WO2022237214A1 - 定子冷却结构、驱动电机和新能源汽车 - Google Patents

定子冷却结构、驱动电机和新能源汽车 Download PDF

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Publication number
WO2022237214A1
WO2022237214A1 PCT/CN2022/071261 CN2022071261W WO2022237214A1 WO 2022237214 A1 WO2022237214 A1 WO 2022237214A1 CN 2022071261 W CN2022071261 W CN 2022071261W WO 2022237214 A1 WO2022237214 A1 WO 2022237214A1
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WIPO (PCT)
Prior art keywords
oil injection
oil
inner ring
cooling
outer ring
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PCT/CN2022/071261
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English (en)
French (fr)
Inventor
胡余生
张小波
刘健宁
高峰
薛家宁
赵丹丰
Original Assignee
珠海格力电器股份有限公司
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Application filed by 珠海格力电器股份有限公司 filed Critical 珠海格力电器股份有限公司
Publication of WO2022237214A1 publication Critical patent/WO2022237214A1/zh

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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K9/00Arrangements for cooling or ventilating
    • H02K9/19Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/24Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K5/00Casings; Enclosures; Supports
    • H02K5/04Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium

Definitions

  • the present application relates to the field of vehicle technology, in particular to a stator cooling structure, a drive motor and a new energy vehicle.
  • the scheme adopted is mainly to increase the motor speed and improve the cooling conditions to increase the power density.
  • Increasing the speed of the motor is limited by factors such as bearings, oil seals, and the speed ratio of the matching reducer, which often produces more negative effects.
  • the cooling effect of water cooling is limited, and the use of filled heat-conducting materials to improve heat transfer efficiency is generally restricted by factors such as material cost or process complexity, and is not suitable for mass production. Therefore, at this stage, the most effective solution is to use oil cooling technology, but the traditional oil cooling solution is mostly complex oil circuit structure, which increases the processing cost, or the oil circuit structure is unreasonable, and the cooling effect is limited, especially for the cooling of the stator. , there are many cases of uneven cooling.
  • the cooling oil can be directly in contact with the heat sources of the motor, and targeted cooling is achieved in the structure, and the heat sources of the main drive motor can be effectively cooled.
  • the water-cooled motor can increase the heat load, reduce the size of the motor, and increase the power density.
  • the cooling oil can lubricate and cool the motor bearings at the same time, and the life of the motor is also improved.
  • the current motor oil cooling method is to directly cool the stator winding with cooling oil, but the traditional oil cooling method has the problem of uneven cooling of the winding, which leads to the problem of excessive local temperature of the winding, which easily affects the service life of the motor.
  • the technical problem to be solved in this application is to provide a stator cooling structure, a drive motor and a new energy vehicle, which can ensure uniform cooling of the windings, avoid local overheating of the windings, and improve the stability and service life of the motor.
  • the present application provides a stator cooling structure for cooling the stator windings, including the oil inlet of the motor, the oil injection structure of the inner ring and the oil injection structure of the outer ring, the oil injection structure of the inner ring is arranged on the stator winding On the inner peripheral side, the oil injection structure of the outer ring is arranged on the outer peripheral side of the stator winding. Both the oil injection structure of the inner ring and the oil injection structure of the outer ring are connected with the oil inlet of the motor.
  • the oil injection structure includes a second oil injection hole, the opening of the first oil injection hole faces the inner peripheral wall of the stator winding, and the opening of the second oil injection hole faces the outer peripheral wall of the stator winding.
  • the first oil injection hole is arranged on the outer peripheral wall of the inner ring oil injection structure, and extends along the radial direction of the inner ring oil injection structure; and/or, the second oil injection hole is arranged on the outer ring oil injection structure
  • the inner peripheral wall of the outer ring extends along the radial direction of the oil injection structure of the outer ring.
  • first oil injection holes there are a plurality of first oil injection holes, and the plurality of first oil injection holes are evenly spaced along the outer circumference of the inner ring oil injection structure; and/or, there are a plurality of second oil injection holes , a plurality of second fuel injection holes are evenly spaced along the inner circumferential direction of the outer ring fuel injection structure.
  • the oil injection structure of the inner ring and the oil injection structure of the outer ring are arranged in groups to form a fuel injection ring assembly, and the oil injection structure of the inner ring of the same oil injection ring assembly is located radially inside the oil injection structure of the outer ring.
  • there are at least two oil injection ring assemblies at least one oil injection ring assembly is correspondingly provided on the first end of the stator winding, at least one oil injection ring assembly is correspondingly provided on the second end of the stator winding, and the stator winding The end of the oil injection ring assembly is located between the inner ring oil injection structure and the outer ring oil injection structure.
  • the oil injection ring assemblies located at both ends of the stator winding are in communication with the oil inlet of the motor.
  • the oil injection structure of the inner ring includes at least two first split structures, and the at least two first split structures are sequentially connected end-to-end along the circumferential direction to form the oil injection structure of the inner ring.
  • the first split structure includes a male end at the first end and a female end at the second end, the male end of the adjacent first split structure is fixedly connected with the female end, and the first split structure After the structures are combined, the oil injection structure of the inner ring forms a first annular channel penetrating in the circumferential direction, and the first oil injection hole communicates with the first annular channel.
  • both the male end and the female end are arranged on the inner peripheral side of the first split structure, and the male end and the female end are plugged together to form an inner ring installation boss, and the inner ring installation boss is provided with a The first connecting hole axially penetrates.
  • a first plug-in structure is provided on the end surface of the end where the male end of the first split structure is located
  • a second plug-in structure is provided on the end face of the end where the female end of the first split structure is located, and the first plug-in structure
  • the connecting structure and the second plugging structure are plug-fitted to form a sealed connection.
  • the first plug-in structure is a slot
  • the second plug-in structure is a plug
  • the first annular passage runs through the plug along the circumferential direction, and when the plug is mated with the slot, the adjacent first split body
  • the first annular channels of the structures communicate with each other.
  • At least one of the first split structures is provided with an oil inlet of the inner ring, the oil inlet of the motor communicates with the oil inlet of the inner ring, and the oil inlet of the inner ring communicates with the first annular channel.
  • the oil inlet of the inner ring is provided with a first oil inlet joint, and the first oil inlet joint is arranged on the axial end surface of the oil injection structure of the inner ring.
  • the oil injection structure of the inner ring is integrally formed.
  • the outer edge of the inner ring oil injection structure is provided with an annular flange extending along the axial direction of the inner ring oil injection structure, and the outer peripheral wall of the annular flange is flush with the outer peripheral wall of the inner ring oil injection structure .
  • the oil injection structure of the outer ring includes a plurality of second split structures, and the second split structures are sequentially connected end-to-end along the circumferential direction to form the oil injection structure of the outer ring.
  • the second split structure includes a male end at the first end and a female end at the second end, the male end of the adjacent second split structure is fixedly connected with the female end, and the second split structure After the structures are combined, a second annular passage penetrating in the circumferential direction is formed in the oil injection structure of the outer ring, and the second oil injection hole communicates with the second annular passage.
  • both the male end and the female end of the second split structure are arranged on the outer peripheral side of the second split structure, and the male end and the female end are plugged together to form an outer ring installation boss, and the outer ring installation boss A second connection hole penetrating in the axial direction is arranged on the platform.
  • a radial oil inlet is provided on the outer peripheral wall of at least one second split structure, the motor oil inlet communicates with the radial oil inlet, and the radial oil inlet communicates with the second annular channel.
  • the oil injection structure of the outer ring is integrally formed.
  • the outer peripheral wall of the oil injection structure of the outer ring is provided with an outer ring installation boss, and the outer ring installation boss is provided with a second connection hole penetrating in the axial direction.
  • a driving motor including a stator winding and the above-mentioned stator cooling structure, the stator winding is located between the inner ring oil injection structure and the outer ring oil injection structure of the stator cooling structure.
  • a new energy vehicle including the above-mentioned stator cooling structure or the above-mentioned drive motor.
  • the stator cooling structure provided by this application is used to cool the stator winding, including the oil inlet of the motor, the oil injection structure of the inner ring and the oil injection structure of the outer ring.
  • the oil injection structure is arranged on the outer peripheral side of the stator winding, the inner ring oil injection structure and the outer ring oil injection structure are connected with the motor oil inlet, the inner ring oil injection structure includes the first oil injection hole, and the outer ring oil injection structure includes the second oil injection hole.
  • the opening of the first oil injection hole faces the inner peripheral wall of the stator winding, and the opening of the second oil injection hole faces the outer peripheral wall of the stator winding.
  • the stator cooling structure is equipped with an oil injection structure on the inside and outside of the stator winding, so the oil injection structure can be used to spray oil from the inside and outside of the stator winding at the same time, so that the end of the stator winding is cooled evenly inside and outside, ensuring the cooling of the stator winding
  • the uniformity of the stator winding can effectively avoid the problem of excessive local temperature caused by the uneven cooling of the stator winding, and prolong the service life of the motor.
  • FIG. 1 is a schematic cross-sectional structure diagram of a drive motor of the present application.
  • FIG. 2 is a schematic diagram of an enlarged structure at L in FIG. 1 .
  • FIG. 3 is a schematic diagram of an enlarged structure at M in FIG. 1 .
  • FIG. 4 is a flow channel diagram of a stator cooling structure of a drive motor according to an embodiment of the present application.
  • Fig. 5 is a three-dimensional structure diagram of an oil injection structure of the outer ring of the driving motor according to an embodiment of the present application.
  • FIG. 6 is a three-dimensional structure diagram of an inner ring oil injection structure of a drive motor according to an embodiment of the present application.
  • FIG. 7 is a schematic diagram of an exploded structure of a drive motor of the present application.
  • FIG. 8 is a three-dimensional structure diagram of an outer ring oil injection structure of a driving motor according to an embodiment of the present application.
  • FIG. 9 is a three-dimensional structure diagram of an inner ring oil injection structure of a driving motor according to an embodiment of the present application.
  • Fig. 10 is a structural diagram of cooling the front bearing of the driving motor according to an embodiment of the present application.
  • FIG. 11 is a schematic diagram of a casing structure of a driving motor according to an embodiment of the present application.
  • FIG. 12 is a schematic perspective view of the front end cover of the driving motor according to an embodiment of the present application.
  • Fig. 13 is an assembly structure diagram of the front end cover of the driving motor and the oil injection structure of the front inner ring according to an embodiment of the present application.
  • Fig. 14 is a schematic diagram of the assembly structure of the rear outer ring oil injection structure and the casing of the drive motor according to an embodiment of the present application.
  • Fig. 15 is a cross-sectional structure diagram of a T-shaped connecting pipe of a driving motor according to an embodiment of the present application.
  • Fig. 16 is a three-dimensional structure diagram of an outer ring oil injection structure of a driving motor according to an embodiment of the present application.
  • Fig. 17 is a schematic diagram of the expanded structure of the injection hole position of the front outer ring fuel injection structure of the driving motor according to an embodiment of the present application.
  • Fig. 18 is a schematic diagram showing the expanded structure of the injection hole position of the rear outer ring oil injection structure of the drive motor according to an embodiment of the present application.
  • Fig. 19 is a structural diagram of an oil circulation circuit in a cooling channel of a driving motor according to an embodiment of the present application.
  • the stator cooling structure is used to cool the stator winding 16, and the stator cooling structure includes the motor oil inlet 9, the inner ring oil injection structure and the outer ring oil injection structure , the inner ring oil injection structure is arranged on the inner peripheral side of the stator winding 16, the outer ring oil injection structure is arranged on the outer peripheral side of the stator winding 16, and both the inner ring oil injection structure and the outer ring oil injection structure are connected with the motor oil inlet 9,
  • the inner ring oil injection structure includes a first oil injection hole 10
  • the outer ring oil injection structure includes a second oil injection hole 45
  • the opening of the first oil injection hole 10 faces the inner peripheral wall of the stator winding 16, and the opening of the second oil injection hole 45 Towards the outer peripheral wall of the stator winding 16 .
  • the stator cooling structure is equipped with an oil injection structure on the inner and outer sides of the stator winding 16, so the oil injection structure can be used to carry out oil injection cooling from the inner and outer sides of the stator winding 16 at the same time, so that the end windings of the stator winding 16 are evenly cooled inside and outside, ensuring
  • the cooling uniformity of the stator winding 16 is improved, the problem of local overheating caused by uneven cooling of the stator winding 16 can be effectively avoided, the heat island effect inside the motor can be reduced, and the stability and service life of the motor can be improved.
  • the stator cooling structure of the embodiment of the present application adds an inner ring oil injection structure and an outer ring oil injection structure in the space between the stator winding 16 and the casing 19 inside the motor, and the stator winding 16 and the motor shaft 1, so it can fully
  • the internal space of the motor is used to arrange the cooling structure of the stator winding 16, so as to avoid additional increase in the size of the motor, and at the same time realize effective cooling of the stator winding 16 and improve the internal cooling performance of the motor.
  • the first oil injection hole 10 is arranged on the outer peripheral wall of the inner ring oil injection structure, and extends radially along the inner ring oil injection structure, since the stator winding 16 is located on the outer peripheral side of the inner ring oil injection structure, therefore , so that the first oil injection hole 10 extends radially along the inner ring oil injection structure, it can be ensured that when a plurality of first oil injection holes 10 are arranged circumferentially along the outer peripheral wall of the inner ring oil injection structure, each first oil injection The injection position of the hole 10 on the inner peripheral wall of the stator winding 16 is more precise, which facilitates the precise distribution of cooling oil and improves the oil cooling efficiency.
  • the setting of the first oil injection hole 10 can also be considered from other injection angles.
  • the first oil injection hole 10 can be compared to the stator iron.
  • the central axis of the core 17 is arranged obliquely, so that when the cooling oil in the first oil injection hole 10 is sprayed on the inner surface of the stator winding 16, a certain lateral component force can be formed, so that the cooling oil can spread a certain area along the axial direction , increasing the contact area between the cooling oil and the stator winding 16 , thereby improving the cooling efficiency of the cooling oil on the stator winding 16 .
  • first fuel injection holes 10 When a plurality of first fuel injection holes 10 are arranged at intervals along the circumference of the inner ring fuel injection structure, the first fuel injection holes 10 are divided into two groups, and a group of first fuel injection holes 10 faces the first end of the inner ring fuel injection structure.
  • the other group of first oil injection holes 10 is inclined toward the second end of the inner ring oil injection structure, and the two groups of first oil injection holes 10 are arranged alternately along the circumferential direction, so that the end winding of the stator winding 16 is All directions can fully contact with the cooling oil, thereby maximizing the contact area between the cooling oil and the stator winding 16, and improving the cooling effect of the cooling oil on the stator winding 16.
  • a group of first oil injection holes 10 extending radially and perpendicular to the central axis of the stator core 17 may be added to form three groups of first injection holes 10
  • the oil holes 10 and the three groups of first oil injection holes 10 are arranged alternately along the circumferential direction, so that the cooling oil can cover the stator winding 16 more comprehensively.
  • the oil injection structure of the inner ring can be a ring structure or a half-ring structure.
  • the oil injection structure of the inner ring is set above the motor spindle 1, and When the cooling oil reaches the inner wall surface of the stator winding 16, it will flow downward along the inner wall surface of the stator winding 16, so as to spread over the entire inner wall surface of the stator winding 16 under the action of gravity, forming a comprehensive cooling effect on the stator winding 16.
  • the effective cooling of the inner ring of the stator winding 16 can be achieved, and the oil injection structure of the inner ring of the half-ring structure, the material used Less will cost less.
  • the cooling oil will flow downward along the inner wall of the stator winding 16 under the action of gravity, the residence time at the top is relatively short. Therefore, when the first oil injection holes 10 on the inner ring oil injection structure When distributing, the cooling oil at the bottom of the stator winding 16 will be enriched, and the amount of cooling oil at the top will be slightly insufficient. After adopting the inner ring oil injection structure of the half-ring structure, the cooling oil will be more efficient under the same amount of cooling oil.
  • the second oil injection hole 45 is arranged on the inner peripheral wall of the oil injection structure of the outer ring, and extends along the radial direction of the oil injection structure of the outer ring. Since the stator winding 16 is located on the inner peripheral side of the oil injection structure of the outer ring, therefore , so that the second oil injection hole 45 extends radially along the outer ring oil injection structure, it can be ensured that when a plurality of second oil injection holes 45 are arranged circumferentially along the inner peripheral wall of the outer ring oil injection structure, each second oil injection The injection position of the hole 45 on the outer peripheral wall of the stator winding 16 is more precise, which is more convenient for precise distribution of cooling oil and improves the oil cooling efficiency.
  • the setting of the second oil injection hole 45 can also be considered from other injection angles.
  • the second oil injection hole 45 can be compared to the stator iron.
  • the central axis of the core 17 is inclined, so that when the cooling oil in the second oil injection hole 45 is sprayed on the outer surface of the stator winding 16, a certain lateral component force can be formed, so that the cooling oil can spread a certain area along the axial direction , increasing the contact area between the cooling oil and the stator winding 16 , thereby improving the cooling efficiency of the cooling oil on the stator winding 16 .
  • the second fuel injection holes 45 are divided into two groups, and one group of second fuel injection holes 45 faces the first end of the outer ring fuel injection structure.
  • the other group of second oil injection holes 45 is inclined toward the second end of the outer ring oil injection structure, and the two groups of second oil injection holes 45 are arranged alternately along the circumferential direction, so that the end winding of the stator winding 16 All directions can fully contact with the cooling oil, thereby maximizing the contact area between the cooling oil and the stator winding 16, and improving the cooling effect of the cooling oil on the stator winding 16.
  • a group of second oil injection holes 45 extending radially and perpendicular to the central axis of the stator core 17 may be added to form three groups of second oil injection holes.
  • the holes 45 and the three groups of second oil injection holes 45 are arranged alternately along the circumferential direction, so that the cooling oil can cover the stator winding 16 more comprehensively.
