WO2023178927A1 - 一种电机油冷系统及电机油冷方法 - Google Patents

一种电机油冷系统及电机油冷方法 Download PDF

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Publication number
WO2023178927A1
WO2023178927A1 PCT/CN2022/116698 CN2022116698W WO2023178927A1 WO 2023178927 A1 WO2023178927 A1 WO 2023178927A1 CN 2022116698 W CN2022116698 W CN 2022116698W WO 2023178927 A1 WO2023178927 A1 WO 2023178927A1
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WIPO (PCT)
Prior art keywords
oil
cooling
housing
rotor
channel
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PCT/CN2022/116698
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English (en)
French (fr)
Inventor
王宗浩
赵德建
孙明扬
徐帅
王朋
Original Assignee
上海纳铁福传动系统有限公司
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Priority claimed from CN202210288070.6A external-priority patent/CN114629298A/zh
Priority claimed from CN202220637946.9U external-priority patent/CN217159491U/zh
Application filed by 上海纳铁福传动系统有限公司 filed Critical 上海纳铁福传动系统有限公司
Publication of WO2023178927A1 publication Critical patent/WO2023178927A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/19—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil

Definitions

  • the invention belongs to the technical field of motor heat dissipation, and specifically relates to a motor oil cooling system and a motor oil cooling method.
  • Chinese patent CN206149098U discloses an oil-cooled motor and vehicle.
  • the rotor oil circuit of this patent is realized through the opening of the balance plate and the opening of the rotor core.
  • Chinese patent CN111181300A discloses an oil-cooling structure of a permanent magnet synchronous motor.
  • the patented housing oil circuit consists of an upper and lower housing. There is no fixed oil circuit after the cooling oil enters the housing, and there are many parallel branches. , it is difficult to ensure the flow direction.
  • the rotor oil circuit of this patent only has a simple axial oil passage. The cooling oil directly enters the oil passage hole of the rotor core from the rotating shaft.
  • the rotor core structure is complex.
  • the present invention provides a motor oil cooling system and a motor oil cooling method, which can simultaneously cool the stator core, stator windings, rotor core, bearings and other heating parts to fully cool the motor.
  • a motor oil cooling system includes an oil-cooling housing assembly, a stator assembly disposed in the oil-cooling housing assembly, and a rotor assembly disposed in the stator assembly and rotationally connected to the stator assembly through a bearing, so There is an end cover assembly at the right end of the oil-cooling housing assembly. There is a housing oil path between the oil-cooling housing assembly, the stator assembly and the end cover assembly. There is a rotor inside the rotor assembly. Oil circuit, the oil cooling housing assembly is provided with a housing oil inlet channel and a housing oil return channel that are connected to the housing oil circuit, and the rotor assembly is provided with a rotor oil inlet channel that is connected to the rotor oil circuit. channel, the rotor oil channel is connected with the housing oil return channel.
  • the oil-cooled housing assembly includes a main housing.
  • Oil injection rings are sealed and fixed on the inner circumferential surfaces of the left and right ends of the main housing.
  • the main housing between the two oil injection rings is sealed and fixed.
  • a plurality of oil passage ribs are provided on the circular surface of the body;
  • the stator assembly includes a stator core with slots and a stator winding wound in the slots of the stator core and having left and right ends.
  • the stator iron The core is arranged in the main housing and the outer circular surface contacts the oil channel rib and forms an interference fit.
  • the stator winding corresponds to the position of the fuel injection ring on the corresponding side; the oil inlet channel of the housing is arranged on the At the left end of the main housing, a plurality of oil channel ribs, the outer circumferential surface of the stator core and two fuel injection rings form an oil delivery channel connected to the oil inlet channel of the housing.
  • the fuel injection ring is provided with an
  • the oil inlet connected to the oil delivery channel is provided with a plurality of oil outlets on the inner circumferential surface of the fuel injection ring.
  • the housing oil return channel is provided on the outer circumferential surface of the main housing, and the end cover assembly includes a main end cover and a bearing steel insert provided in the main end cover, as described on the right
  • the bearing is installed in the bearing steel insert.
  • An oil collecting ring is provided on the outer surface of the bearing steel insert.
  • the bearing steel insert is also provided with an opening communicating with the oil collecting ring.
  • the main main body The end cover is provided with an oil return hole;
  • the cooling oil in the oil injection ring on the left side is used to flow to the outside of the stator winding on the left end through a plurality of oil outlets on the corresponding side, and directly flows into the housing return In the oil channel;
  • the cooling oil in the oil spray ring on the right side is used to flow to the outside of the stator winding on the right end through a plurality of oil outlets on the corresponding side, and part of the cooling oil enters the oil collecting ring and passes through all
  • the opening flows into the bearing surface and interior on the right side, and enters the housing oil return passage through the oil return hole.
  • the axial channel formed by the keyway, the welding groove and the marking groove on the outer circumferential surface of the stator core is blocked by oil-resistant silicone rubber; or, the right end of the stator core is provided with multiple pieces for blocking the stator iron. Punching sheet of axial channel on core outer circle.
  • oil channel ribs are arranged along the axial direction of the main housing so that the oil delivery channel forms a Z-shaped channel, and the oil channel ribs are provided with axial auxiliary ribs on their surfaces.
  • the fuel injection ring is integrated with the inner circular surface of the corresponding side end of the main housing through friction stir welding or argon arc welding.
  • the oil outlet hole is an inclined hole.
  • the rotor assembly includes a hollow shaft, a rotor core corresponding to the position of the stator core is sleeved on the hollow shaft, and the hollow shaft is fixedly sleeved on the left and right ends of the rotor core respectively.
  • Balance plate the inner cavity of the hollow shaft forms the rotor oil inlet channel, the hollow shaft is provided with rotor oil outlet holes at the two balance plate positions, and both balance plates are provided with oil passages.
  • the oil passage assembly on the left side includes an annular oil passage provided on the right side of the balance plate on the left side and connected with the corresponding oil outlet hole of the rotor. The inner edge of the annular oil passage on the left side is provided with the corresponding oil outlet hole.
  • the oil inlet groove corresponding to the rotor oil outlet hole, the right side of the balance plate on the left extends outward from the outer edge of the annular oil passage, and there are multiple iron core oil inlet channels.
  • the rotor iron core is provided with multiple A weight reduction hole is connected to the iron core oil inlet channel.
  • the balance plate on the left is also provided with a plurality of avoidance holes outside the annular oil channel; the cooling oil in the annular oil channel is used to pass through the multiple iron cores.
  • the oil inlet passage enters the weight reduction hole and is thrown into the oil-cooling housing cavity through a plurality of avoidance holes to be thrown onto the bearing.
  • the inner cavity of the hollow shaft is provided with an oil sealing plug on the right side of the balance plate.
  • the number of iron core oil inlets and escape holes on the left balance plate is the same and alternately distributed.
  • the positions of the multiple iron core oil inlets on the left and the multiple escape holes on the right are one by one. correspond.
  • the right side of the balance plate on the left side is also provided with a plurality of oil dump channels that are the same number as the iron core oil inlet channels at the outer edge of the annular oil channel.
  • the iron core oil inlet channels and escape holes are Distributed alternately with the oil rejection passages, the cooling oil in the annular oil passage is used to be thrown to the inside of the stator winding through a plurality of the oil rejection passages, and flows into the housing oil return passage.
  • the number of oil inlet channels of the iron core on the left is 2n
  • n is a positive integer
  • two first positioning keyways and two second positioning keyways are respectively provided on the outer circumferential surface of the hollow shaft between the two balance plates.
  • Two positioning keyways, the first positioning keyway and the second positioning keyway are both parallel to the axis of the hollow shaft, the horizontal length of the first positioning keyway is equal to the horizontal distance between the two balance plates, and the two second positioning keyways are Two positioning keyways are close to the balance plate on the right side, and the circumferential angle between the two first positioning keyways is equal to the circumferential angle between the two second positioning keyways and both are 180°.
  • the circumferential angle between a positioning keyway and the adjacent second positioning keyway is 90°/n.
  • the two balance plates are designed to be the same part.
  • the two balance plates are assembled with the hollow shaft. After being positioned by the two first positioning keyways and the two second positioning keyways, an angular deviation of 90°/n is formed with each other, so that the multiple rotor oil inlet channels of the balance plate on the left are aligned with those on the right.
  • the positions of the plurality of escape holes of the balance plate correspond one to one.
  • oil guide fins or oil guide grooves are also provided on the opposite sides of the two balance plates, and the cooling oil flowing out of the rotor core is used to lead to the bearing through the oil guide fins or oil guide grooves;
  • the oil rejection channel is a chute;
  • the motor oil cooling system also includes a motor external oil pump, a filter and a radiator, and the cooling oil in the housing oil return channel is used to pass through the motor external oil pump in sequence , filter and radiator, return to the housing oil inlet channel and the rotor oil inlet channel to circulate again.
