CN112874322A

CN112874322A - Electric drive system

Info

Publication number: CN112874322A
Application number: CN202110241872.7A
Authority: CN
Inventors: 王青
Original assignee: Electric System Branch Of Fuao Auto Parts Co ltd; Fawer Automotive Parts Co Ltd
Current assignee: Electric System Branch Of Fuao Auto Parts Co ltd; Fawer Automotive Parts Co Ltd
Priority date: 2021-03-04
Filing date: 2021-03-04
Publication date: 2021-06-01

Abstract

The application provides an electric drive system, which relates to the technical field of driving and comprises a drive motor and a motor, wherein the drive motor is provided with an output shaft; the motor controller is electrically connected with the driving motor; the speed reducing mechanism comprises an input shaft which is connected with an output shaft of the driving motor and is coaxially arranged; at least part of the motor controller is disposed between the drive motor and the reduction mechanism. According to the electric drive system, at least part of the motor controller is arranged between the drive motor and the speed reducer mechanism, so that the space is effectively utilized, the electric drive system is compact in structure, the outline size is small, and the installation precision is effectively guaranteed; and various requirements of the motor controller for environmental tests are reduced.

Description

Electric drive system

Technical Field

The present application relates to the field of drive technology, and more particularly, to an electric drive system.

Background

As shown in fig. 2, the motor 100 is used as a main driving device to provide power in some applications, for example, in a new energy automobile, the motor 100 is used as a power source of the automobile instead of an engine. When the vehicle is assembled, the motor 100, the controller 200, and the reduction mechanism 300 are assembled together.

Wherein, the output shaft of the motor 100 and the input shaft of the speed reducer are connected by a coupling, and flanges are respectively formed on the housing of the motor 100 and the housing of the speed reducing mechanism 300, and the flanges are fastened by a positioning pin and a screw.

After the motor 100 and the reduction mechanism 300 are assembled integrally, the controller 200 is further mounted above their assembly. For example, two mounting surfaces are formed above the motor 100 and the reduction mechanism 300, respectively, and they are fitted to the mounting surface of the controller 200 and fastened by positioning pins and screws.

A window 110 is reserved on the mounting surface of the upper side of the rear end cover of the motor 100, and the window 110 allows a high-voltage alternating-current cable and a low-voltage signal wire to pass through. A cover is further installed on the outer side of the rear end cover of the motor 100, and a junction box is formed between the cover and the rear end cover of the motor 100 and used for connecting the high-voltage alternating-current cable and the low-voltage signal wire. The mounting surface of the junction box, the abutting surface of the upper side of the rear end cover of the motor 100 and the lower side of the controller 200 are all provided with a sealed dustproof design.

However, the above-described assembly formed by assembling motor 100, reduction mechanism 300, and controller 200 is not space-efficient and is not compact in structure. Moreover, cables and low-voltage signals are connected between the motor 100 and the controller 200, and in order to meet the protection requirements of the cables, windows 110 are designed at positions corresponding to the motor 100 and the controller 200, the windows 110 need to be sealed and dustproof, extra parts need to be machined and installed in the designs, so that the cost is increased, and meanwhile, the problem of connection strength exists. In addition, in the assembly, especially the controller 200 is bridged over the two assemblies of the motor 100 and the speed reducing mechanism 300, the assembly precision is difficult to ensure, and the requirements of vibration tests are difficult to meet (namely, the risk in fatigue resistance is great); the assembly body actually exists in a three-assembly mode, so that the number of parts is large, and the cost is high.

Disclosure of Invention

The present application provides an electric drive system with the aim of obtaining a compact assembly structure.

The present application provides an electric drive system comprising:

a drive motor provided with an output shaft;

the motor controller is electrically connected with the driving motor;

the speed reducing mechanism comprises an input shaft which is connected with an output shaft of the driving motor and is coaxially arranged;

at least a portion of the motor controller is disposed between the drive motor and the reduction mechanism.

