a motor for converting electrical energy into mechanical energy to output torque; and a transmission for receiving torque from the motor and converting the torque to output ; controller, the controller is used to control the motor; according to the wire box, the wire harness is arranged in the wire box; the controller is connected with the transmission and the wire box at the same time. The present invention can reduce the overall size and assembly cost of the entire driving system, and improve the cooling efficiency thereof.

Description

An electric drive integrated system

technical field

The invention relates to the technical field of vehicles, in particular to an electric drive integrated system for new energy vehicles.

Background technique

With the large-scale popularization of new energy vehicles, the types of transmissions used in new energy vehicles are also becoming more and more abundant. An existing two-speed automatic transmission is based on the technical route of the traditional automatic transmission development and application, using two symmetrical multi-disc wet clutches and three pairs of fixed shaft gears, and using electromechanical hydraulic control integrated precise control. , it can realize shift without power interruption, and at the same time, it has the advantages of good shifting comfort and power, high efficiency and low noise. In addition, the driving torque range of the existing dual-clutch two-speed gearbox is further expanded, which is beneficial to the improvement of the power performance of the whole vehicle. For motors with the same performance, the large first gear ratio of the two-speed transmission can improve acceleration and climbing performance, and the small second gear ratio can improve the maximum speed and the dynamic performance of the vehicle. Under the same motor and model, the comprehensive power performance of the 2-speed transmission is improved, the power performance is improved by >20%, the climbing ability is improved by >20%, and the maximum speed is improved by >10%.

However, when the above-mentioned dual-clutch two-speed gearbox is applied to a new energy vehicle, there are the following problems:

1) Compared with the single-speed gearbox, the dual-clutch two-speed gearbox has one more pair of gears and two symmetrical multi-plate wet clutches, electronic oil pump, mechanical pump and valve plate, etc., the size has increased, and the overall drive is divided into two parts. , the overall size is large, the vehicle layout is more difficult.

2) A single independent lubrication and cooling system is used between the motor and the transmission, which has low resource utilization and high cost;

3) The motor, controller and two-speed gearbox are independent of each other, making it difficult to match.

SUMMARY OF THE INVENTION

For this reason, the present invention proposes the following technical solutions:

An electric drive integrated system having:

an electric motor for converting electrical energy into mechanical energy, thereby outputting torque;

a transmission, which receives the torque from the electric motor, converts the torque and outputs it;

a controller, which is used to control the motor;

a junction box, a wire harness is arranged in the junction box;

The controller is connected to the transmission and the junction box at the same time.

Further, the following technical features can be combined with the above-mentioned technical solutions in various ways that are technically feasible:

- in the axial direction of the motor, the transmission, the motor and the junction box are arranged in sequence;

-The box body of the transmission is divided into two parts, one of which is integrated with one side end cover of the motor and the inner casing of the motor;

- further comprising an electronic oil pump, the electronic oil pump and the controller are located on both sides of the shaft of the motor, and the angle between the two in the circumferential direction of the motor is less than 180°;

- the shaft of the electric machine is parallel to the output shaft of the transmission;

- the transmission is a two-speed dual-clutch transmission;

-The motor is selected from water-magnetic synchronous motor or induction motor, the cooling mode is water cooling, oil cooling or oil-cooling mixed cooling, and the winding adopts flat wire or round wire;

- The inner sleeve of the motor is provided with a channel for the circulation of cooling liquid, and the cooling liquid channel is used for communication between the motor and the controller to form a cooling liquid circulation.

On the other hand, the present invention also proposes an electric drive integrated system, which has:

an electric motor for converting electrical energy into mechanical energy, thereby outputting torque;

a transmission, which receives the torque from the electric motor, converts the torque and outputs it;

The box body of the transmission is divided into two parts, one of which is integrated with one side end cover of the motor and the inner casing of the motor casing.

As can be seen from the above, the solution of the present invention has at least the following advantages compared with the prior art:

1) To provide an integrated electric drive assembly that is lighter in weight, more compact in structure, smaller in volume, and has an integrated structure of motor, electric control, and two-gear box.

2) Integrated shell, shared cooling system, greatly reducing volume, improving resource utilization rate and reducing cost;

3) The integrated design of dual-clutch two-speed transmission + flat wire motor + controller saves installation space, spares parts such as wiring harness, and reduces costs.

Other advantages of the present invention will be more easily understood after reading the detailed description of the technical solutions of the present invention in conjunction with the accompanying drawings.