  • a motor oil cooling method using the above motor oil cooling system for motor oil cooling, including the following cooling methods:
  • the cooling oil enters the housing oil passage from the housing oil inlet channel to cool the stator core, the outer side of the stator winding and the right bearing of the stator assembly, and then the cooling oil enters the housing oil return channel;
  • the cooling oil simultaneously enters the rotor oil passage from the rotor oil inlet channel to cool the rotor core of the rotor assembly, the inside of the stator winding and the left and right bearings, and then the cooling oil enters the housing. Oil return channel.
  • cooling oil enters the main housing of the oil-cooling housing assembly from the housing oil inlet channel, and flows to the oil delivery channel to cool the stator iron of the stator assembly. core; after the cooling oil flows several times in the oil delivery channel, it enters the left fuel injection ring and the right fuel injection ring through the oil inlet on the left fuel injection ring and the oil inlet on the right fuel injection ring respectively.
  • the cooling oil in the oil injection ring on the left side flows to the outside of the left stator winding through multiple oil outlets on the corresponding side, and flows directly into the oil return channel of the housing, and the cooling oil in the oil injection ring on the right side flows through the corresponding side
  • Multiple oil outlets pour out to the outside of the right end stator winding, and part of the cooling oil enters the oil collection ring of the end cover assembly and flows into the surface and interior of the bearing on the right through the opening of the bearing steel insert to cool the right side. side of the bearing, and enters the oil return channel of the housing through the oil return hole of the end cover assembly.
  • the cooling oil enters the hollow shaft of the rotor assembly from the rotor oil inlet channel at the same time, and enters the corresponding side balance plate through the rotor oil outlet hole and oil inlet groove on the corresponding side.
  • the cooling oil in the annular oil passage enters the weight reduction hole of the rotor core through multiple iron core oil inlet channels, and is thrown into the oil cooling housing cavity through multiple avoidance holes on the balance plate, and then to the left and right
  • the bearings on both sides are used to cool the left and right bearings.
  • the cooling oil in the annular oil passage is also thrown to the inside of the stator winding through multiple oil throwing channels to cool the stator winding. Finally, the cooling oil flows into the housing under the action of gravity and returns. Oil channel.
  • the motor oil cooling system of the present invention includes an oil-cooling housing assembly, a stator assembly located in the oil-cooling housing assembly, and a rotor assembly located in the stator assembly and rotationally connected to the stator assembly through a bearing.
  • the casing assembly is provided with a casing oil inlet channel and a casing oil return channel that are connected to the casing oil circuit.
  • the rotor assembly is provided with a rotor oil inlet channel that is connected to the rotor oil circuit.
  • the rotor oil circuit is connected to the casing oil return channel.
  • the oil channels are connected; in this way, the cooling oil enters the housing oil circuit from the housing oil inlet channel to cool the stator core of the stator assembly, the outside and right side bearings of the stator winding, and the cooling oil enters the rotor oil circuit from the rotor oil inlet channel at the same time.
  • the cooling oil then enters the oil return channel of the housing. Therefore, the motor oil cooling system can fully cool the main heating parts of the motor.
  • the oil-cooled housing assembly includes a main housing.
  • the inner circular surfaces of the left and right ends of the main housing are respectively sealed and fixed with oil injection rings.
  • the inner circular surface of the main housing between the two fuel injection rings is provided with multiple oil passage ribs.
  • the stator assembly includes a stator core with tooth slots and a stator winding wound in the stator core tooth slots and having left and right ends.
  • the stator core is arranged in the main housing and the outer circular surface contacts the oil passage ribs.
  • the stator winding corresponds to the position of the corresponding side fuel injection ring
  • the oil inlet channel of the housing is set at the left end of the main housing, surrounded by multiple oil passage ribs, the outer circumferential surface of the stator core and the two fuel injection rings
  • the fuel injection ring is provided with an oil inlet connected to the oil delivery channel.
  • the oil return channel of the housing is provided on On the outer circumferential surface of the main housing, the end cover assembly includes the main end cover and the bearing steel insert installed in the main end cover. The right bearing is installed in the bearing steel insert.
  • the outer surface of the bearing steel insert is equipped with an oil collector. ring, the bearing steel insert is also provided with an opening connected to the oil collection ring, and the main end cover is provided with an oil return hole; in this way, the cooling oil enters the main housing from the oil inlet channel of the housing and flows to the oil delivery channel to Cool the stator core. After the cooling oil flows in the oil delivery channel for several turns, it enters the left and right injection rings through the oil inlet on the left fuel injection ring and the oil inlet on the right fuel injection ring respectively. In the oil ring, the cooling oil in the left oil injection ring flows to the outside of the left stator winding through multiple oil outlets on the corresponding side, and directly flows into the oil return channel of the housing.
  • the cooling oil in the right oil injection ring flows through the corresponding Multiple oil outlets on the side pour out to the outside of the right stator winding, and part of the cooling oil enters the oil collection ring and flows into the surface and interior of the right bearing through the opening of the bearing steel insert to cool the right bearing, and passes through the main end cover
  • the oil return hole on the oil return hole enters the oil return channel of the shell.
  • the oil channel ribs are arranged along the axial direction of the main housing, so that the oil transmission channel forms a Z-shaped channel. Since the inner circular surface of the main housing and the outer circular surface of the stator core form a Z-shaped oil transport channel, the channel area is the same as that of the water cooling The shell is quite large, ensuring that the cooling oil fully flows through the stator core at a fast flow rate, which not only provides sufficient cooling oil flow, but also makes full use of the high efficiency of direct cooling, so that the stator core is efficiently and adequately cooled; due to The oil injection ring oil lines on the left and right sides are connected in series with the oil delivery channels, which ensures that all cooling oil entering the oil inlet channel of the housing is poured out of the stator winding, ensuring that the stator winding has sufficient cooling oil flow; The oil channel ribs on the circular surface are arranged axially, which can greatly simplify the casting process; because the oil injection ring is connected to the inner circular surface of the corresponding side end of the main housing through
  • the axial channel formed by the keyway, welding groove and marking groove on the outer circumferential surface of the stator core is blocked by oil-resistant silicone rubber to avoid leakage of cooling oil in the Z-shaped channel; alternatively, the right end of the stator core is provided with multiple The sheet is punched to block the axial passage of the outer circle of the stator core; the surface of the oil passage ribs is provided with axial auxiliary ribs, which can not only increase the flow area of the cooling oil, but also improve the strength of the main shell; the oil outlet hole is inclined holes, and adjust the angles of the inclined holes to achieve a better oil spraying effect.
  • the rotor assembly includes a hollow shaft.
  • the hollow shaft is covered with a rotor core corresponding to the position of the stator core.
  • the hollow shaft is fixedly equipped with balance plates at the left and right ends of the rotor core.
  • the hollow shaft has an inner cavity.
  • a rotor oil inlet channel is formed, and the hollow shaft is provided with rotor oil outlet holes at the two balance plates.
  • Both balance plates are equipped with oil circuit components.
  • the left oil circuit component includes a component located on the right side of the left balance plate. And there is an annular oil passage connected with the corresponding rotor oil outlet.
  • the inner edge of the left annular oil passage is equipped with an oil inlet groove corresponding to the corresponding rotor oil outlet.
  • the right side of the left balance plate extends outward at the outer edge of the annular oil passage.
  • the rotor iron core is provided with multiple weight-reducing holes connected to the iron core oil inlet channel.
  • the left balance plate is also equipped with multiple avoidance holes on the outside of the annular oil channel. As mentioned on the left The number of iron core oil inlet channels and escape holes on the balance plate is the same and distributed alternately.
  • the positions of the multiple iron core oil inlet channels on the left correspond to the multiple escape holes on the right.
  • the positions of the left balance plate and the right On the side there are multiple oil rejection channels with the same number as the iron core oil inlet channels at the outer edge of the annular oil channel.
  • the iron core oil inlet channels, avoidance holes and oil rejection channels are alternately distributed; in this way, the cooling oil enters from the rotor oil inlet channels.
  • the cooling oil in the annular oil passage enters the weight reduction hole of the rotor core through multiple iron core oil inlet passages. , and is thrown into the oil-cooling housing cavity through multiple avoidance holes on the balance plate, and then thrown to the bearings on the left and right sides to cool the bearings on the left and right sides.
  • the cooling oil in the annular oil passage is also thrown to the stator through multiple oil throwing channels.
  • the inside of the winding is used to cool the stator winding, and finally the cooling oil flows into the oil return channel of the shell under the action of gravity.
  • the number of oil inlet channels of the iron core on the left side is 2n
  • n is a positive integer
  • the outer circumferential surface of the hollow shaft between the two balance plates is respectively provided with two first positioning keyways and two
  • the second positioning keyway, the first positioning keyway and the second positioning keyway are both parallel to the axis of the hollow shaft.
  • the horizontal length of the first positioning keyway is equal to the horizontal distance between the two balance plates.
  • the second positioning keyway is close to the balance plate on the right side, and the circumferential angle between the two first positioning keyway is equal to the circumferential angle between the two second positioning keyway and both are 180°.