Preferably, the motor controller comprises a housing and a plurality of power components integrally packaged within the housing.

Preferably, the housing is formed of a non-metallic material;

the housing is provided at an outer portion thereof with a plurality of wiring members integrally formed with the housing.

Preferably, the electric drive system further includes a positioning guard provided between the drive motor and the speed reduction mechanism;

the motor controller comprises a positioning part, and the positioning part is matched with the positioning protection part.

Preferably, the positioning protector is formed as a sheathing member provided to one of the drive motor and the reduction mechanism; or

The positioning protection member includes a first nesting member and a second nesting member that are respectively disposed on the driving motor and the reduction mechanism and are engaged with each other.

Preferably, in a case where the positioning protection member includes first and second nesting members that are provided to the drive motor and the reduction mechanism, respectively, and that mate with each other, the first and second nesting members are nested and mated with each other.

Preferably, the first nesting member and the second nesting member are nested with one another to form a stepped configuration for positioning the motor controller.

Preferably, in a state where the electric drive system is assembled, an output shaft of the drive motor and an input shaft of the reduction mechanism are defined inside the positioning guard.

Preferably, the entirety of the motor controller is disposed between the drive motor and the reduction mechanism;

the motor controller is supported by at least one of the drive motor and the reduction mechanism; a surrounding wall portion is formed on a surface supporting the motor controller in both the drive motor and the reduction mechanism;

the surrounding wall portion cooperates with a portion of the motor controller.

Preferably, the motor controller is supported by at least the driving motor, the motor controller is provided with an interface, and the driving motor is provided with a window;

and a circuit for electrically connecting the motor controller and the driving motor penetrates through the window from the interface.

According to the electric drive system, at least part of the motor controller is arranged between the drive motor and the speed reducer mechanism, so that the space is effectively utilized, the electric drive system is compact in structure, the outline size is small, and the installation precision is effectively guaranteed; and various requirements of the motor controller for environmental tests are reduced.

In order to make the aforementioned objects, features and advantages of the present application more comprehensible, preferred embodiments accompanied with figures are described in detail below.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are required to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained from the drawings without inventive effort.

Fig. 1 shows a schematic diagram of an explosion diagram of an electric drive system.

Fig. 2 shows a schematic diagram of an explosion diagram of an electric drive system in the prior art.

Reference numerals:

1-driving a motor; 2-a first sleeve; 3-a surrounding wall portion; 4-a motor controller; 5-a positioning part; 6-a speed reducer;

100-a motor; 110-a window; 200-a controller; 300-speed reduction mechanism.

Detailed Description

The technical solutions of the present application will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are only some embodiments of the present application, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.

In the description of the present application, it is to be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present application can be understood in a specific case by those of ordinary skill in the art.

In addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present application.

The present embodiment provides an electric drive system including a drive motor 1, a speed reducer 6, and a motor controller 4, and the specific structure, connection relationship, and operation principle of the above components will be described in detail below.

Fig. 1 shows a schematic diagram of an explosion diagram of an electric drive system, as shown in fig. 1, in the example given in fig. 1, a coupling (not shown) is used for connecting the drive motor 1 and the speed reducer 6. The aforementioned coupling arranged between the drive motor 1 and the retarder 6 has a coupling length and between the drive motor 1 and the retarder 6 at least a shaft section distance equal to the sum of the partial length of the output shaft of the drive motor 1 and the partial length of the input shaft of the retarder 6, which results in an accommodation span between the housing of the drive motor 1 and the housing of the retarder 6 comprising at least the sum of the coupling length and the shaft section distance. In the present embodiment, an accommodation space having the aforementioned accommodation span is defined by a portion of the drive motor 1 and a portion of the reduction gear 6.

At least a part of the motor controller 4 is disposed in the accommodating space, so that the accommodating space in an idle state in the prior art is effectively utilized, which makes the structure of the electric drive system more compact.