Description of drawings

FIG. 1 is a schematic structural diagram of an electric drive integrated system according to an embodiment of the present invention.

FIG. 2 is a schematic structural diagram of an electric drive integrated system from another angle according to an embodiment of the present invention.

FIG. 3 is a front view of an electric drive integrated system according to an embodiment of the present invention.

FIG. 4 is a top view of an electric drive integrated system according to an embodiment of the present invention.

FIG. 5 is a right side view of an electric drive integrated system according to an embodiment of the present invention.

Detailed ways

It should be noted that the accompanying drawings are only schematic, and the dimensions of the various components are not actual dimensions, and may not be drawn in the same scale, but are only used to illustrate the mutual positional relationship between the various components. In addition, only the components closely related to the present invention are shown in the drawings, and other components not closely related to the present invention may not be shown in the drawings.

FIG. 1 is a schematic structural diagram of an electric drive integrated system according to an embodiment of the present invention. As can be seen from FIG. 1 , the electric drive integrated system of the present invention mainly includes a motor 1 and a transmission 2 . The motor 1 is used to provide power, and the output shaft of the motor 1 is connected to the input shaft of the transmission 2 . Transmission 2 is used to adopt different gears according to driving conditions, so that the power output can better match the load. In the present invention, the transmission 2 preferably adopts a dual-clutch two-speed non-power terminal shift transmission. Also shown in FIG. 1 is a controller 3 which will be described further below.

FIG. 2 is a schematic structural diagram of an electric drive integrated system from another angle according to an embodiment of the present invention. As can be seen from FIG. 2 , the electric drive integrated system also integrates a junction box 4 and an electronic oil pump 6 . The junction box 4 is arranged on one side of the motor 1 and on the side opposite to the transmission 2 . A wiring harness is accommodated in the junction box 4 for supplying electric power and/or control signals to the motor 1 . In addition, the high and low voltage wiring harness of the controller 3 can also be arranged in the junction box 4 . The electronic pump oil 6 and the controller 3 are located approximately on both sides of the axis of the motor 1 in the radial direction. When the electric drive integrated system of the present invention is installed in a vehicle, the position of the electronic oil pump 6 is located at the lower part of the middle of the differential and the motor 1 .

FIG. 3 is a front view of an electric drive integrated system according to an embodiment of the present invention. As can be seen in FIG. 3 , the electric machine 1 has a housing jacket 7 . The motor 1 also has an inner casing of the casing, and the inner casing is arranged inside the outer casing 7 of the casing. Components such as a stator assembly, a rotor assembly and the like are also arranged inside the motor.

It can be seen in conjunction with FIGS. 1-3 that the axis of the motor 1 is parallel to the axis of the output shaft of the transmission 2 . In the axial direction of the motor 1 , the transmission 2 , the motor 1 , and the junction box 4 are arranged in sequence. In particular, it can be seen from FIG. 1 that the casing of the transmission 2 consists of two parts: a left casing and a right casing. Further, in the present invention, the right case of the transmission 2 is integrated with the one side end cover of the motor 1 and the inner sleeve of the motor as one piece, and the reference numeral 5 in FIG. 2 indicates this one piece.

The inner casing of the motor 1 is arranged inside the outer casing 7 of the casing, and the two are sealed by an O-ring; the inner casing of the casing is provided with a channel for the circulation of cooling liquid, so as to cool the motor. As a possible embodiment, the cooling liquid adopts water. Of course, the coolant can also be oil, or other liquids with good heat transfer.

Further, a cooling liquid channel may also be used for communication between the motor 1 and the controller 3 to form a cooling liquid circulation, so as to cool the motor 1 and the controller 3 at the same time. Preferably, the controller 3 can be fixed on the reducer 2 with bolts.

The motor 1 can use the following types of motors: oil-cooled motors, water-cooled motors or oil-cooled mixed-cooled motors; round wire motors, flat wire motors; permanent magnet synchronous motors, induction motors; and combinations of the above types. For example, oil-cooled flat wire permanent magnet synchronous motor, water-cooled flat wire permanent magnet synchronous motor. Transmission 2 employs a two-speed transmission with two clutches. Preferably, a flat wire motor is employed in the present invention. The flat wire motor has the advantages of small size, material saving, high efficiency, strong thermal conductivity, low temperature rise, low noise, etc. However, due to the serious "skin effect" of the flat wire motor at high speed, the motor efficiency is low at high speed. , it is difficult to achieve high speed. In the present invention, the motor 1 is used in conjunction with the dual-clutch two-speed transmission, which widens the range of the transmission ratio, can effectively reduce the rotational speed of the motor, and improve the efficiency of the drive system.