  • the circumferential angle between the first positioning keyway and the adjacent second positioning keyway is 90°/n.
  • the two balance plates are designed to be the same part.
  • the two balance plates are in contact with the hollow shaft.
  • an angular deviation of 90°/n is formed with each other, so that the multiple rotor oil inlet channels of the left balance plate are aligned with the right
  • the positions of the multiple avoidance holes of the balance plate correspond one to one; in this way, by arranging two pairs of first positioning keyways and second positioning keyways at special angles on the outer circumferential surface of the hollow shaft, the same balance plate can be used to realize multiple rotors Pass oil.
  • the oil groove on the surface of the balance plate that is, the iron core oil inlet channel
  • the end face of the rotor core cooperates with the end face of the rotor core to form an oil path, this not only reduces the processing difficulty of the balance plate, but also reduces the axial space; since the balance plates on the left and right sides use the same part, Different oil circuits are formed only through different assembly positioning, which reduces the number of parts and further reduces material costs.
  • the opposite sides of the two balance plates are also provided with oil guide fins or oil guide grooves, which facilitate the cooling oil flowing out from the rotor core to the bearings;
  • the oil rejection channel is a chute, and is adjusted by adjusting the chute. angles in all directions to achieve better oil rejection effect.
  • Figure 1 is a schematic front cross-sectional structural diagram of the motor oil cooling system in the present invention
  • Figure 2 is a schematic three-dimensional structural diagram of the oil cooling housing assembly
  • Figure 3 is a schematic three-dimensional structural diagram of the end cover assembly
  • Figure 4 is a schematic diagram of the three-dimensional structure of the main housing
  • Figure 5 is a schematic diagram of the three-dimensional structure of the fuel injection ring
  • Figure 6 is a schematic three-dimensional structural diagram of the stator assembly
  • Figure 7 is a schematic diagram of the flow of cooling oil in the housing oil circuit
  • Figure 8 is a schematic three-dimensional structural diagram of the rotor assembly
  • Figure 9 is a schematic diagram of the three-dimensional structure of the hollow shaft
  • Figure 10 is a schematic three-dimensional cross-sectional structural diagram of the hollow shaft
  • Figure 11 is a schematic structural diagram of the balance board
  • Figure 12 is a schematic structural diagram of Figure 11 in another direction
  • Figure 13 is a schematic diagram of the flow of cooling oil in the rotor oil circuit.
  • Oil-cooled housing assembly 2. Stator assembly, 3. End cover assembly, 4. Main housing, 5. Fuel injection ring, 6. Housing oil inlet channel, 7 , Oil channel rib, 8. Shell oil return channel, 9. Oil inlet, 10. Oil outlet, 11. Stator core, 12. Stator winding, 13. Main end cover, 14. Bearing steel insert, 15. Bearing, 16. Oil collecting ring, 17. Oil return hole, 18. Hollow shaft, 19. Rotor core, 20. Balance plate, 21. Locking piece, 22. Rotor oil inlet channel, 23. Oil sealing plug, 24 , Rotor oil outlet hole, 25. Annular oil channel, 26. Oil inlet groove, 27. Iron core oil inlet channel, 28. Avoidance hole, 29. Oil dump channel, 30. First positioning keyway, 31. Second positioning keyway.
  • a motor oil cooling system includes an oil cooling housing assembly 1, a stator assembly 2 located in the oil cooling housing assembly 1, and a stator assembly 2 located in the stator assembly 2 and connected to the stator assembly. 2
  • the rotor assembly is rotatably connected through the bearing 15.
  • the right end of the oil-cooling housing assembly 1 is provided with an end cover assembly 3.
  • the rotor assembly is equipped with a rotor oil circuit
  • the oil-cooling housing assembly 1 is provided with a housing oil inlet channel 6 and a housing oil return channel 8 that are connected to the housing oil circuit
  • the rotor assembly is provided with
  • the oil-cooled housing assembly 1 includes a main housing 4.
  • the inner circumferential surfaces of the left and right ends of the main housing 4 are respectively sealed and fixed with oil injection rings 5.
  • Two oil injection rings There are a plurality of oil passage ribs 7 on the inner circumferential surface of the main housing 4 between 5.
  • the stator assembly 2 includes a stator core 11 with tooth slots and a stator core 11 wound in the tooth slots. And it has stator windings 12 at both left and right ends.
  • the stator core 11 is arranged in the main housing 4 and the outer circular surface contacts the oil passage ribs 7 and forms an interference fit.
  • the stator winding 12 corresponds to the position of the corresponding side fuel injection ring 5.
  • the casing oil inlet channel 6 is provided at the left end of the main casing 4.
  • a plurality of oil channel ribs 7, the outer circumferential surface of the stator core 11 and two fuel injection rings 5 form an oil delivery channel connected to the casing oil inlet channel 6.
  • the fuel injection ring 5 is provided with an oil inlet 9 connected with the oil delivery channel.
  • the housing oil return channel 8 is provided on the outer circumferential surface of the main housing 4.
  • the end cover assembly 3 includes a main end cover 13 and a bearing steel insert 14 arranged in the main end cover 13.
  • the right bearing 15 is installed in the bearing steel insert 14.
  • the bearing steel insert 14 is provided with an oil collecting ring 16 on the outer surface, the bearing steel insert 14 is also provided with an opening connected to the oil collecting ring 16, and the main end cover 13 is provided with an oil return hole 17; in this way, the cooling oil enters from the housing Channel 6 enters the main housing 4 and flows to the oil delivery channel to cool the stator core 11. After the cooling oil flows several times in the oil delivery channel, it passes through the oil inlet 9 on the left side of the fuel injection ring 5 and the right side The oil inlet 9 on the fuel injection ring 5 enters the left fuel injection ring 5 and the right fuel injection ring 5 respectively. The cooling oil in the left fuel injection ring 5 flows to the left end stator through multiple oil outlets 10 on the corresponding side.
  • the cooling oil in the right oil injection ring 5 pours to the outside of the right end stator winding 12 through multiple oil outlets 10 on the corresponding side, and part of the cooling oil enters the oil collection Inside the ring 16 and through the opening of the bearing steel insert 14, it flows into the surface and interior of the right bearing 15 to cool the right bearing 15, and enters the housing oil return passage 8 through the oil return hole 17 on the main end cover 13.
  • the oil channel ribs 7 are arranged along the axial direction of the main housing 4, so that the oil delivery channel forms a Z-shaped channel. Since the inner circular surface of the main housing 4 and the outer circular surface of the stator core 11 form a Z-shaped channel, The oil transfer channel has a channel area equivalent to that of the water-cooling shell, ensuring that the cooling oil fully flows through the stator core 11 at a fast flow rate, which not only provides sufficient cooling oil flow, but also makes full use of the high efficiency of direct cooling.
  • the stator core 11 is efficiently and adequately cooled; since the oil channel ribs 7 are arranged axially, the casting process can be greatly simplified.
  • the surface of the oil channel ribs 7 is provided with axial auxiliary ribs, which can increase the flow area of the cooling oil.
  • the strength of the main housing 4 can also be improved; the fuel injection ring 5 is connected to the inner circular surface of the corresponding side end of the main housing 4 through friction stir welding or argon arc welding, so that the fuel injection rings 5 on the left and right sides are connected to the main housing 4 They are processed separately and connected through the welding process, which not only simplifies the product processing technology, but also reduces the final number of parts, thereby reducing production costs and management costs; the oil outlet hole 10 is an oblique hole, and by adjusting the angle of the oblique hole Various angles to achieve better oil spraying effect.
  • the axial channel formed by the keyway, welding groove and marking groove on the outer surface of the stator core 11 is blocked by oil-resistant silicone rubber to avoid the leakage of cooling oil in the Z-shaped channel; alternatively, the right end of the stator core 11 is provided with multiple
  • the special-shaped punched sheet only retains basic functional features such as stator slots and teeth, and is fixed with the rest of the iron core by gluing, thereby blocking the axial channel of the outer circle of the stator core 11.
  • the rotor assembly includes a hollow shaft 18.
  • the hollow shaft 18 is covered with a rotor core 19 corresponding to the position of the stator core 11.
  • the hollow shaft 18 is on the left and right sides of the rotor core 19.
  • Balance plates 20 are fixedly sleeved at both ends.
  • the inner cavity of the hollow shaft 18 forms the rotor oil inlet channel 22.
  • the inner cavity of the hollow shaft 18 is provided with an oil seal plug 23 on the right side of the balance plate 20.
  • the hollow shaft 18 is at the position of the balance plate 20 on the left side.
  • the hollow shaft 18 is also provided with two rotor oil outlets 24 with a circumferential angle of 180° at the right balance plate 20.
  • Two balance The plates 20 are equipped with oil passage components, as shown in Figures 8, 11 and 12.
  • the left oil passage assembly includes an annular oil passage 25 provided on the right side of the left balance plate 20 and connected with the corresponding rotor oil outlet hole 24. , there are two oil inlet grooves 26 corresponding to the corresponding rotor oil outlets 24 at the inner edge of the left annular oil passage 25, and the right side of the left balance plate 20 extends outward at the outer edge of the annular oil passage 25.