The above-mentioned "at least a part of the motor controller 4 is provided in the accommodation space" can be understood to have the following cases: a part of the motor controller 4 is provided in the accommodation space and the entirety of the motor controller 4 is provided in the accommodation space. In order to ensure a high degree of compactness of the electric drive system, i.e., to make full use of the accommodation span and to ensure mounting accuracy, in the present embodiment, an embodiment is employed in which the entirety of the motor controller 4 is disposed in the accommodation space and occupies the entire accommodation span, which will also be specifically described below on the basis thereof. In the embodiment, the housing space is defined by a front cover and a surrounding wall portion 3 of the drive motor 1 and a front cover and a surrounding wall portion of the reduction gear 6 described below, which will be described in detail below.

Since the output shaft of the driving motor 1, the coupling and the input shaft of the reducer 6 have sufficient rigidity and strength after assembly, the motor controller 4 is positioned by the rigidity and strength of the three. For this purpose, the present embodiment adopts the following settings: the motor controller 4 is positioned by a positioning protector provided outside the output shaft, the coupling, and the input shaft of the speed reducer 6, while protecting the output shaft, the coupling, and the input shaft of the speed reducer 6.

In a first embodiment (not shown in the figures), the front end cap of the housing of the drive motor may be formed with a sleeve in which a portion of the coupling and the output shaft of the drive motor are housed. The end of the sleeve may be removably mounted to the front end cap of the reducer, for example, the end of the sleeve is embedded in the front end cap of the reducer. Thus, in this embodiment, the input shaft of the reducer is pre-assembled with another portion of the coupling, such that during installation of the sleeve, one portion of the coupling located within the sleeve will be installed with another portion of the coupling mounted to the input shaft of the reducer. In order to accommodate such a mounting process, the coupling may, for example, be a splined coupling in this embodiment. Similarly, in the second embodiment, the sleeve may be formed at a front cover of the decelerator, and its tip may be detachably mounted to the front cover of the driving motor.

In the third embodiment, two bushings are respectively provided at the front end cover of the driving motor 1 and the front end cover of the speed reducer 6, and for convenience of description, as shown in fig. 1, the bushing provided at the front end cover of the driving motor 1 is defined as a first bushing 2, and the bushing provided at the front end cover of the speed reducer 6 is defined as a second bushing (not shown in the figure). Wherein the first sleeve 2 and the second sleeve can be plugged in a bore-shaft fit, for example, as an example the first sleeve 2 can have an outer side which is fitted over the second sleeve, during which plugging the two parts of the coupling are also fitted together as in the first and second embodiments.

In the example given in fig. 1, the first sleeve 2 can abut just against the front end cap of the reduction gear 6, so that the positioning protection jointly formed by the first sleeve 2 and the second sleeve, without a stepped configuration on the outer side, facilitates a quick mounting of the motor controller 4. In other cases, not shown, the end of the first sleeve may be spaced from the front cover of the reducer, so that a stepped structure is formed on the outer side of the positioning protection, for which the motor controller may be configured to fit the stepped structure, and the motor controller may be axially positioned by the stepped member.

On the basis of the features described above, the electric drive system will be further described below with reference to fig. 1, i.e. it will be described further with reference to the example given in fig. 1. In an embodiment, the motor controller 4 may have a positioning portion 5, and the positioning portion 5 cooperates with the first sleeve 2 to position the motor controller 4. As shown in fig. 1, in the example given in fig. 1, the motor controller 4 has a positioning portion 5 in the shape of an arc, and the positioning portion 5 in the shape of an arc may be adapted to the outer side portion of the first sleeve 2, for example, completely fit to the outer side portion of the first sleeve 2. Since the motor controller 4 occupies the entire accommodation span, the motor controller 4 is positioned in the axial direction (i.e., in the axial direction of the output shaft of the drive motor 1 or the input shaft of the reduction gear 6) by the front cover of the drive motor 1 and the front cover of the reduction gear 6, respectively, and the motor controller 4 is positioned in the radial direction (i.e., in the radial direction of the first sleeve 2) by the first sleeve 2.