  • the oil injection structure of the outer ring can be a ring structure or a half-ring structure.
  • the oil injection structure of the outer ring is set above the motor spindle 1, and the oil sprayed by the outer ring structure is
  • the cooling oil reaches the outer wall surface of the stator winding 16, it will flow downward along the outer wall surface of the stator winding 16, so as to spread over the entire outer wall surface of the stator winding 16 under the action of gravity, forming a comprehensive cooling effect on the stator winding 16.
  • the cooling oil will flow downward along the outer wall of the stator winding 16 under the action of gravity, and stay at the top for a short time, when the second oil injection holes 45 on the outer ring oil injection structure are evenly arranged in the circumferential direction At the same time, the cooling oil at the bottom of the stator winding 16 will be enriched, and the cooling oil at the top will be slightly insufficient. However, after the outer ring oil injection structure of the half-ring structure is adopted, the cooling oil will be more concentrated under the same cooling oil volume.
  • the ground flows to the top position of the outer ring of the stator winding 16, so that the top of the outer ring of the stator winding 16 can have more cooling oil for cooling, thereby improving the cooling effect of the top winding of the stator winding 16, and at the same time, the cooling oil goes down along the top of the stator winding 16 During the flowing process, the lower stator winding 16 can be effectively cooled, so that the cooling effect of the cooling oil on the stator winding 16 can be improved as a whole.
  • first oil injection holes 10 there are a plurality of first oil injection holes 10, and the plurality of first oil injection holes 10 are evenly spaced along the outer circumference of the inner ring oil injection structure, which can improve the stability of the first oil injection holes 10 in the stator winding. Uniformity of fuel injection distribution on the 16.
  • the oil injection structure of the inner ring and the oil injection structure of the outer ring are arranged in groups to form a fuel injection ring assembly, and the oil injection structure of the inner ring of the same oil injection ring assembly is located radially inside the oil injection structure of the outer ring.
  • An oil injection cooling space is formed between the oil injection structure of the inner ring and the oil injection structure of the outer ring, and the end winding of the stator winding 16 is arranged in the oil injection cooling space, so it will be affected by the oil injection structure of the inner ring and the oil injection structure of the outer ring at the same time.
  • the oil spray cooling can not only form the cooling oil cooling from the circumferential direction, but also form the cooling oil cooling from the inner and outer sides, which can make the cooling target of the cooling oil clearer, the cooling area is more concentrated, and the cooling efficiency of the cooling oil is higher , form the centralized cooling of the stator winding 16, realize the centralized cooling of the large heat source inside the motor, and the utilization efficiency of the cooling oil is higher.
  • the end winding of the stator winding 16 is a winding portion where the designated sub-winding 16 protrudes from both ends of the stator core 17 .
  • the stator winding 16 Since the stator winding 16 is located inside the oil injection structure of the outer ring and outside the oil injection structure of the inner ring, the cooling oil at the top of the oil injection structure of the outer ring can Under the action, it flows to the surface of the stator winding 16, and if the cooling oil sprayed by the inner ring oil injection structure is too far away from the stator winding 16, or the injection pressure is insufficient, the cooling oil of the inner ring oil injection structure cannot reach the stator winding 16
  • the stator winding 16 is cooled, therefore, under the same cooling oil pressure, the distance between the oil injection structure of the inner ring and the stator winding 16 is smaller than the distance between the oil injection structure of the outer ring and the stator winding 16, as a preferred implementation
  • the distance between the oil injection structure of the inner ring and the stator winding 16 is L1
  • the distance between the oil injection structure of the outer ring and the stator winding 16 is L2, where L1 ⁇ 0.9L2, so that the oil injection cooling space
  • the cooling oil injected from 10 can form a sputtering effect on the surface of the stator winding 16, further increase the distribution area of the cooling oil after reaching the surface of the stator winding 16, and improve the heat exchange efficiency between the cooling oil and the stator winding 16.
  • stator winding 16 since the stator winding 16 includes an end winding at the front end and an end winding at the rear end, there are at least two fuel injection ring assemblies, and the first end of the stator winding 16, that is, the rear end winding is provided correspondingly There is at least one oil injection ring assembly, and the second end of the stator winding 16, that is, the front end winding, is correspondingly provided with at least one oil injection ring assembly, and the end winding of the stator winding 16 is located at the inner circle of the oil injection ring assembly and the outer In this way, both the inner ring oil injection structure and the outer ring oil injection structure are used for oil injection cooling at the front end winding and the rear end end winding of the stator winding 16, so the stator can be cooled at the same time Both ends of the winding 16 are cooled inside, outside and in the circumferential direction, which can further improve the cooling efficiency and cooling effect of the stator winding 16 .
  • the oil injection ring assemblies located at both ends of the stator winding 16 are in communication with the motor oil inlet 9, so only one motor oil inlet 9 is needed to supply oil to the oil injection ring assemblies at both ends of the stator winding 16,
  • the structure is simpler and the implementation is more convenient.
  • two motor oil inlets 9 can also be arranged in parallel, wherein one motor oil inlet 9 communicates with the oil injection ring assembly at the rear end of the motor, and the other motor oil inlet 9 communicates with the oil injection ring assembly at the front end of the motor. connected, oil can be directly supplied to each oil injection ring assembly through two motor oil inlets 9, and the oil supply quantity and oil supply pressure of each oil injection ring assembly can be guaranteed.
  • the outer ring oil injection structure is used to cool the outer ring of the stator winding 16
  • the outer ring oil injection structure includes a body, the body is built with channels extending in the circumferential direction, and the inner wall of the body is provided with a second
  • the oil injection hole 45 and the second oil injection hole 45 communicate with the channel corresponding to the second oil injection hole 45
  • a plurality of second oil injection holes 45 are circumferentially arranged along the inner wall surface of the main body.
  • a plurality of passages can be arranged at intervals along the circumference of the body, and can also communicate along the circumference.
  • the second oil injection holes 45 of the outer ring oil injection structure are arranged circumferentially along the inner wall surface of the main body, and can cool the outer ring of the stator winding 16 along the circumferential direction, so that the cooling of the stator winding 16 can be made uniform, and the stator winding 16 can be avoided.
  • the winding 16 has the problem of local overheating, which improves the stability and service life of the motor.
  • the second oil injection hole 45 includes a main oil injection hole 46 and an auxiliary oil injection hole 47, and the main oil injection hole 46 is circumferentially arranged in a linear direction on the unfolded structure of the inner wall surface of the body, at least partly auxiliary
  • the oil injection hole 47 is arranged on the peripheral side of the main oil injection hole 46 at the top of the main body, and the main oil injection hole 46 is arranged in the middle of the inner wall along the axial direction.
  • the main oil injection hole 46 is a basic oil injection hole arranged in the middle of the axial direction of the body, and the auxiliary oil injection hole 47 surrounds the main oil injection hole according to the heating position of the stator winding 16 and the shape and structure of the stator winding 16.
  • the hole 46 is designed, the main oil injection hole 46 can be used to meet the basic oil supply requirements of the stator winding 16, and the auxiliary oil injection hole 47 can be used to carry out targeted oil supply according to the characteristics of the stator winding 16, so that the oil supply of the stator winding 16 can be matched with the stator winding 16.
  • the structure and heating characteristics of the winding 16 are matched to achieve uniform cooling of the stator winding 16 and improve the cooling effect and cooling efficiency of the stator winding 16 .
  • the main oil injection holes 46 are evenly arranged along the inner wall surface of the main body. It is more necessary to achieve uniform oil supply at each position of the stator winding 16, and the oil supply to the key area of the stator winding 16 needs to be realized through the auxiliary oil injection hole 47, so that the function of the oil injection hole is improved. After the division, the structural design and position design of the oil injection hole are more clear, and the design difficulty is also greatly reduced. After the main oil injection hole 46 meets the design requirements, auxiliary oil injection can be performed according to the characteristics of the stator winding 16 and the heating position The precise design of the hole 47 uses the auxiliary oil injection hole 47 to achieve targeted cooling.
  • the oil injection structure of the outer ring is divided into the front outer ring oil injection structure 23 and the rear outer ring oil injection structure 14 according to the different setting positions, and the motor oil inlet 9 supplies the two outer ring oil injection structures at the same time. oil, and the motor oil inlet 9 is set at the rear end of the motor. In this case, since the front outer ring oil injection structure 23 is farther away from the motor oil inlet 9, the pressure loss is greater.
  • the oil supply pressure and oil supply volume of the front outer ring oil injection structure 23 are smaller than the rear outer ring oil injection structure 14, therefore, in order to ensure that the front outer ring oil injection structure 23 Consistency with the oil supply quantity of the rear outer ring oil injection structure 14, the total area of the second oil injection holes 45 of the front outer ring oil injection structure 23 is greater than the total area of the second oil injection holes 45 of the rear outer ring oil injection structure 14 Therefore, the oil injection area is used to compensate for the insufficient oil quantity, and the oil supply consistency of the outer ring oil injection structure at the front and rear ends is realized.
  • the rear outer ring oil injection structure 14 is provided with an auxiliary oil injection hole 47 on at least one circumferential side of the main oil injection hole 46 at the top.
  • auxiliary oil injection holes 47 are respectively provided on both circumferential sides of the main oil injection hole 46 at the top.
  • stator winding 16 For the rear outer ring oil injection structure 14, since the top calorific value of the stator winding 16 is the largest in the entire stator winding 16, and the cooling oil stays at the top of the stator winding 16 for a short time, if the oil is insufficient, it will cause the stator winding 16 The top position with the largest calorific value cannot be sufficiently and effectively cooled, so that the top of the stator winding 16 is still prone to the problem of local overheating.
  • Retrofit increase the number of the second oil injection holes 45 in this area, so that the cooling oil can cool the top position of the outer ring of the stator winding 16 in a large amount and continuously, by increasing the oil supply of the top coil of the stator winding 16 In this way, the cooling of the large heat-generating part on the top of the stator winding 16 is realized.
  • auxiliary oil injection holes 47 on both sides of the main oil injection hole 46 at the top in the circumferential direction, the area of the oil injection holes at the top of the rear outer ring oil injection structure 14 is increased, and the stator is enlarged.
  • the amount of oil supplied to the top of the winding 16 is to increase the number of auxiliary oil injection holes 47 around the main oil injection hole 46 on the top to achieve focused cooling on the top of the stator winding 16 and ensure the cooling of the top of the stator winding 16 Effect.
  • At least two auxiliary oil injection holes 47 are respectively arranged on both sides of the main oil injection hole 46 at the top, in the auxiliary oil injection hole 47 between the main oil injection hole 46 at the top and the adjacent main oil injection hole 46 , the auxiliary fuel injection hole 47 adjacent to the adjacent main fuel injection hole 46 is located in the middle of the top main fuel injection hole 46 and the adjacent main fuel injection hole 46 .
  • Four auxiliary oil injection holes 47 are arranged on the side, thereby greatly increasing the area of the oil injection hole corresponding to the top area of the stator winding 16, increasing the amount of oil injection, and effectively cooling the top of the stator winding 16.
  • the auxiliary injection hole 47 close to the adjacent main injection hole 46 is located in the middle of the top main injection hole 46 and the adjacent main injection hole 46, and the two auxiliary injection holes on one side of the top main injection hole 46
  • the oil holes 47 are arranged at even intervals, which can realize the uniform distribution of the auxiliary oil injection holes 47 on both sides of the main oil injection hole 46 on the top, and realize the uniform oil supply to different regions on the top of the stator winding 16 .
  • the main oil injection hole 46 adjacent to the top main oil injection hole 46 is provided with an auxiliary oil injection hole 47 on a side away from the top main oil injection hole 46 .
  • the number of auxiliary oil injection holes 47 arranged on the side of the main oil injection hole 46 away from the top is two, and they are respectively arranged on both sides of the center line of the adjacent main oil injection holes 46 .
  • the main fuel injection hole 46 adjacent to the main fuel injection hole 46 at the top is the first adjacent main fuel injection hole 46, and the first adjacent main fuel injection hole 46 is adjacent to the main fuel injection hole 46.
  • the main oil injection hole 46 is the second adjacent main oil injection hole 46, and the position between the first adjacent main oil injection hole 46 and the second adjacent main oil injection hole 46 is provided with two Auxiliary injection holes 47, two auxiliary injection holes 47 are arranged in the axial direction, and are respectively located in the center connection with the first adjacent main injection hole 46 and the second adjacent main injection hole 46.
  • the main function is to realize oil replenishment in this area.
  • auxiliary oil injection holes 47 are set corresponding to the two ends of the end winding respectively, so that the oil supply to the end winding can be realized, so that the cooling oil can be redistributed to the two ends of the end winding here, and then from the The regions flow downward to achieve the purpose of effectively cooling each region at the end of the stator winding 16 .
  • the winding at the top Auxiliary oil injection holes 47 are respectively provided on both axial sides of the main oil injection hole 46 .
  • auxiliary oil injection holes 47 are provided on both axial sides of the main oil injection hole 46 at the top.
  • a total of six auxiliary oil injection holes 47 are arranged on the peripheral side, which can supply oil to both the axial and circumferential directions of the top of the stator winding 16, so that the oil injection holes in the top area can be evenly distributed to the heat source of the coil, and the cooling effect is optimal.
  • the body is provided with an outer ring oil inlet 34, the outer ring oil inlet 34 is located on the circumferential side of the main oil injection hole 46 at the top, and the auxiliary oil injection hole on the side where the outer ring oil inlet 34 is located 47 is less than the number of auxiliary oil injection holes 47 on the other side of the circumference of the main oil injection hole 46 located at the top.
  • the main oil injection hole 46 at the top is provided on the side of the outer ring oil inlet 34, and at least part of the adjacent main oil injection holes 46 are provided with auxiliary oil injection holes 47, and the auxiliary oil injection holes 47 It is arranged on the side of the main oil injection hole 46 away from the outer edge of the stator winding 16 .
  • the oil injection structure of the outer ring is a full ring or half ring structure.
  • adjacent passages communicate along the circumferential direction to form a second annular passage 50 penetrating in the circumferential direction.
  • the front outer ring oil injection structure 23 is provided with an auxiliary oil injection hole 47 on at least one circumferential side of the main oil injection hole 46 at the top.
  • auxiliary oil injection holes 47 are respectively provided on both circumferential sides of the main oil injection hole 46 at the top.
  • the structure of the front outer ring oil injection structure 23 is basically the same as that of the rear outer ring oil injection structure 14 , the difference lies in that the number and location of the second oil injection holes 45 are different.
  • an auxiliary oil injection hole 47 is provided on one axial side of the main oil injection hole 46 at the top of the front outer ring oil injection structure 23 .
  • the calorific value of the front end winding of the stator winding 16 is less than that of the rear end end winding, it can be compared with the main oil injection structure at the top of the rear outer ring oil injection structure 14.
  • the half-ring structure not only has less material and lower cost, but also effectively controls the maximum temperature of the coil winding, and the maximum temperature of the coil winding is reduced by at least 7°C.
  • the percentage reduction is at least 7%, which effectively improves the temperature distribution uniformity of the coil winding, especially for the front outer ring oil injection ring structure, after adopting the half-ring structure, the maximum temperature is reduced by 28.6%, and the average temperature is reduced by 17.0% , so that the maximum temperature and the average temperature of the coil winding corresponding to the oil injection ring of the front outer ring are greatly reduced, and the coil winding has a more effective cooling effect.
  • the body is provided with an outer ring oil inlet 34, the outer ring oil inlet 34 is located on the circumferential side of the main oil injection hole 46 at the top, and the auxiliary oil injection hole on the side where the outer ring oil inlet 34 is located 47 is less than the number of auxiliary oil injection holes 47 on the other side of the circumference of the main oil injection hole 46 located at the top. Due to the existence of the outer ring oil inlet 34, the main oil injection hole 46 and the auxiliary oil injection hole 47 located on the same side of the outer ring oil inlet 34 can have greater injection pressure and injection flow rate. Therefore, in order to make the main injection hole at the top The cooling oil on both sides of the oil hole 46 is distributed more evenly. By adjusting the number of auxiliary oil injection holes 47 on both sides of the main oil injection hole 46 on the top, the two sides of the main oil injection hole 46 on the top can be adjusted. Consistency of cooling oil supply.
  • the main oil injection hole 46 at the top is provided on the side of the outer ring oil inlet 34, and at least part of the adjacent main oil injection holes 46 are provided with auxiliary oil injection holes 47, and the auxiliary oil injection holes 47 It is arranged on the side of the main oil injection hole 46 away from the outer edge of the stator winding 16 .
  • the coil height of the outer edge of the end winding at the top position is higher than the coil height of the inner edge of the end winding, therefore, the coil height of the outer edge of the end winding located in the area below the middle position is lower
  • the auxiliary oil injection hole 47 is arranged on the side of the main oil injection hole 46 away from the outer edge of the stator winding 16, so that it is close to the inner edge of the end winding.
  • the cooling oil When the cooling oil is under the action of gravity When flowing downward, it will flow from the inner edge of the higher end winding to the outer edge of the lower end winding, so that only one side of the stator winding 16 in the axial direction needs to be supplemented with oil, and the entire stator winding 16 can be realized.
  • the design of the auxiliary oil injection hole 47 is more compatible with the structure of the motor winding, the cooling effect for the stator winding 16 is also better, and the utilization efficiency of the cooling oil is also higher.
  • auxiliary oil injection holes 47 are arranged at the position of the two auxiliary oil injection holes 47, which are arranged in the axial direction, and are respectively located in the first adjacent main oil injection hole 46 and the second adjacent main oil injection hole.
  • Two auxiliary oil injection holes 47 are arranged between the second adjacent main oil injection hole 46 and the third adjacent main oil injection hole 46, and the two auxiliary oil injection holes 47 are arranged in the axial direction , and are respectively located on both sides of the line connecting the centers of the second adjacent main oil injection hole 46 and the third adjacent main oil injection hole 46, and are mainly used to realize oil replenishment in this area.