  • the rotor iron core 19 is provided with a plurality of weight-reducing holes connected with the iron core oil inlet channel 27.
  • the left balance plate 20 is also provided with a plurality of avoidance holes 28 outside the annular oil channel 25.
  • the iron core oil inlet channels 27 and the escape holes 28 on the left balance plate 20 have the same number and are alternately distributed.
  • the positions of the multiple iron core oil inlets 27 on the left correspond to the multiple escape holes 28 on the right.
  • the right side of the balance plate 20 is also provided with a plurality of oil dump channels 29 with the same number as the iron core oil inlet channels 27 at the outer edge of the annular oil channel 25.
  • the iron core oil inlet channels 27, avoidance holes 28 and oil dump channels 29 alternate Distribution; in this way, the cooling oil enters the hollow shaft 18 from the rotor oil inlet channel 22, and enters the annular oil channel 25 on the balance plate 20 of the corresponding side through the rotor oil outlet hole 24 and the oil inlet groove 26 on the corresponding side.
  • the annular oil channel 25 The cooling oil in the rotor enters the weight reduction hole of the rotor core 19 through multiple iron core oil inlet channels 27, and is thrown into the oil cooling housing cavity through multiple avoidance holes 28 on the balance plate 20, and then thrown to the left and right bearings.
  • the cooling oil in the annular oil passage 25 is also thrown to the inside of the stator winding 12 through a plurality of oil throwing channels 29 to cool the stator winding 12, and finally the cooling oil flows into the housing under the action of gravity and returns Oil channel 8.
  • the number of the left iron core oil inlet channels 27 is 2n, n is a positive integer, and the outer circumferential surface of the hollow shaft 18 between the two balance plates 20 is respectively provided with two first positioning keyways 30 and two second positioning keyways 30.
  • the positioning keyway 31, the first positioning keyway 30 and the second positioning keyway 31 are all parallel to the axis of the hollow shaft 18.
  • the horizontal length of the first positioning keyway 30 is equal to the horizontal distance between the two balance plates 20, and the two second positioning keyway 31 are parallel to the axis of the hollow shaft 18. 31 is close to the right balance plate 20.
  • the circumferential angle between the two first positioning keyways 30 is equal to the circumferential angle between the two second positioning keyways 31 and both are 180°.
  • the first positioning keyway 30 is adjacent to The circumferential angle between the second positioning keyways 31 is 90°/n.
  • the two balance plates 20 are designed to be the same part. When the two balance plates 20 are assembled with the hollow shaft 18, they pass through the two first positioning keyways 30 and After the two second positioning keyways 31 are positioned, they form an angular deviation of 90°/n from each other, so that the multiple rotor oil inlet passages 22 of the left balance plate 20 and the multiple avoidance holes 28 of the right balance plate 20 are positioned one by one. Correspondingly; in this way, through the arrangement of two pairs of first positioning keyways 30 and second positioning keyways 31 at special angles on the outer circumferential surface of the hollow shaft 18, the same balance plate 20 can be used to achieve multi-path rotor oil passage.
  • the opposite sides of the two balance plates 20 are also provided with oil guide fins or oil guide grooves, and the cooling oil flowing out of the rotor core 19 is used to pass through the oil guide fins or oil guide grooves to the bearing 15;
  • the oil rejection channel 29 It is a chute, and by adjusting the angles of the chute in all directions, a better oil throwing effect can be achieved;
  • the motor oil cooling system also includes an external oil pump of the motor, a filter and a radiator, and cooling in the oil return channel 8 of the casing The oil is used to pass through the motor's external oil pump, filter and radiator in sequence and then return to the housing oil inlet channel 6 and the rotor oil inlet channel 22 for recirculation.
  • the hollow shaft 18 is provided with a protrusion 32 at the left end of the left balance plate 20.
  • the protrusion 32 cooperates with the rotor core 19 to clamp the left balance plate 20.
  • the hollow shaft 18 is on the right side.
  • the right end of the balance plate 20 is provided with a locking piece 21 for locking the right balance plate 20, see Figure 1 .
  • a motor oil cooling method using the above motor oil cooling system for motor oil cooling, including the following cooling methods:
  • the cooling oil enters the housing oil passage from the housing oil inlet channel 6 to cool the stator core 11, the outer side of the stator winding 12 and the right bearing 15 of the stator assembly 2. Specifically, cooling The oil enters the main housing 4 of the oil-cooling housing assembly 1 from the housing oil inlet channel 6 and flows to the oil delivery channel to cool the stator core 11 of the stator assembly 2; the cooling oil circulates in the oil delivery channel for a certain amount of time.
  • the cooling oil in the ring 5 flows to the outside of the left stator winding 12 through multiple oil outlets 10 on the corresponding side, and flows directly into the oil return channel 8 of the housing.
  • the cooling oil in the right oil injection ring 5 passes through multiple oil outlets 10 on the corresponding side.
  • the oil outlet hole 10 flows to the outside of the right end stator winding 12, and part of the cooling oil enters the oil collection ring 16 of the end cover assembly 3 and flows into the surface and interior of the right bearing 15 through the opening of the bearing steel insert 14 to cool the right side. side bearing 15, and enters the housing oil return passage 8 through the oil return hole 17 of the end cover assembly 3;
  • the cooling oil simultaneously enters the rotor oil passage from the rotor oil inlet channel 22 to cool the rotor core 19 of the rotor assembly, the inside of the stator winding 12 and the left and right bearings 15. Specifically, the cooling oil At the same time, it enters the hollow shaft 18 of the rotor assembly from the rotor oil inlet channel 22, and enters the annular oil passage 25 on the balance plate 20 of the corresponding side through the rotor oil outlet hole 24 and the oil inlet groove 26 on the corresponding side.
  • the annular oil passage 25 The cooling oil in the rotor enters the weight reduction hole of the rotor core 19 through multiple iron core oil inlet channels 27, and is thrown into the oil cooling housing cavity through multiple avoidance holes 28 on the balance plate 20, and then thrown to the left and right bearings. 15 to cool the left and right bearings 15, the cooling oil in the annular oil passage 25 is also thrown to the inside of the stator winding 12 through a plurality of oil throwing channels 29 to cool the stator winding 12, and finally the cooling oil flows into the housing under the action of gravity and returns Oil channel 8.
  • the motor oil cooling system in the present invention is an oil cooling system for a vehicle permanent magnet synchronous drive motor.
  • the present invention has only one main housing 4.
  • the oil path of the housing is surrounded by the oil passage ribs 7 of the main housing 4 and the stator core 11.
  • the flow direction of the oil path is an axial Z-shape, and both ends of the oil path pass through
  • the fuel injection ring 5 welded together with the main housing 4 is airtight.
  • the main housing 4 has good craftsmanship.
  • the rotor oil routing of the present invention is realized by complex grooves in the balance plate 20 and weight-reducing holes in the rotor core 19, including an annular oil passage. 25, used to distribute the flow direction of the cooling oil.
  • the cooling oil enters the core oil inlet channel 27 and the radial oil rejection channel 29 respectively through the annular oil channel 25.
  • the same balance plate 20 is used to realize multiple rotor oil passages.
  • the motor oil cooling system of the present invention can simultaneously cool the stator core 11, stator windings 12, rotor core 19, bearings 15 and other heating parts to efficiently and fully cool the motor, and has good workmanship. and cost advantages.