However, without being limited thereto, the positioning portion may also be served by a cylindrical surface, which means that the positioning portion is substantially formed as a hole portion opened on the motor controller, via which the motor controller is fitted on the outer side portion of the first bushing.

Further, still referring to fig. 1, in order to further perform positioning of the motor controller 4 in the radial direction, a surrounding wall portion 3 may be further formed in at least one of the front cover of the drive motor 1 and the front cover of the speed reducer 6, for example, it is preferable that the surrounding wall portion 3 is formed on each of the front cover of the drive motor 1 and the front cover of the speed reducer 6 (the surrounding wall portion on the front cover of the speed reducer 6 is not shown in the drawing). Taking the surrounding wall portion 3 provided at the front end cover of the drive motor 1 shown in fig. 1 as an example, the surrounding wall portion 3 protrudes toward the speed reducer 6 with respect to the front end cover of the drive motor 1 and is provided at the periphery of the first sleeve 2, so that the motor controller 4 can be positioned by the surrounding wall portion 3 when the inner side of the surrounding wall portion 3 (i.e., the side portion close to the first sleeve 2) is fitted to the outer contour of the motor controller 4 on the side close to the drive motor 1.

In fig. 1, the motor controller 4 may have an outer contour defined by a cylindrical surface, and preferably, the motor controller 4 may be integrally formed as a part of a ring shape, that is, the axis of the positioning portion 5 and the outer contour of the motor controller 4 may be coaxial, which facilitates the machining of the housing of the motor controller 4. Advantageously, the enclosure wall 3 defines a cylindrical enclosure adapted to the external profile of the motor controller 4, so as to reduce the difficulty of assembly and to effectively position the motor controller 4. Therefore, it can be understood that the motor controller 4 is embedded in the peripheral wall portion 3 of the drive motor 1 and the peripheral wall portion 3 of the reduction gear 6. Therefore, in this case, when viewed in the axial direction (i.e., the axial direction of the output shaft of the drive motor 1 or the axial direction of the input shaft of the reduction gear 6), the motor controller 4, that is, the motor controller 4 is completely located between the drive motor 1 and the reduction gear 6, cannot be viewed either on the side of the drive motor 1 where the reduction gear 6 is located or on the side of the drive motor 1 where the reduction gear 6 is located, which makes the electric drive system further compact.

In an embodiment, a window (not shown in the figure) may be formed on the front end cover of the driving motor 1, and an interface is reserved outside the motor controller 4, so that a line led out from the interface of the motor controller 4 may be connected to the inside of the driving motor 1 through the window. The interface of the motor controller 4 will be explained in the following description.

From the above-described characteristics, it can be seen that the motor controller 4 occupies the above-mentioned housing span, i.e. is arranged between the drive motor 1 and the reducer 6, considerably reducing the requirements of the environmental tests that the motor controller 4 needs to possess, thereby allowing the motor controller 4 to be produced in an integrated manner. Specifically, in the motor controller 4 in this embodiment, components such as the dc busbar, the ac busbar, the high-voltage wire connector, and the low-voltage wire connector are directly integrated and encapsulated in the plastic housing (where the dc busbar and the ac busbar are integrally designed), which is equivalent to integrating these components together and reserving an interface by using only one mold. Compared with the prior art in which the motor controller 4 is in a poor external environment, the aforementioned components need to be integrated by using a plurality of dies, and therefore, a large number of connecting, sealing and insulating designs are required for assembly. Therefore, compared with the prior art, the motor controller 4 in the embodiment realizes structural simplification and light weight, reduces production cost, and effectively improves the reliability of insulation sealing. In addition, because the wiring distance between the motor controller 4 and the driving motor 1 is shorter, the connection of the circuit is more facilitated, and a connector does not need to be arranged independently, so that the cost is further effectively reduced.