  • the oil supply is less, and more auxiliary oil injection holes 47 are needed to supplement the oil supply to realize the two sides of the main oil injection hole 46 on the top.
  • the amount of oil supplied is consistent, meeting the uniform cooling requirements of the front end winding of the stator winding 16.
  • the structure of the second oil injection hole 45 on the circumferential sides of the main oil injection hole 46 at the top can also adopt a symmetrical structure, which can also achieve the cooling effect on the winding at the front end of the stator winding 16 .
  • the oil injection structure of the inner ring is made of plastic materials, such as PA, PP, ABS and so on.
  • the oil injection structure of the inner ring includes at least two first split structures, and the at least two first split structures are sequentially connected end to end along the circumferential direction to form the oil injection structure of the inner ring.
  • the oil injection structure of the inner ring adopts a split structure, which can reduce the difficulty of forming the oil injection structure of the inner ring, facilitate the design and processing of the internal oil circuit structure of the inner ring oil injection structure, improve processing efficiency, and reduce processing costs.
  • the first split structure includes a male end 51 at the first end and a female end 52 at the second end.
  • the male end 51 of the adjacent first split structure is fixedly connected with the female end 52.
  • the oil injection structure of the inner ring forms a first annular passage 49 penetrating in the circumferential direction, and the first oil injection hole 10 communicates with the first annular passage 49 .
  • Two adjacent first split structures are connected through the male end 51 and the female end 52.
  • a sealing ring 35 is arranged between the two adjacent first split structures. All the first split structures The split structures are arranged sequentially along the circumferential direction and connected end to end, and are combined to form a ring-shaped inner ring oil injection structure.
  • the inner ring fuel injection structure forms an annular penetrating fluid domain through the first annular passage 49, and the outer ring of the inner ring fuel injection structure is provided with a plurality of first fuel injection holes 10, and each first fuel injection hole 10 is connected with the first annular passage. 49, and the cooling oil is distributed through the first annular channel 49.
  • the cooling oil enters the inner ring oil injection structure from the inner ring oil inlet 33, the cooling oil can be radially sprayed from the first oil injection hole 10 to The inside of the end winding of the stator winding 16 cools the end winding of the stator winding 16 .
  • both the male end 51 and the female end 52 are arranged on the inner peripheral side of the first split structure, and the male end 51 and the female end 52 are plugged together to form the inner ring installation boss 38, and the inner ring installation boss 38 is provided with a first connection hole penetrating in the axial direction.
  • the front end cover 26 and the rear end cover 11 of the motor are respectively provided with installation structures that match the oil injection structure of the inner ring, and installation holes extending in the axial direction are provided on the installation structures, and the first connecting hole is correspondingly provided with the installation holes.
  • the inner ring oil injection structure cooperates with the installation hole on the installation structure through the first connecting hole on the inner ring mounting boss 38, and is connected by bolts to realize the inner ring oil injection structure on the front end cover 26 and the rear end cover 11.
  • the installation is fixed.
  • the height of the inner ring mounting boss 38 can control the relative position of the inner ring oil injection structure relative to the end winding of the stator winding 16, so as to achieve the best cooling position.
  • the structure of the female end 52 includes two protruding plates arranged oppositely, and a slot is formed between the two protruding plates, and the structure of the male end 51 includes a protruding block, and the protruding block corresponds to the slot between the two protruding plates.
  • a first plug-in structure 53 is provided on the end face of the end where the male end 51 of the first split structure is located, and a second plug-in structure 54 is provided on the end face of the end where the female end 52 of the first split structure is located,
  • the first plug-in structure 53 and the second plug-in structure 54 are plug-fitted to form a sealed connection.
  • the plug-in fit between two adjacent first split structures can be realized,
  • the plugging fit between the first plug-in structure 53 and the second plug-in structure 54 can be used to improve the sealing performance of the adjacent first split structures at the connection positions.
  • a sealing ring 35 and the like can be provided at the mating position of the two plug-in structures.
  • the first plugging structure 53 is a socket
  • the slot is, for example, a cylindrical groove
  • the second plugging structure 54 is a plug
  • the plug is, for example, a cylindrical head adapted to the cylindrical groove.
  • the annular passage 49 runs through the plug along the circumferential direction, and when the plug is mated with the socket, the first annular passages 49 of adjacent first split structures communicate with each other. Since there is a long matching length between the cylindrical groove and the cylindrical head, it is more convenient to arrange a sealing ring 35 between the groove wall of the cylindrical groove and the outer wall of the cylindrical head to form a seal.
  • the first plug-in structure 53 and the second plug-in structure 54 are used to form a seal, it is equivalent to separately setting the fixed connection and sealing function between adjacent first split structures, using the male end 51 and The female end 52 realizes the fixed connection, and utilizes the plug-in cooperation of the first plug-in structure 53 and the second plug-in structure 54 to realize sealing. Therefore, the connection between the male end 51 and the female end 52 does not need to consider the sealing problem.
  • the first plug-in structure The plug-and-socket fit between the connecting structure 53 and the second plug-in structure 54 does not need to consider the connection problem, so that the respective functions are simpler and the structural design is simpler.
  • the structure can be further strengthened. The effect of the desired function enables the connection structure and sealing performance between the adjacent first split structures to be further enhanced.
  • At least one of the first split structures is provided with an inner ring oil inlet 33
  • the motor oil inlet 9 communicates with the inner ring oil inlet 33
  • the inner ring oil inlet 33 is connected to the first annular passage 49 connected.
  • the oil supplied by the motor oil inlet 9 enters the first annular passage 49 through the inner ring oil inlet 33, and then is sprayed out from each first oil injection hole 10 to the end winding of the stator winding 16 through the first annular passage 49 , to cool the stator winding 16.
  • the oil inlet port 33 of the inner ring is provided with a first oil inlet joint, and the first oil inlet joint is arranged on the axial end surface of the oil injection structure of the inner ring.
  • the first oil inlet joint is arranged on the axial end surface of the oil injection structure of the inner ring, and the axial end surface faces the outside of the motor. Since the oil injection structure of the inner ring is installed The axial position corresponds to the rotor assembly, the radially outside corresponds to the stator winding 16, and the radially inside corresponds to the motor shaft 1.
  • the structure is fixed on the end cover located outside the oil injection structure of the inner ring, and is fixedly connected with the end cover, and the oil delivery pipeline is also arranged on the end cover correspondingly, and corresponds to the first oil inlet joint of the inner ring oil injection structure position to achieve a sealed connection.
  • the oil injection structure of the inner ring is integrally formed. Since the oil injection structure of the inner ring can be formed by injection molding, the oil injection structure of the inner ring can be directly formed into an integrated structure by injection molding, thereby improving the structural integrity of the oil injection structure of the inner ring and improving the oil injection structure of the inner ring. Excellent sealing performance, reducing installation procedures and improving installation efficiency.
  • the outer edge of the inner ring oil injection structure is provided with an annular flange extending along the axial direction of the inner ring oil injection structure, and the outer peripheral wall of the annular flange is flush with the outer peripheral wall of the inner ring oil injection structure.
  • the annular flange extends outward toward the side where the end cover is located, which can extend the axial length of the outer peripheral wall of the inner ring oil injection structure, increase the matching area between the inner ring oil injection structure and the stator winding 16, and make the inner ring oil injection structure A larger contact oil film can be formed with the stator winding 16 for heat exchange, improving the heat exchange efficiency of the stator winding 16 .
  • the oil injection structure of the inner ring is made of plastic materials, such as PA, PP, ABS and so on.
  • the oil injection structure of the outer ring includes a plurality of second split structures, and the second split structures are sequentially connected end-to-end along the circumferential direction to form the oil injection structure of the outer ring.
  • the oil injection structure of the outer ring adopts a split structure, which can reduce the difficulty of forming the oil injection structure of the outer ring, facilitate the design and processing of the internal oil circuit structure of the oil injection structure of the outer ring, improve processing efficiency, and reduce processing costs.
  • the second split structure includes a male end 51 at the first end and a female end 52 at the second end.
  • the male end 51 of the adjacent second split structure is fixedly connected with the female end 52.
  • a second annular channel 50 penetrating in the circumferential direction is formed in the oil injection structure of the outer ring, and the second oil injection hole 45 communicates with the second annular channel 50 .
  • Two adjacent second split structures are connected through the male end 51 and the female end 52.
  • a sealing ring 35 is arranged between the two adjacent second split structures. All the second split structures The split structures are arranged sequentially along the circumferential direction and connected end to end, and are combined to form a ring-shaped outer ring fuel injection structure.
  • the inside of the outer ring fuel injection structure forms an annular penetrating fluid domain through the second annular channel 50.
  • the outer ring of the outer ring fuel injection structure is provided with a plurality of second oil injection holes 45, and each second oil injection hole 45 is connected to the second annular channel. 50, and distribute the cooling oil through the second annular channel 50.
  • the cooling oil enters the oil injection structure of the outer ring from the inner ring oil inlet 33, the cooling oil can be radially sprayed from the second oil injection hole 45 to The inside of the end winding of the stator winding 16 cools the end winding of the stator winding 16 .
  • both the male end 51 and the female end 52 are arranged on the outer peripheral side of the second split structure, and the male end 51 and the female end 52 are plugged together to form the outer ring mounting boss 37, and the outer ring mounting boss 37
  • a second connection hole penetrating in the axial direction is arranged on the top.
  • an outer ring mounting seat 39 is provided at a position corresponding to the outer ring mounting boss 37.
  • the outer ring mounting seat 39 includes a mounting groove, and an axially extending mounting hole is provided at the bottom of the mounting groove.
  • the connecting holes are set corresponding to the mounting holes, and the oil injection structure of the outer ring is installed in the axial direction, so that the outer ring mounting boss 37 enters the mounting groove of the outer ring mounting seat 39, and slides to the mounting position along the mounting groove, so that The outer ring mounting boss 37 stops at the bottom of the mounting groove.
  • the second connection hole on the outer ring mounting boss 37 matches the mounting hole on the mounting structure, and is connected by bolts to realize the oil injection structure of the outer ring.
  • the installation of casing 19 is fixed.
  • the structure of the female end 52 includes two protruding plates arranged oppositely, and a slot is formed between the two protruding plates, and the structure of the male end 51 includes a protruding block, and the protruding block corresponds to the slot between the two protruding plates.
  • a first plug-in structure 53 is provided on the end face of the end where the male end 51 of the second split structure is located, and a second plug-in structure 54 is provided on the end face of the end where the female end 52 of the second split structure is located,
  • the first plug-in structure 53 and the second plug-in structure 54 are plug-fitted to form a sealed connection.
  • the plug-in fit between two adjacent second split structures can be realized,
  • the sealing performance of the adjacent second split structure at the connection position can be improved by utilizing the plug-in fit between the first plug-in structure 53 and the second plug-in structure 54 .
  • a sealing ring 35 and the like may be provided at the matching positions of the two plug-in structures.
  • the first plugging structure 53 is a socket
  • the slot is, for example, a cylindrical groove
  • the second plugging structure 54 is a plug
  • the plug is, for example, a cylindrical head adapted to the cylindrical groove.
  • the annular channel 50 runs through the plug along the circumferential direction, and when the plug is mated with the socket, the second annular channels 50 of adjacent second split structures communicate with each other. Since there is a long matching length between the cylindrical groove and the cylindrical head, it is more convenient to arrange a sealing ring 35 between the groove wall of the cylindrical groove and the outer wall of the cylindrical head to form a seal.
  • the seal is formed by the plug-in fit of the first plug-in structure 53 and the second plug-in structure 54, it is equivalent to separately setting the fixed connection and sealing function between the adjacent second split structures, using the male end 51 and The female end 52 realizes the fixed connection, and utilizes the plug-in cooperation of the first plug-in structure 53 and the second plug-in structure 54 to realize sealing. Therefore, the connection between the male end 51 and the female end 52 does not need to consider the sealing problem.
  • the first plug-in structure The plug-and-socket fit between the connecting structure 53 and the second plug-in structure 54 does not need to consider the connection problem, so that the respective functions are simpler and the structural design is simpler.
  • the structure can be further strengthened. The effect of the desired function enables the connection structure and sealing performance between the adjacent second split structures to be further enhanced.
  • At least one of the second split structures is provided with an outer ring oil inlet 34, the outer ring oil inlet 34 is connected to the motor oil inlet 9, and the outer ring oil inlet 34 is connected to the second annular passage 50 connected.
  • the oil supplied by the motor oil inlet 9 enters the second annular passage 50 through the outer ring oil inlet 34, and then is sprayed out from each second oil injection hole 45 to the end winding of the stator winding 16 through the second annular passage 50 , to cool the stator winding 16.
  • a second oil inlet joint is provided at the oil inlet port 33 of the inner ring, and the second oil inlet joint is arranged on the outer peripheral wall of the oil injection structure of the outer ring.
  • the second oil inlet joint is arranged on the outer peripheral wall of the oil injection structure of the outer ring, and an avoidance groove is provided at a corresponding position on the casing 19, and the second oil inlet joint can slide into the installation position along the avoidance groove, The installation and positioning of the oil injection structure of the outer ring in the casing 19 is realized.
  • the oil injection structure of the outer ring is integrally formed. Since the oil injection structure of the outer ring can be formed by injection molding, the oil injection structure of the outer ring can be directly formed into an integrated structure by injection molding, thereby improving the structural integrity of the oil injection structure of the outer ring and improving the oil injection structure of the outer ring. Excellent sealing performance, reducing installation procedures and improving installation efficiency.
  • the outer edge of the inner peripheral wall of the outer ring oil injection structure is provided with an annular flange extending along the axial direction of the outer ring oil injection structure, and the inner peripheral wall of the annular flange is flush with the inner peripheral wall of the outer ring oil injection structure.
  • the annular flange extends outward toward the side where the end cover is located, which can extend the axial length of the inner peripheral wall of the outer ring oil injection structure, increase the matching area between the outer ring oil injection structure and the stator winding 16, and make the outer ring oil injection structure A larger contact oil film can be formed with the stator winding 16 for heat exchange, improving the heat exchange efficiency of the stator winding 16 .
  • the embodiment of the application also discloses a bearing cooling structure, including an end cover, the end cover is provided with a bearing chamber, the bearing chamber is provided with a bearing 2, and the end cover is also provided with cooling oil for supplying oil to the inner ring oil injection structure
  • the bearing chamber is connected with the cooling oil passage through the bearing oil supply passage, and the bearing chamber is supplied with oil through the cooling oil passage.
  • the above-mentioned communication refers to the state between the bearing chamber and the cooling oil circuit, and does not mean that there is a direct connection relationship between the bearing chamber, the bearing oil supply circuit and the cooling oil circuit. Both indirect communication and direct communication should be within the scope of protection of this application Inside.
  • the bearing cooling structure uses the oil supply circuit of the inner ring oil injection structure to supply oil to the bearing chamber, so the system's own oil circuit can be used to provide the cooling oil circuit for the bearing chamber, and the existing cooling oil circuit can be used to provide cooling oil for the bearing.
  • An additional separate bearing cooling oil circuit is added, and the structure of the oil circuit is simpler, so that the structure of the motor is also simpler, and the processing cost can be effectively controlled.
  • the end cover in this embodiment includes a front end cover 26 and a rear end cover 11, wherein the front end cover 26 is the end cover at the end where the shaft extension end of the motor main shaft 1 is located, and the rear end cover 11 is the end that is arranged at the other end of the motor main shaft 1 cover.
  • the inner ring oil injection structure in this embodiment includes a front inner ring oil injection structure 29 and a rear inner ring oil injection structure 6, wherein the front inner ring oil injection structure 29 is connected to the front end cover 26, and the rear inner ring oil injection structure 6 is connected to the rear inner ring oil injection structure 6.
  • the end cover 11 is connected, and the structure of the fuel injection structure 29 of the front inner ring and the structure of the fuel injection structure 6 of the rear inner ring can be completely the same, or basically the same, and only differ in some parts, or two inner rings with different structures can be used.
  • the bearing 2 includes a front bearing and a rear bearing, wherein the front bearing is arranged in the bearing chamber of the front end cover 26 , and the rear bearing is arranged in the bearing chamber of the rear end cover 11 .
  • Bearing steel sleeves 3 are also arranged in each bearing chamber, due to strengthening the structural strength of the bearing chamber.
  • the cooling oil can be introduced into the bearing chamber of the motor, so as to achieve targeted lubrication of the motor bearings, save costs, and prolong the service life of the bearings.
  • the motor oil inlet 9 is arranged on the end cover, and the cooling oil circuit includes a radial flow channel and an axial flow channel.
  • the radial flow channel communicates with the motor oil inlet 9.
  • the flow passage communicates with the oil injection structure of the inner ring.
  • the oil injection structure of the inner ring needs to be connected with the end cover, and the position design needs to correspond to the stator winding 16, it is necessary to arrange the oil injection structure of the inner ring and the end cover in sequence along the axial direction, And the connection between the inner ring fuel injection structure and the end cover is realized at the axial position, thereby increasing the axial protrusion height of the inner ring oil injection structure relative to the end cover, so that after the inner ring oil injection structure is installed on the end cover, The axial position of the oil injection structure of the inner ring can correspond to the end winding of the stator winding 16, so as to realize the cooling of the inner ring of the end winding by the oil injection structure of the inner ring.
  • the axial flow is set on the end cover, and the first oil inlet joint of the oil injection structure of the inner ring is extended in the axial direction to realize docking with the installation structure on the end cover.
  • the installation structure of the end cover is provided with a shaft To the flow channel, it can communicate with the axial flow channel of the first oil inlet joint, so as to supply the cooling oil in the cooling oil circuit to the first annular channel 49 of the inner ring oil injection structure, and realize the supply to the inner ring oil injection structure. Oil.
  • one end of the end cover facing the oil injection structure of the inner ring is provided with a mounting structure for installing the oil injection structure of the inner ring.