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Abstract

本发明公开了一种电机油冷系统及电机油冷方法，该电机油冷系统包括油冷壳体总成、设置在油冷壳体总成内的定子总成以及设于定子总成内且与定子总成通过轴承转动连接的转子总成，油冷壳体总成右端设有端盖总成，油冷壳体总成、定子总成与端盖总成之间设有壳体油路，转子总成内设有转子油路，油冷壳体总成上设有与壳体油路连通的壳体进油通道和壳体回油通道，转子总成上设有与转子油路连通的转子进油通道，转子油路与壳体回油通道连通；本发明可以同时冷却定子铁芯、定子绕组、转子铁芯、轴承等发热零件，以对电机进行高效、充分地冷却，并且具有较好的工艺性和成本优势。

Description

一种电机油冷系统及电机油冷方法 技术领域
本发明属于电机散热技术领域，具体涉及一种电机油冷系统及电机油冷方法。
背景技术
随着新能源汽车的快速发展，追求车用永磁同步电机的高效率、高功率密度、高转速正成为大势所趋，随之而来的电机温升挑战也愈发严峻，因此亟需更高效的冷却系统，将电机运行时产生的热量及时带走，否则容易造成电机温升过高，轻则影响性能表现，重则导致绕组烧毁、磁钢退磁、轴承损伤等后果，严重影响电机的使用寿命。
一般来说，常采用三种方式来冷却电机，包括风冷系统、水冷系统和油冷系统，受冷却方式和冷却效率限制，前两种方式已愈来愈难以满足电机的散热需求；而油冷系统仍在发展阶段，当前的油冷系统存在冷却不充分、结构复杂、成本较高等缺点。
中国专利CN206149098U公开了一种油冷电机和车辆，该专利的转子油路通过平衡板开孔和转子铁芯开孔实现，但只有简单的径向甩油，无法冷却轴承，而且该专利的壳体油路也无法冷却轴承；中国专利CN111181300A公开了一种永磁同步电机油冷结构，该专利的壳体油路由上下壳体组成，冷却油进入壳体后无固定油路，并联支路很多，难以保证流向，该专利的转子油路只有简单的轴向通油，冷却油由转轴直接进入转子铁芯通油孔，转子铁芯结构复杂。
发明内容
鉴于现有技术存在的缺陷，本发明提供一种电机油冷系统及电机油冷方法，可以同时冷却定子铁芯、定子绕组、转子铁芯、轴承等发热零件，以对电机进行充分地冷却。
本发明解决其技术问题所采用的技术方案是：
一种电机油冷系统，包括油冷壳体总成、设置在油冷壳体总成内的定子总成以及设于定子总成内且与定子总成通过轴承转动连接的转子总成，所述油冷壳体总成右端设有端盖总成，所述油冷壳体总成、定子总成与端盖总成之间设有壳体油路，所述转子总成内设有转子油路，所述油冷壳体总成上设有与壳体油路连通的壳体进油通道和壳体回油通道，所述转子总成上设有与转子油路连通的转子进油通道，所述转子油路与壳体回油通道连通。
进一步地，所述油冷壳体总成包括主壳体，所述主壳体左右两端内圆面上分别密封固定有喷油环，两个所述喷油环之间的所述主壳体内圆面上设有多个油道筋；所述定子总成包括带有齿槽的定子铁芯和缠绕于所述定子铁芯齿槽中且具有左右两端部的定子绕组，所述定子 铁芯设置在所述主壳体内且外圆面接触所述油道筋并形成过盈配合，所述定子绕组与相应侧所述喷油环位置相对应；所述壳体进油通道设置在所述主壳体左端处，多个所述油道筋、定子铁芯外圆面与两个喷油环围成与所述壳体进油通道连通的输油通道，所述喷油环上设有与所述输油通道连通的进油口，所述喷油环内圆面上设有多个出油孔。
进一步地，所述壳体回油通道设置在所述主壳体外圆面上，所述端盖总成包括主端盖和设置在所述主端盖内的轴承钢嵌件，右侧所述轴承安装于所述轴承钢嵌件内，所述轴承钢嵌件外侧面上设有集油环，所述轴承钢嵌件上还设有与所述集油环连通的开孔，所述主端盖上设有回油孔；左侧所述喷油环内的冷却油用于通过相应侧多个所述出油孔淋向左端所述定子绕组外侧，并直接流进所述壳体回油通道内；右侧所述喷油环内的冷却油用于通过相应侧多个所述出油孔淋向右端所述定子绕组外侧，且部分冷却油进入所述集油环内并通过所述开孔流入右侧所述轴承表面和内部，并通过所述回油孔进入所述壳体回油通道。
进一步地，所述定子铁芯外圆面上的键槽、焊接槽和标记槽形成的轴向通道通过耐油硅橡胶堵塞；或者，所述定子铁芯右端设有多片用于堵塞所述定子铁芯外圆轴向通道的冲片。
进一步地，所述油道筋沿主壳体的轴向设置，使所述输油通道形成Z型通道，所述油道筋表面设有轴向辅助筋。
进一步地，所述喷油环通过搅拌摩擦焊或者氩弧焊与主壳体相应侧端部内圆面连接成一体。
进一步地，所述出油孔为斜孔。
进一步地，所述转子总成包括空心轴，所述空心轴上套设有与所述定子铁芯位置相对应的转子铁芯，所述空心轴在转子铁芯的左右两端分别固定套设平衡板；所述空心轴内腔形成所述转子进油通道，所述空心轴在两个所述平衡板位置处分别设有转子出油孔，两个所述平衡板上均设有油路组件，左侧所述油路组件包括设置于左侧所述平衡板右侧面且与相应所述转子出油孔连通的环形油道，左侧所述环形油道内边缘处设有与相应所述转子出油孔相对应的进油槽，左侧所述平衡板右侧面在所述环形油道外边缘处向外延伸有多个铁芯进油通道，所述转子铁芯上设有多个与所述铁芯进油通道连通的减重孔，左侧所述平衡板在所述环形油道外侧还设有多个避让孔；所述环形油道内的冷却油用于通过多个铁芯进油通道进入所述减重孔，并通过多个所述避让孔甩到油冷壳体腔体内以甩到轴承上。
进一步地，所述空心轴内腔在所述平衡板右侧处设有封油塞。
进一步地，左侧所述平衡板上的铁芯进油通道与避让孔的数目相同且交替分布，左侧多 个所述铁芯进油通道与右侧多个所述避让孔的位置一一对应。
进一步地，左侧所述平衡板右侧面在所述环形油道外边缘处还设有多个与所述铁芯进油通道数目相同的甩油通道，所述铁芯进油通道、避让孔与甩油通道交替分布，所述环形油道内的冷却油用于通过多个所述甩油通道甩到所述定子绕组内侧，并流进所述壳体回油通道。
进一步地，左侧所述铁芯进油通道的数目为2n，n为正整数，两个所述平衡板之间的空心轴外圆面上分别设有两个第一定位键槽和两个第二定位键槽，所述第一定位键槽和第二定位键槽均与空心轴轴线平行，所述第一定位键槽的水平长度与两个所述平衡板之间的水平间距相等，两个所述第二定位键槽靠近右侧所述平衡板，两个所述第一定位键槽之间的周向角度与两个所述第二定位键槽之间的周向角度相等且均为180°，所述第一定位键槽与相邻所述第二定位键槽之间的周向角度为90°/n，两个所述平衡板在设计上为同一零件，两个所述平衡板在与所述空心轴装配时通过两个所述第一定位键槽和两个所述第二定位键槽定位后，互相形成90°/n的角度偏差，使左侧所述平衡板的多个转子进油通道与右侧所述平衡板的多个避让孔的位置一一对应。
进一步地，两个所述平衡板相对的侧面上还设有导油翼片或导油槽，所述转子铁芯内流出的冷却油用于通过所述导油翼片或导油槽通向轴承；所述甩油通道为斜槽；所述电机油冷系统还包括电机外置油泵、滤清器和散热器，所述壳体回油通道内的冷却油用于依次通过所述电机外置油泵、滤清器和散热器后回到所述壳体进油通道和转子进油通道以再次循环。
一种电机油冷方法，采用上述电机油冷系统进行电机油冷，包括以下冷却方式：
(1)、冷却油从所述壳体进油通道进入所述壳体油路，以冷却所述定子总成的定子铁芯、定子绕组外侧和右侧轴承，之后冷却油进入所述壳体回油通道；
(2)、冷却油同时从所述转子进油通道进入所述转子油路，以冷却所述转子总成的转子铁芯、定子绕组内侧和左右两侧轴承，之后冷却油进入所述壳体回油通道。
进一步地，冷却方式(1)中：冷却油从所述壳体进油通道进入所述油冷壳体总成的主壳体内，并流向输油通道，以冷却所述定子总成的定子铁芯；冷却油在输油通道中流转若干圈后，通过左侧喷油环上的进油口和右侧喷油环上的进油口分别进入左侧喷油环和右侧喷油环内，左侧喷油环内的冷却油通过相应侧多个出油孔淋向左端定子绕组外侧，并直接流进所述壳体回油通道内，右侧喷油环内的冷却油通过相应侧多个出油孔淋向右端定子绕组外侧，且部分冷却油进入所述端盖总成的集油环内并通过轴承钢嵌件的开孔流入右侧所述轴承表面和内部，以冷却右侧所述轴承，并通过所述端盖总成的回油孔进入所述壳体回油通道。