As an improvement of the present invention, the controller 3 is fixed on the transmission 2 and the junction box 4 at the same time. As can be seen from FIG. 2 , one end of the controller 3 is fixed on the junction box 4 , and one side of the controller 3 is fixed on the right case of the transmission 2 from FIG. 1 . Through this setting, the strength of the entire drive system can be enhanced to withstand stronger impacts. In addition, since the controller 3 is located on the side opposite to the electronic oil pump 6 in the radial direction, the controller 3 is located on the inner side of the motor 1 and the transmission 2 after installation, which makes the system more compact, saves space and does not need to find another controller space. In addition, the controller 3 is directly installed on the junction box 4 and the transmission 2, which reduces components such as brackets, reduces the assembly process, and reduces the cost.

4 and 5 are a top view and a right side view of the electric drive integrated system, respectively. 1 , 2 and 4 , it can be seen that although the controller 3 and the electronic oil pump are located on both sides of the motor 1 in the radial direction, the distance between them is smaller than the outer diameter of the motor 1 . In other words, in order to reduce the overall size of the entire electric drive integrated system in the radial direction, the controller 3 and the electronic oil pump 6 are not located at both ends of a diameter of the motor 1, that is, the angle between the two in the circumferential direction is not 180°, but is less than 180°. This positional relationship is evident from FIG. 5 .

In addition, it can be seen from FIG. 5 that the controller 3 , the junction box 4 and the electronic oil pump 6 are basically located inside the outline of the motor 1 and the transmission 2 , viewed from the axial direction of the output shaft of the motor 1 and the transmission 2 . As a result, the electric drive integrated system is reduced in size in all directions as an integral part.

Various embodiments of the present invention have been described above in detail. Any person skilled in the art, without departing from the scope of the technical solution of the present invention, can use the above-mentioned technical content to make many possible changes and modifications to the technical solution of the present invention, or be modified to equivalent embodiments of equivalent changes. . Therefore, any modifications, equivalent changes and modifications made to the above embodiments according to the technology of the present invention without departing from the content of the technical solution of the present invention all belong to the protection scope of the technical solution of the present invention.

Claims (10)

1. An electric drive integrated system having: an electric motor for converting electrical energy into mechanical energy, thereby outputting torque; a transmission, which receives the torque from the electric motor, converts the torque and outputs it; a controller, which is used to control the motor; a junction box, a wire harness is arranged in the junction box; It is characterized in that, The controller is connected to the transmission and the junction box at the same time. 2. An electric drive integrated system according to claim 1, characterized in that, In the axial direction of the motor, the transmission, the motor and the junction box are arranged in sequence. 3. An electric drive integrated system according to claim 1, characterized in that, The box body of the transmission is divided into two parts, one of which is integrated with one side end cover of the motor and the inner casing of the motor casing. 4. An electric drive integrated system according to claim 2, characterized in that, The box body of the transmission is divided into two parts, one of which is integrated with one side end cover of the motor and the inner casing of the motor casing. 5. An electric drive integrated system according to any one of claims 1-4, characterized in that, It also includes an electronic oil pump, the electronic oil pump and the controller are located on both sides of the shaft of the motor, and the angle between the two in the circumferential direction of the motor is less than 180°. 6. An electric drive integrated system according to any one of claims 1-4, characterized in that, The shaft of the electric machine is parallel to the output shaft of the transmission. 7. An electric drive integrated system according to any one of claims 1-4, characterized in that, The transmission is a two-speed dual-clutch transmission. 8. An electric drive integrated system according to any one of claims 1-4, characterized in that, The motor is selected from a permanent magnet synchronous motor or an induction motor, the cooling method is water cooling, oil cooling or oil-cooling mixed cooling, and the winding adopts flat wire or round wire. 9. The electric drive integrated system according to any one of claims 1-4, characterized in that, The inner sleeve of the motor is provided with a channel for the circulation of cooling liquid, and the cooling liquid channel is used for communication between the motor and the controller to form a cooling liquid circulation. 10. An electric drive integrated system having: an electric motor for converting electrical energy into mechanical energy, thereby outputting torque; a transmission, which receives the torque from the electric motor, converts the torque and outputs it; It is characterized in that, The box body of the transmission is divided into two parts, one of which is integrated with one side end cover of the motor and the inner casing of the motor casing.

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