  • the oil injection structure protrudes, and the inner ring oil injection structure is installed on the inner ring mounting seat 43 through the inner ring mounting boss 38, and is fixed and locked by screws.
  • the multiple inner ring mounting seats 43 there are multiple inner ring mounting seats 43, and the multiple inner ring mounting seats 43 are arranged at intervals along the circumferential direction of the end cover. hole, the axial flow channel runs through one of the inner ring mounting seats 43 . Because the inner ring mounting seat 43 is arranged on the inner end face of the end cap, and the radial flow channel is located in the end cap, therefore, the inner ring mounting seat 43 is entirely outside the end face of the end cap, and the radial flow channel reaches When the inner ring mounting seat 43 is located, it intersects with the axial flow channel on the inner ring mounting seat 43, thereby connecting the radial flow channel and the axial flow channel, and the cooling oil enters the inner ring mounting seat through the radial flow channel 43, and then enter the axial flow channel of the inner ring mounting boss 38 through the axial flow channel on the inner ring mounting seat 43, and then pass through the axial flow channel of the inner ring mounting boss 38 to the In the first annular channel 49 of the inner
  • the mounting holes are arranged in a dislocation toward one side of the inner ring mounting seat 43 in the circumferential direction relative to the axial flow channel.
  • the mounting hole on the inner ring mounting seat 43 is set at the middle position of the inner ring mounting seat 43, which can ensure that the wall thickness around the mounting hole can be maximized and improve the structural durability of the inner ring mounting seat 43 .
  • the axial flow channel and the mounting hole are both are arranged on the same inner ring mounting seat 43, therefore, not only the thickness of the side wall of the mounting hole, but also the thickness of the partition wall between the mounting hole and the axial flow channel needs to be considered.
  • the axial flow channel is set at the radially outer position of the inner ring mounting seat 43, and the mounting hole is set at the mounting position between the axial flow channel and the inner ring.
  • the axial flow channel is arranged at the radially outer side of the inner ring mounting seat 43 , it will not affect the structural strength of the axial flow channel too much, nor will it cause too much influence on the overall structural strength of the inner ring mounting seat 43, and the mounting hole is arranged in the radial direction of the axial flow channel and the inner ring mounting seat 43
  • the area between the inner corners is because the area between the axial flow channel and the radially inner corners of the inner ring mounting seat 43 is relatively large, there is enough space to set the mounting holes, and it is also possible to realize the shaft
  • the installation of the position of the installation hole can ensure that the wall thickness of the installation hole is maximized under the current structure, so that the overall structure of the inner ring mounting seat 43 is optimized, and the structural strength is guaranteed. While rationally arranged, the installation support and connection capability of the inner ring mounting seat 43 are guaranteed.
  • the lower part of the end cap is provided with an end cap oil sump 44 .
  • the bottom of the front end cover 26 and the rear end cover 11 is provided with an end cap oil sump 44, and the bottom of the casing 19 is provided with an organic casing oil sump 40.
  • the front end cover 26 and the rear end cover 11 are all provided with an end cover oil sump 44 for collecting cooling oil, and the end cover oil sump 44 of the front end cover 26 and the rear end cover 11 are all connected to the casing oil sump 40 of the casing 19, therefore After the front end cover 26, the rear end cover 11 and the casing 19 are assembled, by adding accessories such as an oil pump and a heat exchanger, the self-circulation of the cooling oil inside the motor can be realized.
  • a protrusion 48 is provided on the end cover facing the oil injection structure of the inner ring, and the protrusion 48 is connected between the motor oil inlet 9 and the axial flow channel, and the radial flow channel is at least partly provided on the protrusion 48 . Since the thickness of the end cover itself is relatively thin, if the radial flow channel is directly provided on the end cover, the thickness of the end cover at the position where the radial flow channel is set will be small, which cannot meet the structural strength requirements of the end cover.
  • Adding a bar-shaped protrusion 48 at the location of the radial flow channel can set the radial flow channel at the position corresponding to the bar-shaped protrusion 48, and make the radial flow channel not completely limited in the cover body of the end cap, and can at least Some of them are arranged in the strip-shaped protrusions 48.
  • the adverse effect of setting the radial flow channel on the end cap structure can be avoided, so as to ensure the overall structural strength of the end cap and the durability of the end cap.
  • the end cover includes a rear end cover 11, and the rear end cover 11 is provided with a rear bearing flow channel 4 on the end surface away from the oil injection structure of the inner ring, and the radial flow channel includes a first Radial flow channel 8, the first radial flow channel 8 is provided with a first axial oil injection hole 7, the rear bearing flow channel 4 communicates with the first axial oil injection hole 7, the bearing chamber includes a rear end cover 11 The upper rear bearing chamber communicates with the first radial flow passage 8 through the rear bearing flow passage 4 and the first axial oil injection hole 7 in sequence.
  • the motor oil inlet 9 is opened on the rear end cover 11 and communicates with the first radial flow channel 8. After the cooling oil enters the first radial flow channel 8 from the motor oil inlet 9, it flows from the second A radial flow channel 8 sprays oil to the rear bearing flow channel 4 through the first axial oil injection hole 7 to cool and lubricate the rear bearing.
  • the end cover includes a front end cover 26, and the front end cover 26 is provided with a front bearing flow channel 36, the radial flow channel includes a fourth radial flow channel 25 arranged on the front end cover 26, and the axial flow channel includes The fourth axial flow passage 28 arranged on the front end cover 26, the bearing chamber includes the front bearing chamber arranged on the front end cover 26, the front bearing chamber passes through the front bearing flow passage 36 and the fourth axial flow passage 28 and the fourth diameter Connected to flow channel 25.
  • the motor oil inlet 9 communicates with the casing flow passage 18 provided on the casing 19, and then communicates with the fourth radial flow passage 25 on the front end cover 26 through the casing flow passage 18, and then passes through The fourth radial flow channel 25 flows to the fourth axial flow channel 28 and enters the front bearing flow channel 36 through the fourth axial flow channel 28 to cool and lubricate the front bearing.
  • the front bearing flow channel 36 is opened on the side wall of the front bearing chamber, and the front bearing flow channel 36 extends along the direction from top to bottom toward the direction away from the oil injection structure of the inner ring, and the cooling oil enters the front After the bearing runner 36, it flows into the front bearing chamber along the front bearing runner 36, and enters the front bearing chamber to lubricate the front bearing.
  • two opposite oil guide plates 55 are arranged on the inner wall surface of the front end cover 26, and an oil guide channel 56 extending up and down is formed between the two oil guide plates 55, and the front bearing flow channel 36 is arranged on the guide plate. Oil passage 56 bottom, and communicate with oil guide passage 56.
  • the guide channel can be used to guide the cooling oil delivered from the fourth axial flow channel 28, so that the cooling The oil can be gathered by the oil guide channel 56, and enter the front bearing flow channel 36 along the oil guide channel 56 under the action of gravity and oil pressure, thereby improving the utilization efficiency of the cooling oil, so that the cooling oil can flow to the front bearing more concentratedly indoor.
  • a second axial oil injection hole 32 is opened on the side wall of the inner ring oil injection structure, and the second axial oil injection hole 32 communicates with the first annular channel 49 of the inner ring oil injection structure.
  • the axial oil injection hole 32 faces the oil guide passage 56 .
  • the cooling oil in the fourth axial channel 28 first enters the first annular channel 49, and then part of the cooling oil is sprayed out from the first oil injection hole 10 to cool the stator winding 16, and part of the cooling oil The oil is sprayed from the second axial oil injection hole 32 to the inner wall of the front end cover 26, and enters the oil guide passage 56 along the inner wall of the front end cover 26, and is transported through the front bearing flow channel 36 after being collected in the oil guide passage 56. to the front bearing chamber.
  • the driving motor includes a stator winding 16 and also includes the above-mentioned stator cooling structure, and the stator winding 16 is located between the oil injection structure of the inner ring and the oil injection structure of the outer ring of the stator cooling structure.
  • the driving motor includes a stator winding 16 and also includes the above-mentioned outer ring oil injection structure, and the outer ring oil injection structure is arranged on the outer peripheral side of the stator winding 16 .
  • the driving motor includes a bearing cooling structure
  • the bearing cooling structure is the above-mentioned bearing cooling structure
  • the drive motor includes a front end cover 26, a front inner ring oil injection structure 29, a front outer ring oil injection structure 23, a casing 19, a rear inner ring oil injection structure 6, a rear outer ring oil injection structure 14, a rear
  • the cooling oil can enter the motor to cool the stator winding 16 and the rotor, and can cool and lubricate the bearings.
  • the cooling water can support the cooling of the stator core 17 and indirectly cool the rotor core 20 .
  • Rotor baffles 27 are arranged at both ends of the rotor core 20 , and an oil seal 31 , an oil seal cover plate 30 , and a sealing ring 35 are arranged on the axially outer side of the front end cover 26 to improve the end sealing performance of the front end cover 26 .
  • the casing 19 adopts an oil-water mixing casing 19, and a water inlet and outlet and a cooling oil flow channel are opened on the casing 19.
  • the cooling oil flow path is isolated from the water channel inside the casing 19, which can realize simultaneous cooling of the motor oil cooling and water cooling. Effectively improve cooling efficiency.
  • the water-cooling structure of the present application can borrow the water-cooling system on the traditional new energy vehicle, which will not affect the original cooling system on the new energy vehicle, and also does not need to add an external cooling oil heat exchange system, and the cooling water cools the stator iron in the casing 19
  • the core 17 can cool the cooling oil inside the motor at the same time, which can greatly improve the cooling efficiency. This application does not need to add corresponding equipment parts to the traditional new energy vehicles, so the cost can also be saved.
  • the motor also includes a front T-shaped connecting pipe 24 and a rear T-shaped connecting pipe 12, wherein the front T-shaped connecting pipe 24 and the rear T-shaped connecting pipe 12 have the same structure, and the rear T-shaped connecting pipe 12 includes a second shaft To the flow channel 13 and the second radial flow channel 15, wherein the two ends of the second axial flow channel 13 are respectively connected between the rear end cover 11 and the casing 19, and connect the motor oil inlet 9 on the rear end cover 11 It communicates with the casing flow passage 18 on the casing 19 , and the second radial flow passage 15 is connected to the outer ring oil inlet 34 of the rear outer ring oil injection structure 14 to realize oil supply to the rear outer ring oil injection structure 14 .
  • the front T-shaped connecting pipe 24 includes a third axial flow channel 21 and a third radial flow channel 22, wherein the two ends of the third axial flow channel 21 are respectively connected between the front end cover 26 and the casing 19, and the front end cover
  • the fourth radial channel 25 on 26 communicates with the casing channel 18 on the casing 19, and the third radial channel 22 is connected to the outer ring oil inlet 34 of the front outer ring oil injection structure 23 to realize the front The oil supply of the oil injection structure 23 of the outer ring.
  • Both the front T-shaped connecting pipe 24 and the rear T-shaped connecting pipe 12 are provided with sealing rings 35 at the connecting positions, thereby improving the sealing effect, avoiding oil leakage, and ensuring the oil pressure and oil quantity of the cooling oil delivery.
  • the T-shaped connecting pipe is made of plastic materials, such as PA, PP, ABS, etc., and the T-shaped connecting pipes at both ends of the casing flow channel 18 have the same structure, that is, the T-shaped connecting pipes can be used in common.
  • the inside of the T-shaped connecting pipe is a through-type structure. Sealing grooves are provided at the three outlets of the T-shaped connecting pipe. Assemble and extrude each other to achieve sealing, and the oil outlet at the bottom of the T-shaped connecting pipe is inserted into the outer ring oil inlet 34 of the oil injection structure of the outer ring at the same time. After the cooling oil flows into the T-shaped connecting pipe, the cooling oil flows along both sides of the oil injection structure of the outer ring.
  • the cooling oil will be injected from the second oil injection hole on the outer peripheral side wall of the oil injection structure of the outer ring.
  • Hole 45 sprays out, realizes the end outer wall of stator winding 16 to spray oil and cool (the second oil injection hole 45 positions can be distributed in any region of stator winding 16 end outer wall, preferably in stator winding 16 end outer wall axial direction 1/ 2 position).
  • the rear end cover 11 is provided with a motor oil inlet 9, a first radial flow channel 8, a first axial flow channel 5, a first axial oil injection hole 7 and a rear bearing flow channel 4, and the casing 19 is provided with The casing flow channel 18, the cooling water flow channel and the cooling oil flow channel, the front end cover 26 is provided with the fourth radial flow channel 25, the fourth axial flow channel 28 and the front bearing flow channel 36, the rear inner ring oil injection structure 6 Installed on the rear end cover 11, the inner ring oil inlet 33 of the rear inner ring oil injection structure 6 communicates with the first axial flow channel 5, the rear outer ring oil injection structure 14 is installed on the casing 19, and the rear outer ring oil injection The oil inlet 34 of the outer ring of the oil structure 14 communicates with the second radial channel 15, the oil injection structure 29 of the front inner ring is installed on the front end cover 26, the oil inlet 33 of the inner ring of the oil injection structure 29 of the front inner ring is connected with the second The four axial channels 28 communicate
  • the stator assembly includes a stator core 17 and a stator winding 16
  • the rotor assembly includes a rotor core 20
  • the stator assembly is installed on the casing 19
  • the rotor assembly is installed on the motor shaft 1 .
  • the outer ring oil injection structure cooperates with other structures of the motor according to the different setting positions to form a cooling oil circuit for the outer ring at the front end of the stator winding 16 and a cooling oil circuit for the outer ring at the rear end of the stator winding 16.
  • the cooling oil Enter from the motor oil inlet 9 on the rear end cover 11, connect to the second axial flow channel 13 of the rear T-shaped connecting pipe 12, then connect to the casing flow channel 18 of the casing 19, and then to the front T-shaped connecting pipe 24
  • the third axial flow channel 21 is connected to the third radial flow channel 22, and oil is sprayed from a plurality of second oil injection holes 45 of the front outer ring oil injection structure 23 to cool the outer side of the front end winding of the stator winding 16.
  • the cooling oil enters from the motor oil inlet 9 on the rear end cover 11, communicates with the second axial flow channel 13 of the rear T-shaped connecting pipe 12, and then communicates with the second radial direction.
  • the flow channel 15 injects oil from the second oil injection hole 45 of the rear outer ring oil injection structure 14 to cool the outer side of the winding at the rear end of the stator assembly.
  • the oil injection structure of the inner ring cooperates with other structures of the motor according to the different setting positions to form a cooling oil circuit for the inner ring at the front end of the stator winding 16 and a cooling oil circuit for the inner ring at the rear end of the stator winding 16.
  • the third axial flow channel 21 of the front end cover 26 is then connected to the fourth radial flow channel 25, and then enters the front inner ring oil injection structure 29 through the fourth axial flow channel 28, and passes through the front inner ring oil injection structure
  • the first oil injection hole 10 of 29 carries out oil injection, and cooling stator winding 16 front end winding inner ring.
  • the cooling oil enters from the motor oil inlet 9 on the rear end cover 11, communicates with the first radial flow channel 8 of the rear end cover 11, and then passes through the first axial flow channel 5 enters the oil injection structure 6 of the rear inner ring, sprays oil from the first oil injection hole 10 of the oil injection structure 6 of the rear inner ring, and cools the inner ring of the winding at the rear end of the stator winding 16 .
  • the casing 19 is provided with a water inlet 41 and a water outlet 42, wherein the water inlet 41 and the water outlet 42 are located on both sides of the casing flow channel 18 in the circumferential direction, and between the water inlet 41 and the water outlet 42 The minimum spacing is greater than the maximum diameter of the flow channel 18 of the casing.
  • the water inlet 41 and the outlet The difference between the distance between the water ports 42 and the maximum diameter of the casing flow channel 18 is between 10 mm and 30 mm, which can prevent the cooling water flow channel from being too far away from the casing flow channel 18 and reduce the heat exchange efficiency between the cooling water and the cooling oil.
  • the cooling water can more fully fill the inside of the casing 19, effectively cooling the casing, and avoiding the problem that the flow passages are connected if the distance between the cooling water flow channel and the casing flow channel is too short, thereby improving Stability of oil-water separation.
  • the distance between the water inlet 41 and the casing flow channel 18 is the same as the distance between the water outlet 42 and the casing flow channel 18 .
  • the distance between the water inlet 41 and the casing flow channel 18 can also be made smaller than the distance between the water outlet 42 and the casing flow channel 18, thereby more effectively utilizing the cooling water temperature at the water inlet 41.
  • the lower feature improves the heat exchange efficiency between cooling water and cooling oil.
  • the cooling oil circuit can be divided into two parts.
  • the cooling oil enters the interior of the motor from the external oil supply circuit through the motor oil inlet 9 and is divided into two branches.
  • the first branch enters the first radial flow channel 8
  • the second branch enters the second axial channel 13 of the rear T-shaped connecting pipe 12, and the cooling oil starts to flow in two directions along the first branch and the second branch respectively.
  • the first branch is divided into cooling and lubricating rear bearing oil circuit and cooling stator winding 16 rear end end winding inner ring oil circuit.
  • the second branch circuit is divided into the oil circuit for cooling the outer ring of the rear end winding of the stator winding 16, the oil circuit for cooling the outer ring of the front end winding of the stator winding 16, the oil circuit for cooling the inner ring of the front end winding of the stator winding 16, and the front bearing for cooling and lubrication oil circuit.
  • the new energy vehicle includes the above-mentioned outer ring oil injection structure, bearing cooling structure, stator cooling structure or driving motor.
  • the hybrid cooling method of the drive motor cooling system of the present application can fundamentally solve the problem that the stator winding 16 of the current water-cooled drive motor cannot be cooled, and can solve the problems of uneven cooling of the windings and excessive local temperature in the traditional oil cooling method, reducing Small motor internal heat island effect, thereby improving the stability and service life of the motor; it can also enhance the heat dissipation performance of the main heat source inside the motor, increase the power density of the motor, enhance performance, and simplify the complex external cooling structure of the traditional oil-cooled prototype, saving costs , to realize the light weight and integration of the main drive motor system.