进一步地，冷却方式(2)中：冷却油同时从所述转子进油通道进入所述转子总成的空心轴内，并分别通过相应侧的转子出油孔和进油槽进入相应侧平衡板上的环形油道内，环形油道内的冷却油通过多个铁芯进油通道进入转子铁芯的减重孔，并通过平衡板上的多个避让孔甩到油冷壳体腔体内，进而甩到左右两侧所述轴承上以冷却左右两侧轴承，环形油道内的冷却油还通过多个甩油通道甩到定子绕组内侧，以冷却定子绕组，最后冷却油在重力作用下流进所述壳体回油通道。
相对于现有技术，本发明的有益效果为：
本发明的电机油冷系统，包括油冷壳体总成、设置在油冷壳体总成内的定子总成以及设于定子总成内且与定子总成通过轴承转动连接的转子总成，油冷壳体总成右端设有端盖总成，油冷壳体总成、定子总成与端盖总成之间设有壳体油路，转子总成内设有转子油路，油冷壳体总成上设有与壳体油路连通的壳体进油通道和壳体回油通道，转子总成上设有与转子油路连通的转子进油通道，转子油路与壳体回油通道连通；这样冷却油从壳体进油通道进入壳体油路，以冷却定子总成的定子铁芯、定子绕组外侧和右侧轴承，冷却油同时从转子进油通道进入转子油路，以冷却转子总成的转子铁芯、定子绕组内侧和左右两侧轴承，之后冷却油进入壳体回油通道，因此该电机油冷系统能对电机的主要发热零件进行充分地冷却。
本发明中，油冷壳体总成包括主壳体，主壳体左右两端内圆面上分别密封固定有喷油环，两个喷油环之间的主壳体内圆面上设有多个油道筋，定子总成包括带有齿槽的定子铁芯和缠绕于定子铁芯齿槽中且具有左右两端部的定子绕组，定子铁芯设置在主壳体内且外圆面接触油道筋并形成过盈配合，定子绕组与相应侧喷油环位置相对应，壳体进油通道设置在主壳体左端处，多个油道筋、定子铁芯外圆面与两个喷油环围成与壳体进油通道连通的输油通道，喷油环上设有与输油通道连通的进油口，喷油环内圆面上设有多个出油孔，壳体回油通道设置在主壳体外圆面上，端盖总成包括主端盖和设置在主端盖内的轴承钢嵌件，右侧轴承安装于轴承钢嵌件内，轴承钢嵌件外侧面上设有集油环，轴承钢嵌件上还设有与集油环连通的开孔，主端盖上设有回油孔；这样冷却油从壳体进油通道进入主壳体内，并流向输油通道，以冷却定子铁芯，冷却油在输油通道中流转若干圈后，通过左侧喷油环上的进油口和右侧喷油环上的进油口分别进入左侧喷油环和右侧喷油环内，左侧喷油环内的冷却油通过相应侧多个出油孔淋向左端定子绕组外侧，并直接流进壳体回油通道内，右侧喷油环内的冷却油通过相应侧多个出油孔淋向右端定子绕组外侧，且部分冷却油进入集油环内并通过轴承钢嵌件的开孔流入右侧轴承表面和内部，以冷却右侧轴承，并通过主端盖上的回油孔进入壳体回油通道。
本发明中，油道筋沿主壳体的轴向设置，使输油通道形成Z型通道，由于主壳体内圆面与定子铁芯外圆面形成Z型的输油通道，其通路面积与水冷壳体相当，保证冷却油以较快地流速充分流过定子铁芯，既提供了足够的冷却油流量，又充分利用了直接冷却的高效率，使得定子铁芯得到了高效充足的冷却；由于左右两侧的喷油环油路与输油通道串联，这样能保证所有进入壳体进油通道的冷却油都全部淋向定子绕组外侧，保证定子绕组具有充足的冷却油流量；由于主壳体内圆面上的油道筋轴向设置，这样能极大地简化铸造工艺；由于喷油环通过搅拌摩擦焊或者氩弧焊与主壳体相应侧端部内圆面连接成一体，这样左右两侧的喷油环与主壳体分开加工，且通过焊接工艺连接，进而既简化了产品的加工工艺，又减少了最终的零件数量，达到降低生产成本和管理成本的目的。
本发明中，定子铁芯外圆面上的键槽、焊接槽和标记槽形成的轴向通道通过耐油硅橡胶堵塞，以避免Z型通道中的冷却油泄露；或者，定子铁芯右端设有多片冲片，以堵塞定子铁芯外圆的轴向通路；油道筋表面设有轴向辅助筋，这样既可增加冷却油的过流面积，又可提高主壳体强度；出油孔为斜孔，并通过调整斜孔的各向角度，以实现较好的淋油效果。
本发明中，转子总成包括空心轴，空心轴上套设有与定子铁芯位置相对应的转子铁芯，空心轴在转子铁芯的左右两端分别固定套设平衡板，空心轴内腔形成转子进油通道，空心轴在两个平衡板位置处分别设有转子出油孔，两个平衡板上均设有油路组件，左侧油路组件包括设置于左侧平衡板右侧面且与相应转子出油孔连通的环形油道，左侧环形油道内边缘处设有与相应转子出油孔相对应的进油槽，左侧平衡板右侧面在环形油道外边缘处向外延伸有多个铁芯进油通道，转子铁芯上设有多个与铁芯进油通道连通的减重孔，左侧平衡板在环形油道外侧还设有多个避让孔，左侧所述平衡板上的铁芯进油通道与避让孔的数目相同且交替分布，左侧多个所述铁芯进油通道与右侧多个所述避让孔的位置一一对应，左侧平衡板右侧面在环形油道外边缘处还设有多个与铁芯进油通道数目相同的甩油通道，铁芯进油通道、避让孔与甩油通道交替分布；这样冷却油从转子进油通道进入空心轴内，并分别通过相应侧的转子出油孔和进油槽进入相应侧平衡板上的环形油道内，环形油道内的冷却油通过多个铁芯进油通道进入转子铁芯的减重孔，并通过平衡板上的多个避让孔甩到油冷壳体腔体内，进而甩到左右两侧轴承上以冷却左右两侧轴承，环形油道内的冷却油还通过多个甩油通道甩到定子绕组内侧，以冷却定子绕组，最后冷却油在重力作用下流进壳体回油通道。
本发明中，左侧所述铁芯进油通道的数目为2n，n为正整数，两个所述平衡板之间的空心轴外圆面上分别设有两个第一定位键槽和两个第二定位键槽，所述第一定位键槽和第二定 位键槽均与空心轴轴线平行，所述第一定位键槽的水平长度与两个所述平衡板之间的水平间距相等，两个所述第二定位键槽靠近右侧所述平衡板，两个所述第一定位键槽之间的周向角度与两个所述第二定位键槽之间的周向角度相等且均为180°，所述第一定位键槽与相邻所述第二定位键槽之间的周向角度为90°/n，两个所述平衡板在设计上为同一零件，两个所述平衡板在与所述空心轴装配时通过两个所述第一定位键槽和两个所述第二定位键槽定位后，互相形成90°/n的角度偏差，使左侧所述平衡板的多个转子进油通道与右侧所述平衡板的多个避让孔的位置一一对应；这样通过空心轴外圆面上两对成特殊角度的第一定位键槽和第二定位键槽的设置，可以使用同一平衡板实现多路转子通油。
由于平衡板表面的油槽即铁芯进油通道与转子铁芯端面配合形成油路，这样既降低了平衡板的加工难度，又减少了轴向空间；由于左右两侧的平衡板采用同一零件，仅通过装配定位的不同形成不同的油路，减少了零件数量，进一步降低了物料成本。
本发明中，两个平衡板相对的侧面上还设有导油翼片或导油槽，这样便于从转子铁芯内流出的冷却油通向轴承；甩油通道为斜槽，并通过调整斜槽的各向角度，以实现较好的甩油效果。
附图说明
图1为本发明中电机油冷系统的主视剖视结构示意图；
图2为油冷壳体总成的立体结构示意图；
图3为端盖总成的立体结构示意图；
图4为主壳体的立体结构示意图；
图5为喷油环的立体结构示意图；
图6为定子总成的立体结构示意图；
图7为壳体油路中冷却油的走向示意图；
图8为转子总成的立体结构示意图；
图9为空心轴的立体结构示意图；
图10为空心轴的立体剖视结构示意图；
图11为平衡板的结构示意图；
图12为图11的另一个方向的结构示意图；
图13为转子油路中冷却油的走向示意图。
图中附图标记说明：1、油冷壳体总成，2、定子总成，3、端盖总成，4、主壳体，5、 喷油环，6、壳体进油通道，7、油道筋，8、壳体回油通道，9、进油口，10、出油孔，11、定子铁芯，12、定子绕组，13、主端盖，14、轴承钢嵌件，15、轴承，16、集油环，17、回油孔，18、空心轴，19、转子铁芯，20、平衡板，21、锁紧件，22、转子进油通道，23、封油塞，24、转子出油孔，25、环形油道，26、进油槽，27、铁芯进油通道，28、避让孔，29、甩油通道，30、第一定位键槽，31、第二定位键槽。
具体实施方式
如图1所示，一种电机油冷系统，包括油冷壳体总成1、设置在油冷壳体总成1内的定子总成2以及设于定子总成2内且与定子总成2通过轴承15转动连接的转子总成，油冷壳体总成1右端设有端盖总成3，油冷壳体总成1、定子总成2与端盖总成3之间设有壳体油路，转子总成内设有转子油路，油冷壳体总成1上设有与壳体油路连通的壳体进油通道6和壳体回油通道8，转子总成上设有与转子油路连通的转子进油通道22，转子油路与壳体回油通道8连通。