Further, in addition to the above-mentioned components encapsulated in the plastic housing of the motor controller 4, the motor controller 4 further includes an IGBT (Insulated Gate Bipolar Transistor), a driving circuit board, a control circuit board, a current sensor, a vehicle low-voltage connector, and a motor signal connector. In the embodiment, the motor controller 4 is reserved with 4 sets of interfaces, and the four sets of interfaces are embodied as four sets of wiring members (not shown in the figure). Specifically, the four groups of wiring members may be a high-voltage dc wiring terminal, a high-voltage ac wiring terminal, a low-voltage wiring socket connected to the entire vehicle, and a low-voltage wiring socket connected to the motor, which are respectively used for connecting a high-voltage dc cable, a high-voltage three-phase ac cable, a low-voltage connector communicating with the entire vehicle, and a low-voltage connector connected to motor signals such as a rotary transformer, wherein the high-voltage dc cable and the high-voltage three-phase ac cable are connected to the driving motor 1.

Since the housing for packaging is formed by plastic materials, the four groups of wiring components can be integrally formed with the housing, so that the wiring components do not need to be additionally purchased or manufactured and then installed outside the motor controller as in the prior art. Therefore, the motor controller 4 provided by the embodiment has a particularly high integration characteristic, so that the production process flow is effectively saved, and the production cost is greatly reduced.

According to the electric drive system provided by the embodiment, at least part of the motor controller 4 is arranged between the drive motor 1 and the speed reducer 6, so that the space is effectively utilized, the electric drive system is compact in structure, the outline size is small, and the installation precision is effectively ensured; and various requirements of the motor controller 4 required to have an environmental test are reduced, so that the production cost and weight of the motor controller 4 and the number of required parts are effectively reduced, and the reliability of the insulation sealing of the motor controller 4 is improved.

The above description is only a preferred embodiment of the present application, and not intended to limit the scope of the present application, and all changes that can be made in the details of the description and drawings, or directly/indirectly implemented in other related technical fields, are intended to be embraced therein without departing from the spirit of the present application.

Claims

1. An electric drive system, comprising:

a drive motor provided with an output shaft;

the motor controller is electrically connected with the driving motor;

characterized in that at least part of the motor controller is disposed between the drive motor and the reduction mechanism.

2. The electric drive system of claim 1,

the motor controller comprises a shell and a plurality of power components, and the plurality of power components are integrally packaged in the shell.

3. The electric drive system of claim 2,

the housing is formed of a non-metallic material;

4. The electric drive system of claim 1,

the electric drive system further includes a positioning guard disposed between the drive motor and the reduction mechanism;

5. The electric drive system of claim 4,

the positioning protection member is formed as a sheathing member provided to one of the drive motor and the reduction mechanism; or

6. The electric drive system of claim 5,

in a case where the positioning protector includes first and second nesting members that are provided to the drive motor and the reduction mechanism, respectively, and that mate with each other, the first and second nesting members are nested and mated with each other.

7. The electric drive system of claim 6,

the first nesting member and the second nesting member are nested and matched with each other to form a stepped structure, and the stepped structure is used for positioning the motor controller.

8. The electric drive system of claim 4,

in a state where the electric drive system is assembled, an output shaft of the drive motor and an input shaft of the reduction mechanism are defined inside the positioning protection member.

9. The electric drive system of claim 1,

the motor controller is integrally arranged between the driving motor and the speed reducing mechanism;

the motor controller is supported by at least one of the drive motor and the reduction mechanism;

a surrounding wall portion is formed on a surface supporting the motor controller in both the drive motor and the reduction mechanism;

the surrounding wall portion cooperates with a portion of the motor controller.

10. The electric drive system of claim 8,

the motor controller is at least supported by the driving motor, the motor controller is provided with an interface, and the driving motor is provided with a window;