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  • Motor Or Generator Cooling System (AREA)

Abstract

提供一种定子冷却结构、驱动电机和新能源汽车。定子冷却结构用于对定子绕组(16)进行冷却,包括电机入油口(9)、内圈喷油结构和外圈喷油结构,内圈喷油结构设置在定子绕组(16)的内周侧,外圈喷油结构设置在定子绕组(16)的外周侧,内圈喷油结构和外圈喷油结构均与电机入油口(9)连通,内圈喷油结构包括第一喷油孔(10),外圈喷油结构包括第二喷油孔(45),第一喷油孔(10)的开口朝向定子绕组(16)的内周壁,第二喷油孔(45)的开口朝向定子绕组(16)的外周壁。根据定子冷却结构,能够保证绕组冷却均匀,避免绕组出现局部温度过高的问题,提高电机稳定性和使用寿命。

Description

定子冷却结构、驱动电机和新能源汽车
相关申请
本申请要求2021年05月14日申请的,申请号为202110528376.X,名称为“定子冷却结构、驱动电机和新能源汽车”的中国专利申请的优先权,在此将其全文引入作为参考。
技术领域
本申请涉及车辆技术领域,具体涉及一种定子冷却结构、驱动电机和新能源汽车。
背景技术
近年来随着国家政策的大力倡导,新能源车领域快速发展,行业内竞争也与日俱增,同时国家“十三五”新能源汽车重点研发计划提出了功率密度的要求,在2020年≥3.5kW/kg,2025年≥4kW/kg。越来越多的厂商着力于油冷技术在乘用车主驱电机上的应用,以从技术角度出发提升主驱动系统的功率密度。
现阶段各厂家产品,为了减小体积节约成本,采用的方案主要是提高电机转速和改善冷却条件以提高功率密度。提高电机转速受轴承、油封和配套减速器速比等因素限制,往往产生较多的负作用。改善冷却条件方面,水冷冷却效果有限,而采用填充导热材料提高传热效率一般受材料成本,或工艺复杂度等因素制约,不适宜批量生产。因此现阶段,最有效的方案是使用油冷技术,但传统的油冷冷却方案多是油路结构复杂,增加了加工工艺成本,或油路结构不合理,冷却效果有限,尤其对定子的冷却,多存在冷却不均的情况。
当前,新能源汽车主驱电机在实际运行过程中,当处于低速大扭矩时,主驱电机的定子及转子会发出大量的热,当前新能源汽车主驱电机的散热方式多为在电机机壳内部开设螺旋水流道,通过水在机壳内的循环流动,进而实现电机的冷却效果,这种冷却方式存在电机绕组、轴承无法得到直接冷却和润滑,主驱电机的主要发热源得不到有效冷却的问题,因此电机热负荷受限,进而导致电机体积受限。
若采用油冷式冷却,冷却油可直接与电机各发热源接触,并在结构上做到针对性冷却,主驱电机各发热源得到有效冷却,在相同性能要求下,油冷电机相比传统的水冷电机,热负荷得到提高,电机体积可以减小,功率密度进而得到提高,冷却油可同时润滑冷却电机轴承,进而电机寿命也得到提高。
当前电机油冷方式是将冷却油直接冷却定子绕组,但传统油冷方式存在绕组冷却不均匀,导致绕组局部温度过高的问题,容易影响电机的使用寿命。
发明内容
因此,本申请要解决的技术问题在于提供一种定子冷却结构、驱动电机和新能源汽车,能够保证绕组冷却均匀,避免绕组出现局部温度过高的问题,提高电机稳定性和使用寿命。
为了解决上述问题,本申请提供一种定子冷却结构,用于对定子绕组进行冷却,包括电机入油口、内圈喷油结构和外圈喷油结构,内圈喷油结构设置在定子绕组的内周侧,外圈喷油结构设置在定子绕组的外周侧,内圈喷油结构和外圈喷油结构均与电机入油口连通,内圈喷油结构包括第一喷油孔,外圈喷油结构包括第二喷油孔,第一喷油孔的开口朝向定子绕组的内周壁,第二喷油孔的开口朝向定子绕组的外周壁。
在其中一个实施例中,第一喷油孔设置在内圈喷油结构的外周壁,并沿内圈喷油结构的径向延伸;和/或,第二喷油孔设置在外圈喷油结构的内周壁,并沿外圈喷油结构的径向延伸。
在其中一个实施例中,第一喷油孔为多个,多个第一喷油孔沿内圈喷油结构的外周周向均匀间隔排布;和/或,第二喷油孔为多个,多个第二喷油孔沿外圈喷油结构的内周周向均匀间隔排布。
在其中一个实施例中,内圈喷油结构和外圈喷油结构成组设置形成喷油环组件,同一喷油环组件的内圈喷油结构位于外圈喷油结构的径向内侧。
在其中一个实施例中,喷油环组件为至少两个,定子绕组的第一端对应设置有至少一个喷油环组件,定子绕组的第二端对应设置有至少一个喷油环组件,定子绕组的端部位于喷油环组件的内圈喷油结构和外圈喷油结构之间。
在其中一个实施例中,位于定子绕组两端的喷油环组件均与电机入油口连通。
在其中一个实施例中,内圈喷油结构包括至少两个第一分体结构,至少两个第一分体结构沿周向依次首尾连接,形成内圈喷油结构。
在其中一个实施例中,第一分体结构包括位于第一端的公端和位于第二端的母端,相邻的第一分体结构的公端与母端配合固定连接,第一分体结构组合后,在内圈喷油结构形成沿周向贯通的第一环形通道,第一喷油孔与第一环形通道连通。
在其中一个实施例中,公端和母端均设置在第一分体结构的内周侧,公端与母端插接配合,形成内环安装凸台,内环安装凸台上设置有沿轴向贯穿的第一连接孔。
在其中一个实施例中,第一分体结构的公端所在端的端面上设置有第一插接结构,第一分体结构的母端所在端的端面上设置有第二插接结构,第一插接结构和第二插接结构插接配合,形成密封连接。
在其中一个实施例中,第一插接结构为插槽,第二插接结构为插头,第一环形通道沿周向贯穿插头,插头与插槽插接配合时,相邻的第一分体结构的第一环形通道相互连通。
在其中一个实施例中,至少其中一个第一分体结构上设置有内环入油口,电机入油口连通至内环入油口,内环入油口与第一环形通道连通。
在其中一个实施例中,内环入油口处设置有第一入油接头,第一入油接头设置在内圈喷油结构的轴向端面上。
在其中一个实施例中,内圈喷油结构为一体成型结构。
在其中一个实施例中,内圈喷油结构的外缘设置有沿内圈喷油结构的轴向方向延伸的环形凸边,环形凸边的外周壁与内圈喷油结构的外周壁齐平。
在其中一个实施例中,外圈喷油结构包括多个第二分体结构,第二分体结构沿周向依次首尾连接,形成外圈喷油结构。
在其中一个实施例中,第二分体结构包括位于第一端的公端和位于第二端的母端,相邻的第二分体结构的公端与母端配合固定连接,第二分体结构组合后,在外圈喷油结构形成沿周向贯通的第二环形通道,第二喷油孔与第二环形通道连通。
在其中一个实施例中,第二分体结构的公端和母端均设置在第二分体结构的外周侧,公端与母端插接配合,形成外环安装凸台,外环安装凸台上设置有沿轴向贯穿的第二连接孔。
在其中一个实施例中,至少一个第二分体结构的外周壁上设置有径向入油口,电机入油口与径向入油口连通,径向入油口与第二环形通道连通。
在其中一个实施例中,外圈喷油结构为一体成型结构。
在其中一个实施例中,外圈喷油结构的外周壁上设置有外环安装凸台,外环安装凸台上设置有沿轴向贯穿的第二连接孔。
根据本申请的一个方面,提供了一种驱动电机,包括定子绕组,还包括上述的定子冷却结构,定子绕组位于定子冷却结构的内圈喷油结构和外圈喷油结构之间。
根据本申请的一个方面,提供了一种新能源汽车,包括上述的定子冷却结构或上述的驱动电机。
本申请提供的定子冷却结构,用于对定子绕组进行冷却,包括电机入油口、内圈喷油结构和外圈喷油结构,内圈喷油结构设置在定子绕组的内周侧,外圈喷油结构设置在定子绕组的外周侧,内圈喷油结构和外圈喷油结构均与电机入油口连通,内圈喷油结构包括第一喷油孔,外圈喷油结构包括第二喷油孔,第一喷油孔的开口朝向定子绕组的内周壁,第二喷油孔的开口朝向定子绕组的外周壁。该定子冷却结构在定子绕组的内外侧均设置喷油结构,因此能够利用喷油结构同时从定子绕组的内外两侧进行喷油冷却,使得定子绕组的端部内外冷却均匀,保证了定子绕组冷却的均匀性,可以有效避免定子绕组冷却不均匀所导致的局部温度过高的问题,延长电机的使用寿命。
附图说明
图1为本申请一个驱动电机的剖视结构示意图。
图2为图1的L处的放大结构示意图。
图3为图1的M处的放大结构示意图。
图4为本申请一个实施例的驱动电机的定子冷却结构流道图。
图5为本申请一个实施例的驱动电机的外圈喷油结构的立体结构图。
图6为本申请一个实施例的驱动电机的内圈喷油结构的立体结构图。
图7为本申请一个驱动电机的分解结构示意图。
图8为本申请一个实施例的驱动电机的外圈喷油结构的立体结构图。
图9为本申请一个实施例的驱动电机的内圈喷油结构的立体结构图。
图10为本申请一个实施例的驱动电机的前轴承冷却结构图。
图11为本申请一个实施例的驱动电机的机壳结构示意图。
图12为本申请一个实施例的驱动电机的前端盖立体结构示意图。
图13为本申请一个实施例的驱动电机的前端盖与前内圈喷油结构的装配结构图。
图14为本申请一个实施例的驱动电机的后外圈喷油结构与机壳的装配结构示意图。
图15为本申请一个实施例的驱动电机的T型连通管的剖视结构图。
图16为本申请一个实施例的驱动电机的外圈喷油结构的立体结构图。
图17为本申请一个实施例的驱动电机的前外圈喷油结构的喷孔位置展开结构示意图。
图18为本申请一个实施例的驱动电机的后外圈喷油结构的喷孔位置展开结构示意图。
图19为本申请一个实施例的驱动电机的冷却流道油路循环结构图。
具体实施方式
结合参见图1至图5所示,根据本申请的实施例,定子冷却结构用于对定子绕组16进行冷却,定子冷却结构包括电机入油口9、内圈喷油结构和外圈喷油结构,内圈喷油结构设置在定子绕组16的内周侧,外圈喷油结构设置在定子绕组16的外周侧,内圈喷油结构和外圈喷油结构均与电机入油口9连通,内圈喷油结构包括第一喷油孔10,外圈喷油结构包括第二喷油孔45,第一喷油孔10的开口朝向定子绕组16的内周壁,第二喷油孔45的开口朝向定子绕组16的外周壁。
该定子冷却结构在定子绕组16的内外侧均设置喷油结构,因此能够利用喷油结构同时从定子绕组16的内外两侧进行喷油冷却,使得定子绕组16的端部绕组内外冷却均匀,保证了定子绕组16冷却的均匀性,可以有效避免定子绕组16冷却不均匀所导致的局部温度过高的问题,减小电机内部热岛效应,从而提高电机的稳定性和使用寿命。
本申请实施例的定子冷却结构在电机内部的定子绕组16与机壳19、以及定子绕组16与电机主轴1之间的空间中增加了内圈喷油结构和外圈喷油结构,因此能够充分利用电机的内部空间来布置定子绕组16的冷却结构,从而避免额外增大电机体积的同时,实现对定子绕组16的有效冷却,提高电机的内部冷却性能。
在一个实施例中,第一喷油孔10设置在内圈喷油结构的外周壁,并沿内圈喷油结构的径向延伸,由于定子绕组16位于内圈喷油结构的外周侧,因此,使得第一喷油孔10沿内圈喷油结构的径向延伸,可以保证在沿内圈喷油结构的外周壁周向设置多个第一喷油孔10时,每个第一喷油孔10在定子绕组16内周壁上的喷射位置更加精确,更加方便进行冷却油的精确分配,提高油冷却效率。
在一个实施例中,还可以从其他喷射角度对第一喷油孔10的设置进行考虑,例如从冷却油在定子绕组16上的喷射面积考虑,可以使得第一喷油孔10相对于定子铁芯17的中心轴线倾斜设置,使得第一喷油孔10的冷却油喷射在定子绕组16的内表面时,可以形成一定的侧向分力,从而使得冷却油能够沿轴向方向铺开一定面积,增加冷却油与定子绕组16的接触面积,进而提高冷却油对定子绕组16的冷却效率。多个第一喷油孔10沿内圈喷油结构的周向间隔排布时,第一喷油孔10分成两组,一组第一喷油孔10向着内圈喷油结构的第一端倾斜,另一组第一喷油孔10向着内圈喷油结构的第二端倾斜,两组第一喷油孔10沿周向交替排布,从而使得定子绕组16的端部绕组沿整个轴向方向都能够与冷却油充分接触,从而最大化冷却油与定子绕组16之间的接触面积,提高冷却油对定子绕组16的冷却效果。
在一个实施例中,作为上一个实施例的可选方案,还可以增加一组沿径向延伸且垂直于定子铁芯17的中心轴线的第一喷油孔10,从而形成三组第一喷油孔10,三组第一喷油孔10沿周向方向交替排布,从而能够使得冷却油更加全面地覆盖定子绕组16。
内圈喷油结构可以为环形结构,也可以为半环结构,当内圈喷油结构为半环结构时,内圈喷油结构设置在电机主轴1的上方,内圈喷油结构喷出的冷却油在到达定子绕组16的内壁面时,会沿着定子绕组16的内壁面向下流动,从而在重力的作用下遍布整个定子绕组16的内壁面,对定子绕组16形成全面的冷却效果。因此,不管是环形结构的内圈喷油结构,还是半环结构的内圈喷油结构,均能够实现对定子绕组16内圈的有效冷却,且半环结构的内圈喷油结构,所用材料更少,成本也会更低。
此外,由于冷却油会在重力作用下沿着定子绕组16的内壁面向下流动,在顶部的停留时间较短,因此,当内圈喷油结构上的第一喷油孔10沿周向均匀排布时,会使得定子绕组16的底部冷却油富集,顶部冷却油量会略显不足,而在采用半环结构的内圈喷油结构之后,在相同的冷却油量下,冷却油会更加集中地流向定子绕组16内圈顶部位置,使得定子绕组16的内圈顶部可以有更多的冷却油进行冷却,从而提高定子绕组16的顶部绕组冷却效果,同时,冷却油沿着定子绕组16顶部向下流动的过程中,又能够对下部的定子绕组16进行有效冷却,从而能够从整体上提高冷却油对于定子绕组16的冷却效果。
在一个实施例中,第二喷油孔45设置在外圈喷油结构的内周壁,并沿外圈喷油结构的径向延伸,由于定子绕组16位于外圈喷油结构的内周侧,因此,使得第二喷油孔45沿外圈喷油结构的径向延伸,可以保证在沿外圈喷油结构的内周壁周向设置多个第二喷油孔45时,每个第二喷油孔45在定子绕组16外周壁上的喷射位置更加精确,更加方便进行冷却油的精确分配,提高油冷却效率。
在一个实施例中,还可以从其他喷射角度对第二喷油孔45的设置进行考虑,例如从冷却油在定子绕组16上的喷射面积考虑,可以将第二喷油孔45相对于定子铁芯17的中心轴线倾斜设置,使得第二喷油孔45的冷却油喷射在定子绕组16的外表面时,可以形成 一定的侧向分力,从而使得冷却油能够沿轴向方向铺开一定面积,增加冷却油与定子绕组16的接触面积,进而提高冷却油对定子绕组16的冷却效率。多个第二喷油孔45沿外圈喷油结构的周向间隔排布时,第二喷油孔45分成两组,一组第二喷油孔45向着外圈喷油结构的第一端倾斜,另一组第二喷油孔45向着外圈喷油结构的第二端倾斜,两组第二喷油孔45沿周向交替排布,从而使得定子绕组16的端部绕组沿整个轴向方向都能够与冷却油充分接触,从而最大化冷却油与定子绕组16之间的接触面积,提高冷却油对定子绕组16的冷却效果。
在一个实施例中,作为对上一个实施例的变形,还可以增加一组沿径向延伸且垂直于定子铁芯17的中心轴线的第二喷油孔45,从而形成三组第二喷油孔45,三组第二喷油孔45沿周向方向交替排布,从而能够使得冷却油更加全面地覆盖定子绕组16。
外圈喷油结构可以为环形结构,也可以为半环结构,当外圈喷油结构为半环结构时,外圈喷油结构设置在电机主轴1的上方,外圈喷油结构喷出的冷却油在到达定子绕组16的外壁面时,会沿着定子绕组16的外壁面向下流动,从而在重力的作用下遍布整个定子绕组16的外壁面,对定子绕组16形成全面的冷却效果。因此,不管是环形结构的外圈喷油结构,还是半环结构的外圈喷油结构,均能够实现对定子绕组16外圈的有效冷却,且半环结构的外圈喷油结构,所用材料更少,成本也会更少。
此外,由于冷却油会在重力作用下沿着定子绕组16的外壁面向下流动,在顶部停留时间较短,因此,当外圈喷油结构上的第二喷油孔45沿周向均匀排布时,会使得定子绕组16的底部冷却油富集,顶部冷却油量会略显不足,而在采用半环结构的外圈喷油结构之后,在相同的冷却油量下,冷却油会更加集中地流向定子绕组16外圈顶部位置,使得定子绕组16外圈顶部可以有更多的冷却油进行冷却,从而提高定子绕组16的顶部绕组冷却效果,同时,冷却油沿着定子绕组16顶部向下流动的过程中,又能够对下部的定子绕组16进行有效冷却,从而能够从整体上提高冷却油对于定子绕组16的冷却效果。
在一个实施例中,第一喷油孔10为多个,多个第一喷油孔10沿内圈喷油结构的外周周向均匀间隔排布,可以提高第一喷油孔10在定子绕组16上的喷油分布均匀性。