其中，如图2、4和5所示，油冷壳体总成1包括主壳体4，主壳体4左右两端内圆面上分别密封固定有喷油环5，两个喷油环5之间的主壳体4内圆面上设有多个油道筋7，如图6所示，定子总成2包括带有齿槽的定子铁芯11和缠绕于定子铁芯11齿槽中且具有左右两端部的定子绕组12，定子铁芯11设置在主壳体4内且外圆面接触油道筋7并形成过盈配合，定子绕组12与相应侧喷油环5位置相对应，壳体进油通道6设置在主壳体4左端处，多个油道筋7、定子铁芯11外圆面与两个喷油环5围成与壳体进油通道6连通的输油通道，喷油环5上设有与输油通道连通的进油口9，喷油环5内圆面上设有多个出油孔10，壳体回油通道8设置在主壳体4外圆面上，如图3所示，端盖总成3包括主端盖13和设置在主端盖13内的轴承钢嵌件14，右侧轴承15安装于轴承钢嵌件14内，轴承钢嵌件14外侧面上设有集油环16，轴承钢嵌件14上还设有与集油环16连通的开孔，主端盖13上设有回油孔17；这样冷却油从壳体进油通道6进入主壳体4内，并流向输油通道，以冷却定子铁芯11，冷却油在输油通道中流转若干圈后，通过左侧喷油环5上的进油口9和右侧喷油环5上的进油口9分别进入左侧喷油环5和右侧喷油环5内，左侧喷油环5内的冷却油通过相应侧多个出油孔10淋向左端定子绕组12外侧，并直接流进壳体回油通道8内，右侧喷油环5内的冷却油通过相应侧多个出油孔10淋向右端定子绕组12外侧，且部分冷却油进入集油环16内并通过轴承钢嵌件14的开孔流入右侧轴承15表面和内部，以冷却右侧轴承15，并通过主端盖13上的回油孔17进入壳体回油通道8。
其中，如图2和4所示，油道筋7沿主壳体4的轴向设置，使输油通道形成Z型通道，由于主壳体4内圆面与定子铁芯11外圆面形成Z型的输油通道，其通路面积与水冷壳体相当，保证冷却油以较快地流速充分流过定子铁芯11，既提供了足够的冷却油流量，又充分利用了直接冷却的高效率，使得定子铁芯11得到了高效充足的冷却；由于油道筋7轴向设置，这样能极大地简化铸造工艺，油道筋7表面设有轴向辅助筋，这样既可增加冷却油的过流面积，又可提高主壳体4强度；喷油环5通过搅拌摩擦焊或者氩弧焊与主壳体4相应侧端部内圆面连接成一体，这样左右两侧的喷油环5与主壳体4分开加工，且通过焊接工艺连接，进而既简化了产品的加工工艺，又减少了最终的零件数量，达到降低生产成本和管理成本的目的；出油孔10为斜孔，并通过调整斜孔的各向角度，以实现较好的淋油效果。
其中，定子铁芯11外圆面上的键槽、焊接槽和标记槽形成的轴向通道通过耐油硅橡胶堵塞，以避免Z型通道中的冷却油泄露；或者，定子铁芯11右端设有多片冲片，该异形冲片仅保留定子槽和齿等基本功能特征，并通过胶粘方式与其余铁芯固定，从而堵塞定子铁芯11外圆的轴向通道。
其中，如图8-12所示，转子总成包括空心轴18，空心轴18上套设有与定子铁芯11位置相对应的转子铁芯19，空心轴18在转子铁芯19的左右两端分别固定套设平衡板20，空心轴18内腔形成转子进油通道22，空心轴18内腔在平衡板20右侧处设有封油塞23，空心轴18在左侧平衡板20位置处设有两个周向角度为180°的转子出油孔24，空心轴18在右侧平衡板20位置处也设有两个周向角度为180°的转子出油孔24，两个平衡板20上均设有油路组件，如图8、11和12所示，左侧油路组件包括设置于左侧平衡板20右侧面且与相应转子出油孔24连通的环形油道25，左侧环形油道25内边缘处设有两个分别与相应转子出油孔24相对应的进油槽26，左侧平衡板20右侧面在环形油道25外边缘处向外延伸有多个铁芯进油通道27，转子铁芯19上设有多个与铁芯进油通道27连通的减重孔，左侧平衡板20在环形油道25外侧还设有多个避让孔28，左侧平衡板20上的铁芯进油通道27与避让孔28的数目相同且交替分布，左侧多个铁芯进油通道27与右侧多个避让孔28的位置一一对应，左侧平衡板20右侧面在环形油道25外边缘处还设有多个与铁芯进油通道27数目相同的甩油通道29，铁芯进油通道27、避让孔28与甩油通道29交替分布；这样冷却油从转子进油通道22进入空心轴18内，并分别通过相应侧的转子出油孔24和进油槽26进入相应侧平衡板20上的环形油道25内，环形油道25内的冷却油通过多个铁芯进油通道27进入转子铁芯19的减重孔，并通过平衡板20上的多个避让孔28甩到油冷壳体腔体内，进而甩到左右两侧轴承15上以冷却左 右两侧轴承15，环形油道25内的冷却油还通过多个甩油通道29甩到定子绕组12内侧，以冷却定子绕组12，最后冷却油在重力作用下流进壳体回油通道8。
其中，左侧铁芯进油通道27的数目为2n，n为正整数，两个平衡板20之间的空心轴18外圆面上分别设有两个第一定位键槽30和两个第二定位键槽31，第一定位键槽30和第二定位键槽31均与空心轴18轴线平行，第一定位键槽30的水平长度与两个平衡板20之间的水平间距相等，两个第二定位键槽31靠近右侧平衡板20，两个第一定位键槽30之间的周向角度与两个第二定位键槽31之间的周向角度相等且均为180°，第一定位键槽30与相邻第二定位键槽31之间的周向角度为90°/n，两个平衡板20在设计上为同一零件，两个平衡板20在与空心轴18装配时通过两个第一定位键槽30和两个第二定位键槽31定位后，互相形成90°/n的角度偏差，使左侧平衡板20的多个转子进油通道22与右侧平衡板20的多个避让孔28的位置一一对应；这样通过空心轴18外圆面上两对成特殊角度的第一定位键槽30和第二定位键槽31的设置，可以使用同一平衡板20实现多路转子通油。
其中，两个平衡板20相对的侧面上还设有导油翼片或导油槽，转子铁芯19内流出的冷却油用于通过导油翼片或导油槽通向轴承15；甩油通道29为斜槽，并通过调整斜槽的各向角度，以实现较好的甩油效果；电机油冷系统还包括电机外置油泵、滤清器和散热器，壳体回油通道8内的冷却油用于依次通过电机外置油泵、滤清器和散热器后回到壳体进油通道6和转子进油通道22以再次循环。
其中，如图9所示，空心轴18在左侧平衡板20左端处设有凸起32，凸起32与转子铁芯19配合用于卡紧左侧平衡板20，空心轴18在右侧平衡板20右端处设有用于锁紧右侧平衡板20的锁紧件21，见图1。
一种电机油冷方法，采用上述电机油冷系统进行电机油冷，包括以下冷却方式：
(1)、如图7所示，冷却油从壳体进油通道6进入壳体油路，以冷却定子总成2的定子铁芯11、定子绕组12外侧和右侧轴承15，具体为冷却油从壳体进油通道6进入油冷壳体总成1的主壳体4内，并流向输油通道，以冷却定子总成2的定子铁芯11；冷却油在输油通道中流转若干圈后，通过左侧喷油环5上的进油口9和右侧喷油环5上的进油口9分别进入左侧喷油环5和右侧喷油环5内，左侧喷油环5内的冷却油通过相应侧多个出油孔10淋向左端定子绕组12外侧，并直接流进壳体回油通道8内，右侧喷油环5内的冷却油通过相应侧多个出油孔10淋向右端定子绕组12外侧，且部分冷却油进入端盖总成3的集油环16内并通过轴承钢嵌件14的开孔流入右侧轴承15表面和内部，以冷却右侧轴承15，并通过端盖总成3的 回油孔17进入壳体回油通道8；
(2)、如图13所示，冷却油同时从转子进油通道22进入转子油路，以冷却转子总成的转子铁芯19、定子绕组12内侧和左右两侧轴承15，具体为冷却油同时从转子进油通道22进入转子总成的空心轴18内，并分别通过相应侧的转子出油孔24和进油槽26进入相应侧平衡板20上的环形油道25内，环形油道25内的冷却油通过多个铁芯进油通道27进入转子铁芯19的减重孔，并通过平衡板20上的多个避让孔28甩到油冷壳体腔体内，进而甩到左右两侧轴承15上以冷却左右两侧轴承15，环形油道25内的冷却油还通过多个甩油通道29甩到定子绕组12内侧，以冷却定子绕组12，最后冷却油在重力作用下流进壳体回油通道8。
本发明中的电机油冷系统为车用永磁同步驱动电机的油冷系统。
与现有技术相比，本发明仅有一个主壳体4，壳体油路由主壳体4的油道筋7与定子铁芯11包围，油路流向为轴向Z型，油路两端通过与主壳体4焊接在一起的喷油环5密闭，主壳体4的工艺性好，本发明的转子油路由平衡板20开复杂槽及转子铁芯19减重孔实现，包含环形油道25，用来分配冷却油流向，冷却油通过环形油道25分别进入铁芯进油通道27和径向的甩油通道29，通过第一定位键槽30和第二定位键槽31的特殊位置设计，使用同一平衡板20实现多路转子通油。