在一个实施例中,第二喷油孔45为多个,多个第二喷油孔45沿外圈喷油结构的内周周向均匀间隔排布,可以提高第二喷油孔45在定子绕组16上的喷油分布均匀性。
在一个实施例中,内圈喷油结构和外圈喷油结构成组设置形成喷油环组件,同一喷油环组件的内圈喷油结构位于外圈喷油结构的径向内侧。内圈喷油结构和外圈喷油结构之间形成喷油冷却空间,定子绕组16的端部绕组设置在该喷油冷却空间内,因此会同时受到内圈喷油结构和外圈喷油结构的喷油冷却,不仅能够从周向方向上形成冷却油冷却,还能够从内外两侧形成冷却油冷却,可以使得冷却油的冷却目标更加明确,冷却区域更加集中,冷却油的冷却效率更高,形成对定子绕组16的集中冷却,实现对电机内部大发热源的集中冷却,冷却油的利用效率更高。定子绕组16的端部绕组是指定子绕组16伸出定子铁芯17两端的绕组部分。
在进行内圈喷油结构和外圈喷油结构的设计时,需要合理设计内圈喷油结构的外径以及外圈喷油结构的内径,以保证喷油孔喷出的冷却油能够达到定子绕组16的表面,对定子绕组16进行冷却,由于定子绕组16是位于外圈喷油结构的内侧,且位于内圈喷油结构的外侧,因此,外圈喷油结构顶部的冷却油可以在重力作用下流动至定子绕组16的表面,而内圈喷油结构喷出的冷却油如果距离定子绕组16过远,或者喷射压力不足,就会导致内圈喷油结构的冷却油无法到达定子绕组16对定子绕组16进行冷却,因此,在相同的冷却油压力下,内圈喷油结构与定子绕组16之间的间距小于外圈喷油结构与定子绕组16之间的间距,作为一个优选的实施例,内圈喷油结构与定子绕组16之间的间距为L1,外圈喷油结构与定子绕组16之间的间距为L2,其中L1≤0.9L2,从而能够在合理设计喷油冷却空间的同时,实现外圈喷油结构和内圈喷油结构与定子绕组16之间间距的合理分配,保证内圈喷油结构内的冷却油能够被喷射到定子绕组16的表面,对定子绕组16形成有效冷却。
为了进一步保证内圈喷油结构对定子绕组16的冷却效果,需要进一步根据冷却油压力设计内圈喷油结构与定子绕组16之间的间距,使得内圈喷油结构顶部的第一喷油孔10喷射出的冷却油可以在定子绕组16表面形成溅射效果,进一步加大冷却油到达定子绕组16表面后的分布面积,提高冷却油与定子绕组16的换热效率。
在一个实施例中,由于定子绕组16包括位于前端的端部绕组和位于后端的端部绕组,因此喷油环组件为至少两个,定子绕组16的第一端即后端端部绕组对应设置有至少一个喷油环组件,定子绕组16的第二端即前端端部绕组对应设置有至少一个喷油环组件,定子绕组16的端部绕组位于喷油环组件的内圈喷油结构和外圈喷油结构之间,这样一来,在定子绕组16的前端端部绕组和后端端部绕组处均有内圈喷油结构和外圈喷油结构进行喷油冷却,因此能够同时对定子绕组16的两端进行内外以及周向冷却,可以进一步提高定子绕组16的冷却效率和冷却效果。
在一个实施例中,位于定子绕组16两端的喷油环组件均与电机入油口9连通,因此只需要一个电机入油口9就能够实现定子绕组16两端的喷油环组件的供油,结构更加简 单,实现更加方便。
在一个实施例中,也可以并联设置两个电机入油口9,其中一个电机入油口9与电机后端的喷油环组件连通,另一个电机入油口9与电机前端的喷油环组件连通,可以通过两个电机入油口9直接对各喷油环组件进行供油,能够保证各个喷油环组件的供油量和供油压力。
在一个实施例中,外圈喷油结构用于对定子绕组16的外圈进行冷却,外圈喷油结构包括本体,本体内置有沿周向方向延伸的通道,本体的内壁面设置有第二喷油孔45,第二喷油孔45与该第二喷油孔45所对应的通道连通,多个第二喷油孔45沿本体的内壁面周向排布。多个通道可以沿着本体的周向间隔设置,也可以沿周向方向连通。
该外圈喷油结构的第二喷油孔45沿着本体的内壁面周向排布,能够沿周向方向对定子绕组16外圈进行冷却,因此可以使得定子绕组16的冷却均匀,避免定子绕组16出现局部温度过高的问题,提高电机稳定性和使用寿命。
在一个实施例中,第二喷油孔45包括主喷油孔46和辅助喷油孔47,主喷油孔46在本体的内壁面的展开结构上沿直线方向周向排布,至少部分辅助喷油孔47设置在位于本体顶部的主喷油孔46周侧,主喷油孔46沿轴向设置在内壁面的中间位置。在本实施例中,主喷油孔46为设置在本体的轴向方向中间位置的基本喷油孔,辅助喷油孔47依据定子绕组16的发热位置以及定子绕组16的形状结构围绕主喷油孔46进行设计,可以利用主喷油孔46满足定子绕组16的基本供油需求,利用辅助喷油孔47根据定子绕组16特点进行针对性供油,从而使得定子绕组16的供油能够与定子绕组16自身结构以及发热特点相匹配,实现定子绕组16的均匀冷却,提高对定子绕组16的冷却效果和冷却效率。
在一个实施例中,主喷油孔46沿本体的内壁面周向均匀排布,由于主喷油孔46只是为了满足定子绕组16各个位置的基本供油需求,因此主喷油孔46的排布更多地需要实现在定子绕组16的各个位置均能够进行均匀供油,对于定子绕组16重点区域的供油需要通过辅助喷油孔47来实现,如此一来,对喷油孔的功能进行划分之后,喷油孔的结构设计和位置设计都更加分明,设计难度也大幅度降低,可以在主喷油孔46满足设计要求之后,根据定子绕组16的自身特点以及发热位置来进行辅助喷油孔47的精确化设计,利用辅助喷油孔47实现针对性冷却。
在一个实施例中,外圈喷油结构根据设置位置的不同分为前外圈喷油结构23和后外圈喷油结构14,电机入油口9同时对两个外圈喷油结构进行供油,且电机入油口9设置在电机后端,此种情况下,由于前外圈喷油结构23距离电机入油口9更远,因此压力损失更大,相对于后外圈喷油结构14而言,在喷油孔面积相同的情况下,前外圈喷油结构23的供油压力和供油量都小于后外圈喷油结构14,因此,为了保证前外圈喷油结构23和后外圈喷油结构14的供油量的一致性,前外圈喷油结构23的第二喷油孔45的总面积大于后外圈喷油结构14的第二喷油孔45的总面积,从而利用喷油面积来补偿油量不足的问题,实现前后两端外圈喷油结构的供油一致性。
下面分别对后外圈喷油结构14和前外圈喷油结构23的结构进行说明。
在一个实施例中,后外圈喷油结构14位于顶部的主喷油孔46的周向至少一侧设置有辅助喷油孔47。作为一个优选的实施例,位于顶部的主喷油孔46的周向两侧分别设置有辅助喷油孔47。
对于后外圈喷油结构14而言,由于定子绕组16的顶部发热量在整个定子绕组16中最大,且冷却油在定子绕组16顶部停留时间较短,如果油量不足,就会导致定子绕组16发热量最大的顶部位置不能够得到充分有效的冷却,使得定子绕组16的顶部仍然容易出现局部温度过高的问题,因此,需要在后外圈喷油结构14上对应定子绕组16的位置进行改造,增加该区域的第二喷油孔45的数量,从而使得冷却油能够大量且连续不断对对定子绕组16的外圈顶部位置进行冷却,通过加大定子绕组16的顶部线圈的供油量的方式,实现对定子绕组16的顶部大发热部位的冷却。本实施例中通过在顶部的主喷油孔46的周向方向的两侧均增加辅助喷油孔47的方式,加大后外圈喷油结构14顶部的喷油孔面积,加大对定子绕组16顶部的供油量,利用在顶部主喷油孔46周侧针对性增加多个辅助喷油孔47的方式,实现对定子绕组16顶部的重点集中冷却,保证对定子绕组16顶部的冷却效果。
位于顶部的主喷油孔46的周向两侧分别设置有至少两个辅助喷油孔47,位于顶部的主喷油孔46和相邻主喷油孔46之间的辅助喷油孔47中,靠近相邻主喷油孔46的辅助喷油孔47位于顶部的主喷油孔46和相邻主喷油孔46的中间位置。在本实施例中,位于顶部的主喷油孔46和两侧的相邻主喷油孔46之间的辅助喷油孔47各为两个,因此相当于顶部在主喷油孔46的周侧设置有四个辅助喷油孔47,从而大大加大了对应于定子绕组16顶部区域的喷油孔面积,加大了喷油量,可以实现对定子绕组16顶部的有效冷却。靠近相邻主喷油孔46的辅助喷油孔47位于顶部的主喷油孔46和相邻主喷油孔46的中间位置,且位于顶部的主喷油孔46一侧的两个辅助喷油孔47均匀间隔设置,可以实现辅助喷油孔47在顶部的主喷油孔46两侧的均匀分布,实现定子绕组16顶部不同区域的均匀供油。
在一个实施例中,与顶部的主喷油孔46相邻的主喷油孔46在远离顶部的主喷油孔46 的一侧设置有辅助喷油孔47。
作为一个优选的实施例,设置在远离顶部的主喷油孔46一侧的辅助喷油孔47的数量为两个,且分别设置在相邻的主喷油孔46的中心连线的两侧。
在本实施例中,与顶部的主喷油孔46相邻的主喷油孔46为第一个相邻的主喷油孔46,与该第一个相邻的主喷油孔46相邻的主喷油孔46为第二个相邻的主喷油孔46,在第一个相邻的主喷油孔46和第二个相邻的主喷油孔46之间的位置设置有两个辅助喷油孔47,两个辅助喷油孔47沿轴向排布,且分别位于与第一个相邻的主喷油孔46和第二个相邻的主喷油孔46的中心连线的两侧,主要作用为实现该区域的补油。由于定子绕组16缠绕形状的影响,以及定子绕组16本身呈圆柱形结构的特点,当冷却油从定子绕组16顶部在重力作用下向下流动时,可能会出现冷却油向轴向中间位置集中的问题,导致定子绕组16后端端部绕组两端位置冷却油无法到达,因此也就无法对端部绕组两端进行冷却,因此,在冷却油向下流动的中间区域增加辅助喷油孔47,并使得辅助喷油孔47分别对应于端部绕组的两端位置设置,可以实现对端部绕组的补油,使得冷却油在此处能够再次分配到端部绕组的两端区域,进而从该区域向下流动,达到对定子绕组16端部各个区域进行有效冷却的目的。
对于定子绕组16后端的端部绕组而言,由于其发热量大,且发热量体现在整个轴向方向,因此,为了进一步提高对定子绕组16的降温冷却效果,在一个实施例中,位于顶部的主喷油孔46的轴向两侧分别设置有辅助喷油孔47。在本实施例中,同时在顶部的主喷油孔46的轴向两侧设置辅助喷油孔47,结合之前在周向两侧设置的四个喷油孔,在顶部的主喷油孔46周侧共设置有六个辅助喷油孔47,能够对定子绕组16顶部的轴向和周向均进行补油,使得顶部区域的喷油孔能够均匀分配到线圈发热源,冷却效果达到最优。
在一个实施例中,本体上设置有外环入油口34,外环入油口34位于顶部的主喷油孔46的周向一侧,外环入油口34所在侧的辅助喷油孔47数量少于位于顶部的主喷油孔46的周向另一侧的辅助喷油孔47的数量。
在一个实施例中,在顶部的主喷油孔46设置外环入油口34的一侧,至少部分相邻的主喷油孔46之间设置有辅助喷油孔47,辅助喷油孔47设置在主喷油孔46远离定子绕组16外缘的一侧。
外圈喷油结构为整环或半环结构。
外圈喷油结构为整环时,相邻的通道沿周向连通,形成周向贯通的第二环形通道50。
在一个实施例中,前外圈喷油结构23位于顶部的主喷油孔46的周向至少一侧设置有辅助喷油孔47。作为一个优选的实施例,位于顶部的主喷油孔46的周向两侧分别设置有辅助喷油孔47。
前外圈喷油结构23的结构与后外圈喷油结构14的结构基本上相同,不同之处在于,两者的第二喷油孔45的数量以及设置位置有所不同。
在一个实施例中,前外圈喷油结构23位于顶部的主喷油孔46的轴向一侧设置有辅助喷油孔47。对于前外圈喷油结构23而言,由于定子绕组16前端端部绕组的发热量小于后端端部绕组的发热量,因此可以相比于后外圈喷油结构14在顶部的主喷油孔46周侧设置更少的辅助喷油孔47,从而使得前外圈喷油结构23的辅助喷油孔47的数量和位置分布与定子绕组16前端端部绕组的发热量更加匹配,提高定子绕组16前端端部绕组冷却均匀性。
在一个实施例中,参见下表所示:
Figure PCTCN2022071261-appb-000001
从表中可以看出,相比于整环结构,半环结构除了材料更少,成本更低之外,对于线圈绕组的最高温度也进行了有效控制,线圈绕组的最高温度降低至少7℃,降低百分比至少7%,有效提高了线圈绕组的温度分布均匀性,尤其是对于前外圈喷油环结构而言,在采用半环结构之后,最高温度降低了28.6%,平均温度降低了17.0%,使得前外圈喷油环所对应的线圈绕组的最高温度和平均温度均大幅下降,对于线圈绕组起到了更加有效的冷却效果。
在一个实施例中,本体上设置有外环入油口34,外环入油口34位于顶部的主喷油孔46的周向一侧,外环入油口34所在侧的辅助喷油孔47数量少于位于顶部的主喷油孔46的周向另一侧的辅助喷油孔47的数量。由于外环入油口34的存在,位于外环入油口34同侧的主喷油孔46和辅助喷油孔47能够具有更大的喷射压力和喷射流量,因此,为了使顶部的主喷油孔46周向两侧的冷却油分配更加均匀,可以通过调整顶部的主喷油孔46周向两侧的辅助喷油孔47数量的方式,实现顶部的主喷油孔46周向两侧的冷却油量供应一致性。
在一个实施例中,在顶部的主喷油孔46设置外环入油口34的一侧,至少部分相邻的主喷油孔46之间设置有辅助喷油孔47,辅助喷油孔47设置在主喷油孔46远离定子绕组16外缘的一侧。对于定子绕组16而言,在顶部位置位于端部绕组外缘的线圈高度是高于端部绕组内缘的线圈高度的,因此,位于中间位置以下区域的端部绕组外缘的线圈高度是低于端部绕组内缘的线圈高度的,将辅助喷油孔47设置在主喷油孔46远离定子绕组16外缘的一侧,使得其靠近端部绕组内缘,当冷却油在重力作用下向下流动时,会从位置较高的端部绕组内缘向位置较低的端部绕组外缘流动,从而只需要在定子绕组16轴向单侧进行补油,就能够实现整个定子绕组16端部绕组的冷却,辅助喷油孔47的设计与电机绕组的结构更加匹配,对于定子绕组16的冷却效果也更好,冷却油的利用效率也更高。
在本实施例中,在顶部的主喷油孔46远离外环入油口34的一侧,第一个相邻的主喷油孔46和第二个相邻的主喷油孔46之间的位置设置有两个辅助喷油孔47,两个辅助喷油孔47沿轴向排布,且分别位于第一个相邻的主喷油孔46和第二个相邻的主喷油孔46的中心连线的两侧,主要作用为实现该区域的补油。在第二个相邻的主喷油孔46和第三个相邻的主喷油孔46之间的位置设置有两个辅助喷油孔47,两个辅助喷油孔47沿轴向排布,且分别位于第二个相邻的主喷油孔46和第三个相邻的主喷油孔46的中心连线的两侧,主要作用为实现该区域的补油。对于该侧而言,由于距离外环入油口34较远,因此供油量较少,需要通过更多的辅助喷油孔47来补充供油量,实现顶部的主喷油孔46两侧的供油量一致,满足定子绕组16前端端部绕组的均匀冷却需求。
在一个实施例中,顶部的主喷油孔46周向两侧的第二喷油孔45结构也可以采用对称结构,也是能够实现对定子绕组16前端端部绕组的冷却效果的。
在一个实施例中,内圈喷油结构采用塑性材料制成,例如PA、PP、ABS等。
在一个实施例中,内圈喷油结构包括至少两个第一分体结构,至少两个第一分体结构沿周向依次首尾连接,形成内圈喷油结构。内圈喷油结构采用分体结构,能够降低内圈喷油结构的成形难度,便于进行内圈喷油结构内部油路结构的设计和加工,提高加工效率,降低加工成本。
第一分体结构包括位于第一端的公端51和位于第二端的母端52,相邻的第一分体结构的公端51与母端52配合固定连接,第一分体结构组合后,在内圈喷油结构形成沿周向贯通的第一环形通道49,第一喷油孔10与第一环形通道49连通。相邻的两个第一分体结构之间通过公端51和母端52实现连接,为了保证密封效果,相邻的两个第一分体结构之间设置有密封圈35,所有的第一分体结构沿周向依次排布并首尾连接,组合一体形成环形的内圈喷油结构。内圈喷油结构内部通过第一环形通道49形成环形贯穿式流体域,内圈喷油结构外圈开设有多个第一喷油孔10,各第一喷油孔10均与第一环形通道49连通,并通过第一环形通道49进行冷却油分配,当冷却油从内环入油口33进入到内圈喷油结构内部后,冷却油可以从第一喷油孔10径向喷出至定子绕组16的端部绕组内侧,对定子绕组16端部绕组进行冷却。
在一个实施例中,公端51和母端52均设置在第一分体结构的内周侧,公端51与母端52插接配合,形成内环安装凸台38,内环安装凸台38上设置有沿轴向贯穿的第一连接孔。在电机的前端盖26和后端盖11上分别设置有与内圈喷油结构相配合的安装结构,在安装结构上设置有沿轴向延伸的安装孔,第一连接孔与安装孔对应设置,内圈喷油结构通过内环安装凸台38上的第一连接孔与安装结构上的安装孔配合,通过螺栓进行连接,实现内圈喷油结构在前端盖26和后端盖11上的安装固定。内环安装凸台38的高度可以控制内圈喷油结构相对于定子绕组16端部绕组的相对位置,从而达到最佳冷却位置。
在一个实施例中,母端52结构包括两个相对设置的凸板,两个凸板之间形成插槽,公端51结构包括凸块,凸块对应于两个凸板之间的插槽设置,当将凸块插入插槽之后,公端51和母端52上的第一连接孔对齐,可以与安装结构通过螺栓进行固定连接,实现内圈喷油结构的固定组装,同时可以实现内圈喷油结构在前端盖26和后端盖11上的安装固定。
在一个实施例中,第一分体结构的公端51所在端的端面上设置有第一插接结构53,第一分体结构的母端52所在端的端面上设置有第二插接结构54,第一插接结构53和第二插接结构54插接配合,形成密封连接。通过在第一分体结构的一个端面上设置第一插接结构53,另一个端面上设置第二插接结构54,可以实现相邻的两个第一分体结构之间的插接配合,能够利用第一插接结构53和第二插接结构54之间的插接配合提高相邻的第一分体结构在连接位置处的密封性能。为了提高相邻的第一分体结构连接时的密封可靠性,在两个插接结构的配合位置处可以设置密封圈35等。
在一个实施例中,第一插接结构53为插槽,插槽例如为圆柱型槽,第二插接结构54为插头,插头例如为与圆柱型槽相适配的圆柱形头,第一环形通道49沿周向贯穿插头,插头与插槽插接配合时,相邻的第一分体结构的第一环形通道49相互连通。由于圆柱型槽与圆柱形头之间具有较长的配合长度,因此更加方便在圆柱型槽的槽壁与圆柱形头的外壁之间设置密封圈35来形成密封。在利用第一插接结构53和第二插接结构54的插接配合形成密封之后,相当于将相邻的第一分体结构之间的固定连接和密封功能分开设置,利 用公端51和母端52实现固定连接,利用第一插接结构53和第二插接结构54的插接配合实现密封,因此,公端51和母端52的连接无需考虑密封问题,同样的,第一插接结构53和第二插接结构54的插接配合也无需考虑连接问题,使得各自的功能更加简单化,结构设计更加简单,同时由于不同结构专门实现相应的功能,因此也能够进一步强化该结构所要实现功能的效果,使得相邻的第一分体结构之间的连接结构以及密封性能均能够得到进一步的增强。
在一个实施例中,至少其中一个第一分体结构上设置有内环入油口33,电机入油口9连通至内环入油口33,内环入油口33与第一环形通道49连通。电机入油口9的供油通过内环入油口33进入到第一环形通道49内,然后经第一环形通道49从各个第一喷油孔10喷出至定子绕组16的端部绕组上,对定子绕组16进行冷却降温。
在一个实施例中,内环入油口33处设置有第一入油接头,第一入油接头设置在内圈喷油结构的轴向端面上。通过增加该第一入油接头,能够方便实现内圈喷油结构与电机内部输油管道的连接。本实施例中,将第一入油接头设置在内圈喷油结构的轴向端面上,该轴向端面朝向电机外侧,由于内圈喷油结构安装在定子绕组16内侧,内圈喷油结构的轴向位置对应的为转子组件,径向外侧对应的为定子绕组16,径向内侧对应的为电机主轴1,因此在进行内圈喷油结构的安装固定时,只能够将内圈喷油结构固定在位于内圈喷油结构外侧的端盖上,并与端盖实现固定连接,而输油管道也相应地设置在端盖上,并在与内圈喷油结构的第一入油接头对应的位置实现密封连接。
在一个实施例中,内圈喷油结构为一体成型结构。由于内圈喷油结构可以采用注塑方式进行成型,因此,可以直接将内圈喷油结构通过注塑方式成型为一体式结构,从而提高内圈喷油结构的结构整体性,提高内圈喷油结构的密封性能,减少安装工序,提高安装效率。
内圈喷油结构的外缘设置有沿内圈喷油结构的轴向方向延伸的环形凸边,环形凸边的外周壁与内圈喷油结构的外周壁齐平。该环形凸边朝着端盖所在侧向外侧延伸,可以延长内圈喷油结构的外周壁轴向长度,增加内圈喷油结构与定子绕组16之间的配合面积,使得内圈喷油结构与定子绕组16之间能够形成更大面积的接触油膜进行换热,提高定子绕组16的换热效率。
在一个实施例中,内圈喷油结构采用塑性材料制成,例如PA、PP、ABS等。
在一个实施例中,外圈喷油结构包括多个第二分体结构,第二分体结构沿周向依次首尾连接,形成外圈喷油结构。外圈喷油结构采用分体结构,能够降低外圈喷油结构的成形难度,便于进行外圈喷油结构内部油路结构的设计和加工,提高加工效率,降低加工成本。
第二分体结构包括位于第一端的公端51和位于第二端的母端52,相邻的第二分体结构的公端51与母端52配合固定连接,第二分体结构组合后,在外圈喷油结构形成沿周向贯通的第二环形通道50,第二喷油孔45与第二环形通道50连通。相邻的两个第二分体结构之间通过公端51和母端52实现连接,为了保证密封效果,相邻的两个第二分体结构之间设置有密封圈35,所有的第二分体结构沿周向依次排布并首尾连接,组合一体形成环形的外圈喷油结构。外圈喷油结构内部通过第二环形通道50形成环形贯穿式流体域,外圈喷油结构外圈开设有多个第二喷油孔45,各第二喷油孔45均与第二环形通道50连通,并通过第二环形通道50进行冷却油分配,当冷却油从内环入油口33进入到外圈喷油结构内部后,冷却油可以从第二喷油孔45径向喷出至定子绕组16的端部绕组内侧,对定子绕组16端部绕组进行冷却。
在一个实施例中,公端51和母端52均设置在第二分体结构的外周侧,公端51与母端52插接配合,形成外环安装凸台37,外环安装凸台37上设置有沿轴向贯穿的第二连接孔。在机壳19上对应于外环安装凸台37的位置设置有外环安装座39,外环安装座39包括安装凹槽,在安装凹槽底部设置有沿轴向延伸的安装孔,第二连接孔与安装孔对应设置,外圈喷油结构沿轴向方向安装,使得外环安装凸台37进入到外环安装座39的安装凹槽内,并沿安装凹槽滑动至安装位置,使得外环安装凸台37止挡在安装凹槽的底部,此时外环安装凸台37上的第二连接孔与安装结构上的安装孔配合,通过螺栓进行连接,实现外圈喷油结构在机壳19的安装固定。
在一个实施例中,母端52结构包括两个相对设置的凸板,两个凸板之间形成插槽,公端51结构包括凸块,凸块对应于两个凸板之间的插槽设置,当将凸块插入插槽之后,公端51和母端52上的第二连接孔对齐,可以与安装结构通过螺栓进行固定连接,实现外圈喷油结构的固定组装,同时可以实现外圈喷油结构在前端盖26和后端盖11上的安装固定。
在一个实施例中,第二分体结构的公端51所在端的端面上设置有第一插接结构53,第二分体结构的母端52所在端的端面上设置有第二插接结构54,第一插接结构53和第二插接结构54插接配合,形成密封连接。通过在第二分体结构的一个端面上设置第一插接结构53,另一个端面上设置第二插接结构54,可以实现相邻的两个第二分体结构之间的插接配合,能够利用第一插接结构53和第二插接结构54之间的插接配合提高相邻的第二分体结构在连接位置处的密封性能。为了提高相邻的第二分体结构连接时的密封可靠性, 在两个插接结构的配合位置处可以设置密封圈35等。
在一个实施例中,第一插接结构53为插槽,插槽例如为圆柱型槽,第二插接结构54为插头,插头例如为与圆柱型槽相适配的圆柱形头,第二环形通道50沿周向贯穿插头,插头与插槽插接配合时,相邻的第二分体结构的第二环形通道50相互连通。由于圆柱型槽与圆柱形头之间具有较长的配合长度,因此更加方便在圆柱型槽的槽壁与圆柱形头的外壁之间设置密封圈35来形成密封。在利用第一插接结构53和第二插接结构54的插接配合形成密封之后,相当于将相邻的第二分体结构之间的固定连接和密封功能分开设置,利用公端51和母端52实现固定连接,利用第一插接结构53和第二插接结构54的插接配合实现密封,因此,公端51和母端52的连接无需考虑密封问题,同样的,第一插接结构53和第二插接结构54的插接配合也无需考虑连接问题,使得各自的功能更加简单化,结构设计更加简单,同时由于不同结构专门实现相应的功能,因此也能够进一步强化该结构所要实现功能的效果,使得相邻的第二分体结构之间的连接结构以及密封性能均能够得到进一步的增强。
在一个实施例中,至少其中一个第二分体结构上设置有外环入油口34,外环入油口34连通至电机入油口9,外环入油口34与第二环形通道50连通。电机入油口9的供油通过外环入油口34进入到第二环形通道50内,然后经第二环形通道50从各个第二喷油孔45喷出至定子绕组16的端部绕组上,对定子绕组16进行冷却降温。
在一个实施例中,内环入油口33处设置有第二入油接头,第二入油接头设置在外圈喷油结构的外周壁上。通过增加该第二入油接头,能够方便实现外圈喷油结构与电机内部输油管道的连接。本实施例中,第二入油接头设置在外圈喷油结构的外周壁上,在机壳19上的对应位置处设置有避让槽,第二入油接头可以沿该避让槽滑入安装位置,实现外圈喷油结构在机壳19内的安装定位。
在一个实施例中,外圈喷油结构为一体成型结构。由于外圈喷油结构可以采用注塑方式进行成型,因此,可以直接将外圈喷油结构通过注塑方式成型为一体式结构,从而提高外圈喷油结构的结构整体性,提高外圈喷油结构的密封性能,减少安装工序,提高安装效率。
外圈喷油结构的内周壁外缘设置有沿外圈喷油结构的轴向方向延伸的环形凸边,环形凸边的内周壁与外圈喷油结构的内周壁齐平。该环形凸边朝着端盖所在侧向外侧延伸,可以延长外圈喷油结构的内周壁轴向长度,增加外圈喷油结构与定子绕组16之间的配合面积,使得外圈喷油结构与定子绕组16之间能够形成更大面积的接触油膜进行换热,提高定子绕组16的换热效率。
本申请实施例还公开了一种轴承冷却结构,包括端盖,端盖设置有轴承室,轴承室内设置有轴承2,端盖上还开设有用于对内圈喷油结构进行供油的冷却油路,轴承室通过轴承供油路与冷却油路连通,轴承室通过冷却油路进行供油。上述的连通是指轴承室与冷却油路之间的状态,并不表示轴承室、轴承供油路与冷却油路之间具有直接连通关系,间接连通和直接连通都应该在本申请的保护范围内。
该轴承冷却结构利用内圈喷油结构的供油油路对轴承室进行供油,因此可以利用系统自身油路提供轴承室冷却油路,可以利用已有冷却油路为轴承提供冷却油,无需额外增加单独的轴承冷却油路,油路结构更加简单,使得电机结构也更加简单,加工成本能够得到有效控制。本实施例中的端盖,包括前端盖26和后端盖11,其中前端盖26为电机主轴1的轴伸端所在端的端盖,后端盖11为设置在电机主轴1的另一端的端盖。在进行端盖的描述过程中,如果没有特意强调端盖为前端盖26或后端盖11,那么这个端盖所具有的特征一般理解为前端盖26和后端盖11所共有的特征。本实施例中的内圈喷油结构包括前内圈喷油结构29和后内圈喷油结构6,其中前内圈喷油结构29与前端盖26连接,后内圈喷油结构6与后端盖11连接,前内圈喷油结构29的结构与后内圈喷油结构6的结构可以完全相同,也可以基本相同,只在局部位置有所不同,也可以采用两种不同结构的内圈喷油结构。轴承2包括前轴承和后轴承,其中前轴承设置在前端盖26的轴承室内,后轴承设置在后端盖11的轴承室内。在各轴承室内还设置有轴承钢套3,由于加强轴承室的结构强度。
本申请实施例通过在端盖设置专门的轴承润滑流道,可以将冷却油引入到电机的轴承室内,实现电机轴承的针对性润滑,节约成本,延长轴承使用寿命。
端盖上设置有电机入油口9,冷却油路包括径向流道和轴向流道,径向流道与电机入油口9连通,轴向流道设置在径向流道末端,轴向流道与内圈喷油结构连通。在本实施例中,由于内圈喷油结构需要与端盖之间实现连接,同时还需要在位置设计上对应定子绕组16,因此需要将内圈喷油结构和端盖沿轴向依次设置,并且设置内圈喷油结构和端盖之间在轴向位置实现连接,从而增加内圈喷油结构相对于端盖的轴向凸出高度,使得内圈喷油结构安装在端盖上之后,内圈喷油结构的轴向位置与定子绕组16的端部绕组能够对应,实现内圈喷油结构对端部绕组的内圈冷却。基于上述设计,在端盖上设置轴向流动,并使得内圈喷油结构的第一入油接头沿轴向延伸,与端盖上的安装结构实现对接,端盖的安装结构上设置有轴向流道,能够与第一入油接头的轴向流道连通,从而将冷却油路内的冷却 油供应至内圈喷油结构的第一环形通道49,实现对内圈喷油结构的供油。
在一个实施例中,端盖朝向内圈喷油结构的一端设置有用于安装内圈喷油结构的安装结构,该安装结构为内环安装座43,内环安装座43沿轴向向内圈喷油结构凸出,内圈喷油结构通过内环安装凸台38安装在内环安装座43上,并通过螺钉固定锁紧。
在一个实施例中,内环安装座43为多个,多个内环安装座43沿端盖的周向间隔排布,各内环安装座43上分别设置有安装内圈喷油结构的安装孔,轴向流道贯穿其中一个内环安装座43。由于内环安装座43设置在端盖的内端面上,而径向流道又是位于端盖内,因此,内环安装座43整个是位于端盖的端面外的,径向流道在到达内环安装座43所在的位置时,与内环安装座43上的轴向流道相交,从而将径向流道和轴向流道连通,冷却油经径向流道进入到内环安装座43上的轴向流道,然后通过内环安装座43上的轴向流道进入到内环安装凸台38的轴向流道内,进而通过内环安装凸台38的轴向流道输送至内圈喷油结构的第一环形通道49内。
轴向流道所在的内环安装座43上,安装孔相对于轴向流道向着内环安装座43的周向方向的一侧错位设置。一般而言,内环安装座43上的安装孔是设置在内环安装座43的中间位置,这样能够保证安装孔周侧的壁厚能够得到最大加强,提高内环安装座43的结构耐用性。当设置轴向流道后,由于轴向流道也设置在内环安装座43上,因此就需要考虑内环安装座43与安装孔之间的布局问题,由于轴向流道和安装孔均设置在同一个内环安装座43上,因此,不仅需要考虑安装孔侧壁的厚度,而且还需要考虑安装孔与轴向流道之间的间壁厚度。在本实施例中,为了保证轴向流道和安装孔的结构强度,将轴向流道设置在内环安装座43的径向外侧位置,将安装孔设置在轴向流道与内环安装座43的径向内侧边角之间的区域内,由于轴向流道本身并不承接较大的连接作用力,因此,将轴向流道设置在内环安装座43的径向外侧位置,并不会过于影响轴向流道的结构强度,也不会对内环安装座43的整体结构强度造成过大影响,将安装孔设置在轴向流道与内环安装座43的径向内侧边角之间的区域,是由于轴向流道与内环安装座43的径向内侧边角之间的区域面积较大,具有足够的空间来设置安装孔,也能够在实现轴向流道的布置之后,使得安装孔的位置安装可以保证安装孔的壁厚在当前的结构下最大化,使得内环安装座43的整体结构得到优化,结构强度得到保证,在实现流道的合理布置的同时,使得内环安装座43的安装支撑以及连接能力得到保证。
在一个实施例中,端盖的下部设置有端盖集油槽44。在本实施例中,前端盖26和后端盖11的下部均设置有端盖集油槽44,机壳19的底部设置有机壳集油槽40,电机装配后,端盖集油槽44和机壳集油槽40连通,从而方便冷却油的收集以及循环利用。由于前端盖26和后端盖11均设置有收集冷却油的端盖集油槽44,且前端盖26和后端盖11的端盖集油槽44均连通机壳19的机壳集油槽40,因此在前端盖26、后端盖11和机壳19装配组合后,通过增加油泵、换热器等配件,可以实现电机内部冷却油自循环。
端盖朝向内圈喷油结构的一端设置有凸起48,凸起48连接在电机入油口9和轴向流道之间,径向流道至少部分设置在凸起48上。由于端盖本身的厚度较薄,如果直接在端盖上开设径向流道,就会导致端盖在设置径向流道的位置厚度较小,不能够满足端盖的结构强度需求,因此,在径向流道的设置位置增加条形凸起48,能够在条形凸起48所对应的位置设置径向流道,并且使得径向流道不用完全局限在端盖的盖体内,可以至少部分设置在条形凸起48内,通过增加端盖局部厚度的方式来避免设置径向流道对于端盖结构所造成的不利影响,保证端盖的整体结构强度,保证端盖的耐用性。
在一个实施例中,端盖包括后端盖11,后端盖11远离内圈喷油结构的端面上开设有后轴承流道4,径向流道包括设置在后端盖11上的第一径向流道8,第一径向流道8上开设有第一轴向喷油孔7,后轴承流道4与第一轴向喷油孔7连通,轴承室包括设置在后端盖11上的后轴承室,后轴承室依次通过后轴承流道4和第一轴向喷油孔7与第一径向流道8连通。在本实施例中,电机入油口9开设在后端盖11上,并且连通第一径向流道8,冷却油从电机入油口9进入到第一径向流道8之后,从第一径向流道8经第一轴向喷油孔7喷油到后轴承流道4,冷却、润滑后轴承。
在一个实施例中,端盖包括前端盖26,前端盖26上开设有前轴承流道36,径向流道包括设置在前端盖26上的第四径向流道25,轴向流道包括设置在前端盖26上的第四轴向流道28,轴承室包括设置在前端盖26上的前轴承室,前轴承室通过前轴承流道36和第四轴向流道28与第四径向流道25连通。在本实施例中,电机入油口9与设置在机壳19上的机壳流道18连通,然后通过机壳流道18与前端盖26上的第四径向流道25连通,之后通过第四径向流道25流动至第四轴向流道28,经第四轴向流道28进入前轴承流道36,冷却、润滑前轴承。
在一个实施例中,前轴承流道36开设在前轴承室的侧壁上,前轴承流道36沿着由上而下的方向向着远离内圈喷油结构的方向延伸,冷却油进入到前轴承流道36后,沿着前轴承流道36流动至前轴承室内,进入前轴承室内对前轴承进行润滑。
在一个实施例中,前端盖26的内壁面上设置有两个相对设置的导油板55,两个导油板55之间形成上下延伸的导油通道56,前轴承流道36设置在导油通道56底部,并与导 油通道56连通。在本实施例中,通过设置导油板55,并利用导油板55形成导油通道56,能够利用导流通道对从第四轴向流道28输送过来的冷却油进行导流,使得冷却油能够被导油通道56汇聚,并在重力作用以及油压作用下沿着导油通道56进入前轴承流道36,从而提高冷却油的利用效率,使得冷却油能够更加集中地流动至前轴承室内。
在一个实施例中,内圈喷油结构的侧壁上开设有第二轴向喷油孔32,第二轴向喷油孔32与内圈喷油结构的第一环形通道49连通,第二轴向喷油孔32朝向导油通道56。在本实施例中,第四轴向流道28的冷却油先进入到第一环形通道49内,然后部分冷却油从第一喷油孔10喷出,对定子绕组16进行冷却,部分冷却油从第二轴向喷油孔32喷出至前端盖26的内壁面,并沿着前端盖26的内壁面进入到导油通道56,在导油通道56内汇集后通过前轴承流道36输送至前轴承室内。
根据本申请的实施例,驱动电机包括定子绕组16,还包括上述的定子冷却结构,定子绕组16位于定子冷却结构的内圈喷油结构和外圈喷油结构之间。
根据本申请的实施例,驱动电机包括定子绕组16,还包括上述的外圈喷油结构,外圈喷油结构设置在定子绕组16的外周侧。
根据本申请的实施例,驱动电机包括轴承冷却结构,该轴承冷却结构为上述的轴承冷却结构。
在一个实施例中,驱动电机包括前端盖26、前内圈喷油结构29、前外圈喷油结构23、机壳19、后内圈喷油结构6、后外圈喷油结构14、后端盖11、定子组件、转子组件以及电机主轴1,其中在机壳19上开设有冷却水流道和冷却油流道,冷却水流道和冷却油流道相互间隔开,冷却水能够通过冷却水流道与冷却油流道内的冷却油进行换热,对冷却油进行降温,从而实现油冷和水冷混合。冷却油可以进入电机内部冷却定子绕组16、转子,并且能够冷却并润滑轴承,冷却水可以支架冷却定子铁芯17,并间接冷却转子铁芯20。在转子铁芯20的两端设置有转子挡板27,在前端盖26的轴向外侧设置有油封31、油封盖板30以及密封圈35等,能够提高前端盖26的端部密封性能。
机壳19采用油水混合机壳19,在机壳19上开设有进出水口和冷却油流道,冷却油流道与机壳19内部的水道相互隔离,可实现电机油冷与水冷的同时冷却,有效提高冷却效率。本申请的水冷结构可以借用传统新能源汽车上的水冷系统,不会影响新能源汽车上原本的冷却系统,同时也无需新增外部冷却油换热系统,冷却水在机壳19内冷却定子铁芯17的同时可以冷却电机内部的冷却油,可以大幅提高冷却效率。本申请无需在传统新能源汽车上新增相应的设备部件,因此还可节约成本。
在本实施例中,电机还包括前T型连通管24和后T型连通管12,其中前T型连通管24和后T型连通管12结构相同,后T型连通管12包括第二轴向流道13和第二径向流道15,其中第二轴向流道13的两端分别连接在后端盖11和机壳19之间,将后端盖11上的电机入油口9与机壳19上的机壳流道18连通,第二径向流道15连接至后外圈喷油结构14的外环入油口34,实现对后外圈喷油结构14的供油。前T型连通管24包括第三轴向流道21和第三径向流道22,其中第三轴向流道21的两端分别连接在前端盖26和机壳19之间,将前端盖26上的第四径向流道25与机壳19上的机壳流道18连通,第三径向流道22连接至前外圈喷油结构23的外环入油口34,实现对前外圈喷油结构23的供油。前T型连通管24和后T型连通管12在连接位置处均设置有密封圈35,从而提高密封效果,避免发生漏油现象,保证冷却油输送的油压和油量。
T型连通管采用塑性材料制成,如:PA、PP、ABS等,且机壳流道18两端的T型连通管结构相同,即T型连通管可通用。T型连通管内部为贯通式结构,在T型连通管的三个出口处均设有密封槽,装配密封圈35后,通过与电机前端盖26、后端盖11、机壳19安装位的相互装配挤压,进而实现密封,T型连通管底部出油口同时对插外圈喷油结构的外环入油口34。冷却油流入T型连通管内部后,冷却油沿着外圈喷油结构双边流动,同时随着冷却油的充满,冷却油会从外圈喷油结构的外圆周侧壁开设的第二喷油孔45喷出,实现对定子绕组16的端部外壁喷油冷却(第二喷油孔45位置可以分布在定子绕组16端部外壁任一区域,优选在定子绕组16端部外壁轴向1/2位置处)。
后端盖11上设置有电机入油口9、第一径向流道8、第一轴向流道5、第一轴向喷油孔7和后轴承流道4,机壳19上设置有机壳流道18、冷却水流道和冷却油流道,前端盖26上设置有第四径向流道25、第四轴向流道28和前轴承流道36,后内圈喷油结构6安装在后端盖11上,后内圈喷油结构6的内环入油口33与第一轴向流道5连通,后外圈喷油结构14安装在机壳19上,后外圈喷油结构14的外环入油口34与第二径向流道15连通,前内圈喷油结构29安装在前端盖26上,前内圈喷油结构29的内环入油口33与第四轴向流道28连通,前外圈喷油结构23安装在机壳19上,前外圈喷油结构23的外环入油口34与第三径向流道22连通。
定子组件包括定子铁芯17和定子绕组16,转子组件包括转子铁芯20,定子组件安装在机壳19上,转子组件安装在电机主轴1上。
外圈喷油结构依据设置位置的不同与电机其它结构配合形成定子绕组16前端外圈冷却油路和定子绕组16后端外圈冷却油路,定子绕组16前端外圈冷却油路中,冷却油从后 端盖11上的电机入油口9进入,连通后T型连通管12的第二轴向流道13,再连通机壳19的机壳流道18,再到前T型连通管24的第三轴向流道21,然后连通第三径向流道22,从前外圈喷油结构23的多个第二喷油孔45进行喷油,冷却定子绕组16前端端部绕组外侧。定子绕组16后端外圈冷却油路中,冷却油从后端盖11上的电机入油口9进入,连通后T型连通管12的第二轴向流道13,然后连通第二径向流道15,从后外圈喷油结构14的第二喷油孔45喷油,冷却定子组件后端端部绕组外侧。
内圈喷油结构依据设置位置的不同与电机其它结构配合形成定子绕组16前端内圈冷却油路和定子绕组16后端内圈冷却油路,定子绕组16前端内圈冷却油路中,冷却油从后端盖11上的电机入油口9进入,连通后T型连通管12的第二轴向流道13,再连通机壳19的机壳流道18,再到前T型连通管24的第三轴向流道21,然后连通前端盖26上的第四径向流道25,之后经第四轴向流道28进入到前内圈喷油结构29,通过前内圈喷油结构29的第一喷油孔10进行喷油,冷却定子绕组16前端端部绕组内圈。定子绕组16后端内圈冷却油路中,冷却油从后端盖11上的电机入油口9进入,连通后端盖11的第一径向流道8,然后经第一轴向流道5进入到后内圈喷油结构6,从后内圈喷油结构6的第一喷油孔10进行喷油,冷却定子绕组16后端端部绕组内圈。
在本实施例中,机壳19上设置有入水口41和出水口42,其中入水口41和出水口42位于机壳流道18的周向两侧,且入水口41和出水口42之间的最小间距大于机壳流道18的最大直径,为了避免冷却油与冷却水的流道之间壁厚过薄导致结构稳定性较差的问题,作为一种优选的实施例,入水口41和出水口42之间的间距与机壳流道18的最大直径的差值在10mm至30mm之间,既可以避免冷却水流道距离机壳流道18过远导致冷却水与冷却油换热效率降低,使得冷却水能够更加充分地充满机壳19内部,对机壳起到有效的冷却降温作用,又能够避免冷却水流道与机壳流道之间的距离过近容易导致流道连通的问题,提高油水分离的稳定性。在本实施例中,入水口41与机壳流道18之间的距离和出水口42与机壳流道18之间的距离相同。在一个实施例中,也可以使得入水口41与机壳流道18之间的距离小于出水口42与机壳流道18之间的距离,从而更加有效地利用入水口41处的冷却水温度更低的特点,提高冷却水与冷却油之间的换热效率。
本申请的驱动电机,冷却油路可以分成两个部分,冷却油由外部供油路通过电机入油口9进入电机内部,分成两个支路,第一支路进入第一径向流道8,第二支路进入后T型连通管12的第二轴向流道13,冷却油分别沿第一支路和第二支路开始双向流动。第一支路分为冷却、润滑后轴承油路和冷却定子绕组16后端端部绕组内圈油路。第二支路分为冷却定子绕组16后端端部绕组外圈油路、冷却定子绕组16前端端部绕组外圈油路、冷却定子绕组16前端端部绕组内圈油路和冷却润滑前轴承油路。
根据本申请的实施例,新能源汽车包括上述的外圈喷油结构、轴承冷却结构、定子冷却结构或驱动电机。
本申请驱动电机冷却系统的混合冷却方式可从根本上解决当前水冷式驱动电机定子绕组16无法得到冷却的难题,而且可以解决传统油冷方式存在绕组冷却不均匀,局部温度过高的问题,减小电机内部热岛效应,从而提高电机稳定性和使用寿命;还可以增强电机内部主要的发热源的散热性能,提升电机功率密度,增强性能,同时简化传统油冷样机复杂的外部冷却结构,节约成本,实现主驱电机系统的轻量化,集成化。
本领域的技术人员容易理解的是,在不冲突的前提下,上述各有利方式可以自由地组合、叠加。
以上仅为本申请的较佳实施例而已,并不用以限制本申请,凡在本申请的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本申请的保护范围之内。以上仅是本申请的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本申请技术原理的前提下,还可以做出若干改进和变型,这些改进和变型也应视为本申请的保护范围。

Claims (23)

  1. 一种定子冷却结构,用于对定子绕组进行冷却,包括电机入油口、内圈喷油结构和外圈喷油结构,所述内圈喷油结构设置在所述定子绕组的内周侧,所述外圈喷油结构设置在所述定子绕组的外周侧,所述内圈喷油结构和所述外圈喷油结构均与所述电机入油口连通,所述内圈喷油结构包括第一喷油孔,所述外圈喷油结构包括第二喷油孔,所述第一喷油孔的开口朝向所述定子绕组的内周壁,所述第二喷油孔的开口朝向所述定子绕组的外周壁。
  2. 根据权利要求1所述的定子冷却结构,其中,所述第一喷油孔设置在所述内圈喷油结构的外周壁,并沿所述内圈喷油结构的径向延伸;和/或,所述第二喷油孔设置在所述外圈喷油结构的内周壁,并沿所述外圈喷油结构的径向延伸。
  3. 根据权利要求1所述的定子冷却结构,其中,所述第一喷油孔为多个,多个所述第一喷油孔沿所述内圈喷油结构的外周周向均匀间隔排布;和/或,所述第二喷油孔为多个,多个所述第二喷油孔沿所述外圈喷油结构的内周周向均匀间隔排布。
  4. 根据权利要求1所述的定子冷却结构,其中,所述内圈喷油结构和所述外圈喷油结构成组设置形成喷油环组件,同一所述喷油环组件的所述内圈喷油结构位于所述外圈喷油结构的径向内侧。
  5. 根据权利要求4所述的定子冷却结构,其中,所述喷油环组件为至少两个,所述定子绕组的第一端对应设置有至少一个所述喷油环组件,所述定子绕组的第二端对应设置有至少一个所述喷油环组件,所述定子绕组的端部位于所述喷油环组件的内圈喷油结构和外圈喷油结构之间。
  6. 根据权利要求5所述的定子冷却结构,其中,位于所述定子绕组两端的所述喷油环组件均与所述电机入油口连通。
  7. 根据权利要求1至6中任一项所述的定子冷却结构,其中,所述内圈喷油结构包括至少两个第一分体结构,至少两个所述第一分体结构沿周向依次首尾连接,形成所述内圈喷油结构。
  8. 根据权利要求7所述的定子冷却结构,其中,所述第一分体结构包括位于第一端的公端和位于第二端的母端,相邻的所述第一分体结构的公端与母端配合固定连接,所述第一分体结构组合后,在所述内圈喷油结构形成沿周向贯通的第一环形通道,所述第一喷油孔与所述第一环形通道连通。
  9. 根据权利要求8所述的定子冷却结构,其中,所述公端和所述母端均设置在所述第一分体结构的内周侧,所述公端与所述母端插接配合,形成内环安装凸台,所述内环安装凸台上设置有沿轴向贯穿的第一连接孔。
  10. 根据权利要求9所述的定子冷却结构,其中,所述第一分体结构的公端所在端的端面上设置有第一插接结构,所述第一分体结构的母端所在端的端面上设置有第二插接结构,所述第一插接结构和所述第二插接结构插接配合,形成密封连接。
  11. 根据权利要求10所述的定子冷却结构,其中,所述第一插接结构为插槽,所述第二插接结构为插头,所述第一环形通道沿周向贯穿所述插头,所述插头与所述插槽插接配合时,相邻的所述第一分体结构的第一环形通道相互连通。
  12. 根据权利要求8至11中任一项所述的定子冷却结构,其中,至少其中一个所述第一分体结构上设置有内环入油口,所述电机入油口连通至所述内环入油口,所述内环入油口与所述第一环形通道连通。
  13. 根据权利要求12所述的定子冷却结构,其中,所述内环入油口处设置有第一入油接头,所述第一入油接头设置在所述内圈喷油结构的轴向端面上。
  14. 根据权利要求1至6中任一项所述的定子冷却结构,其中,所述内圈喷油结构为一体成型结构。
  15. 根据权利要求1至6中任一项所述的定子冷却结构,其中,所述内圈喷油结构的外缘设置有沿所述内圈喷油结构的轴向方向延伸的环形凸边,所述环形凸边的外周壁与所述内圈喷油结构的外周壁齐平。
  16. 根据权利要求1至6中任一项所述的定子冷却结构,其中,所述外圈喷油结构包括多个第二分体结构,所述第二分体结构沿周向依次首尾连接,形成所述外圈喷油结构。
  17. 根据权利要求16所述的定子冷却结构,其中,所述第二分体结构包括位于第一端的公端和位于第二端的母端,相邻的所述第二分体结构的公端与母端配合固定连接,所述第二分体结构组合后,在所述外圈喷油结构形成沿周向贯通的第二环形通道,所述第二喷油孔与所述第二环形通道连通。
  18. 根据权利要求17所述的定子冷却结构,其中,所述第二分体结构的公端和母端均设置在所述第二分体结构的外周侧,所述公端与所述母端插接配合,形成外环安装凸台, 所述外环安装凸台上设置有沿轴向贯穿的第二连接孔。
  19. 根据权利要求17所述的定子冷却结构,其中,至少一个所述第二分体结构的外周壁上设置有径向入油口,所述电机入油口与所述径向入油口连通,所述径向入油口与所述第二环形通道连通。
  20. 根据权利要求1至6中任一项所述的定子冷却结构,其中,所述外圈喷油结构为一体成型结构。
  21. 根据权利要求20所述的定子冷却结构,其中,所述外圈喷油结构的外周壁上设置有外环安装凸台,所述外环安装凸台上设置有沿轴向贯穿的第二连接孔。
  22. 一种驱动电机,包括定子绕组,还包括权利要求1至21中任一项所述的定子冷却结构,所述定子绕组位于所述定子冷却结构的内圈喷油结构和外圈喷油结构之间。
  23. 一种新能源汽车,包括权利要求1至21中任一项所述的定子冷却结构或权利要求22所述的驱动电机。
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