综上，本发明的电机油冷系统可以同时冷却定子铁芯11、定子绕组12、转子铁芯19、轴承15等发热零件，以对电机进行高效、充分地冷却，并且具有较好的工艺性和成本优势。
以上仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和替换，这些改进和替换也应视为本发明的保护范围。

Claims (15)

  1. 一种电机油冷系统，其特征在于：包括油冷壳体总成(1)、设置在油冷壳体总成(1)内的定子总成(2)以及设于定子总成(2)内且与定子总成(2)通过轴承(15)转动连接的转子总成，所述油冷壳体总成(1)右端设有端盖总成(3)，所述油冷壳体总成(1)、定子总成(2)与端盖总成(3)之间设有壳体油路，所述转子总成内设有转子油路，所述油冷壳体总成(1)上设有与壳体油路连通的壳体进油通道(6)和壳体回油通道(8)，所述转子总成上设有与转子油路连通的转子进油通道(22)，所述转子油路与壳体回油通道(8)连通。
  2. 根据权利要求1所述的一种电机油冷系统，其特征在于：所述油冷壳体总成(1)包括主壳体(4)，所述主壳体(4)左右两端内圆面上分别密封固定有喷油环(5)，两个所述喷油环(5)之间的所述主壳体(4)内圆面上设有多个油道筋(7)；所述定子总成(2)包括带有齿槽的定子铁芯(11)和缠绕于所述定子铁芯(11)齿槽中且具有左右两端部的定子绕组(12)，所述定子铁芯(11)设置在所述主壳体(4)内且外圆面接触所述油道筋(7)并形成过盈配合，所述定子绕组(12)与相应侧所述喷油环(5)位置相对应；所述壳体进油通道(6)设置在所述主壳体(4)左端处，多个所述油道筋(7)、定子铁芯(11)外圆面与两个喷油环(5)围成与所述壳体进油通道(6)连通的输油通道，所述喷油环(5)上设有与所述输油通道连通的进油口(9)，所述喷油环(5)内圆面上设有多个出油孔(10)。
  3. 根据权利要求2所述的一种电机油冷系统，其特征在于：所述壳体回油通道(8)设置在所述主壳体(4)外圆面上，所述端盖总成(3)包括主端盖(13)和设置在所述主端盖(13)内的轴承钢嵌件(14)，右侧所述轴承(15)安装于所述轴承钢嵌件(14)内，所述轴承钢嵌件(14)外侧面上设有集油环(16)，所述轴承钢嵌件(14)上还设有与所述集油环(16)连通的开孔，所述主端盖(13)上设有回油孔(17)；左侧所述喷油环(5)内的冷却油用于通过相应侧多个所述出油孔(10)淋向左端所述定子绕组(12)外侧，并直接流进所述壳体回油通道(8)内；右侧所述喷油环(5)内的冷却油用于通过相应侧多个所述出油孔(10)淋向右端所述定子绕组(12)外侧，且部分冷却油进入所述集油环(16)内并通过所述开孔流入右侧所述轴承(15)表面和内部，并通过所述回油孔(17)进入所述壳体回油通道(8)。
  4. 根据权利要求2所述的一种电机油冷系统，其特征在于：所述定子铁芯(11)外圆面上的键槽、焊接槽和标记槽形成的轴向通道通过耐油硅橡胶堵塞；或者，所述定子铁芯(11)右端设有多片用于堵塞所述定子铁芯(11)外圆轴向通道的冲片。
  5. 根据权利要求2所述的一种电机油冷系统，其特征在于：所述油道筋(7)沿主壳体(4)的轴向设置，使所述输油通道形成Z型通道，所述油道筋(7)表面设有轴向辅助筋。
  6. 根据权利要求2所述的一种电机油冷系统，其特征在于：所述出油孔(10)为斜孔。
  7. 根据权利要求2所述的一种电机油冷系统，其特征在于：所述转子总成包括空心轴(18)，所述空心轴(18)上套设有与所述定子铁芯(11)位置相对应的转子铁芯(19)，所述空心轴(18)在转子铁芯(19)的左右两端分别固定套设平衡板(20)；所述空心轴(18)内腔形成所述转子进油通道(22)，所述空心轴(18)在两个所述平衡板(20)位置处分别设有转子出油孔(24)，两个所述平衡板(20)上均设有油路组件，左侧所述油路组件包括设置于左侧所述平衡板(20)右侧面且与相应所述转子出油孔(24)连通的环形油道(25)，左侧所述环形油道(25)内边缘处设有与相应所述转子出油孔(24)相对应的进油槽(26)，左侧所述平衡板(20)右侧面在所述环形油道(25)外边缘处向外延伸有多个铁芯进油通道(27)，所述转子铁芯(19)上设有多个与所述铁芯进油通道(27)连通的减重孔，左侧所述平衡板(20)在所述环形油道(25)外侧还设有多个避让孔(28)；所述环形油道(25)内的冷却油用于通过多个铁芯进油通道(27)进入所述减重孔，并通过多个所述避让孔(28)甩到油冷壳体腔体内以甩到轴承(15)上。
  8. 根据权利要求7所述的一种电机油冷系统，其特征在于：所述空心轴(18)内腔在所述平衡板(20)右侧处设有封油塞(23)。
  9. 根据权利要求7所述的一种电机油冷系统，其特征在于：左侧所述平衡板(20)上的铁芯进油通道(27)与避让孔(28)的数目相同且交替分布，左侧多个所述铁芯进油通道(27)与右侧多个所述避让孔(28)的位置一一对应。
  10. 根据权利要求9所述的一种电机油冷系统，其特征在于：左侧所述平衡板(20)右侧面在所述环形油道(25)外边缘处还设有多个与所述铁芯进油通道(27)数目相同的甩油通道(29)，所述铁芯进油通道(27)、避让孔(28)与甩油通道(29)交替分布，所述环形油道(25)内的冷却油用于通过多个所述甩油通道(29)甩到所述定子绕组(12)内侧，并流进所述壳体回油通道(8)。
  11. 根据权利要求10所述的一种电机油冷系统，其特征在于：左侧所述铁芯进油通道(27)的数目为2n，n为正整数，两个所述平衡板(20)之间的空心轴(18)外圆面上分别设有两个第一定位键槽(30)和两个第二定位键槽(31)，所述第一定位键槽(30)和第二定位键槽(31)均与空心轴(18)轴线平行，所述第一定位键槽(30)的水平长度与两个所述平衡板(20)之间的水平间距相等，两个所述第二定位键槽(31)靠近右侧所述平衡板(20)，两个所述第一定位键槽(30)之间的周向角度与两个所述第二定位键槽(31)之间的周向角度相 等且均为180°，所述第一定位键槽(30)与相邻所述第二定位键槽(31)之间的周向角度为90°/n，两个所述平衡板(20)在设计上为同一零件，两个所述平衡板(20)在与所述空心轴(18)装配时通过两个所述第一定位键槽(30)和两个所述第二定位键槽(31)定位后，互相形成90°/n的角度偏差，使左侧所述平衡板(20)的多个转子进油通道(22)与右侧所述平衡板(20)的多个避让孔(28)的位置一一对应。
  12. 根据权利要求10所述的一种电机油冷系统，其特征在于：两个所述平衡板(20)相对的侧面上还设有导油翼片或导油槽，所述转子铁芯(19)内流出的冷却油用于通过所述导油翼片或导油槽通向轴承(15)；所述甩油通道(29)为斜槽；所述电机油冷系统还包括电机外置油泵、滤清器和散热器，所述壳体回油通道(8)内的冷却油用于依次通过所述电机外置油泵、滤清器和散热器后回到所述壳体进油通道(6)和转子进油通道(22)以再次循环。
  13. 一种电机油冷方法，采用如权利要求1-12任一项所述的电机油冷系统进行电机油冷，其特征在于包括以下冷却方式：
    (1)、冷却油从所述壳体进油通道(6)进入所述壳体油路，以冷却所述定子总成(2)的定子铁芯(11)、定子绕组(12)外侧和右侧轴承(15)，之后冷却油进入所述壳体回油通道(8)；
    (2)、冷却油同时从所述转子进油通道(22)进入所述转子油路，以冷却所述转子总成的转子铁芯(19)、定子绕组(12)内侧和左右两侧轴承(15)，之后冷却油进入所述壳体回油通道(8)。
  14. 根据权利要求13所述的一种电机油冷方法，其特征在于，冷却方式(1)中：冷却油从所述壳体进油通道(6)进入所述油冷壳体总成(1)的主壳体(4)内，并流向输油通道，以冷却所述定子总成(2)的定子铁芯(11)；冷却油在输油通道中流转若干圈后，通过左侧喷油环(5)上的进油口(9)和右侧喷油环(5)上的进油口(9)分别进入左侧喷油环(5)和右侧喷油环(5)内，左侧喷油环(5)内的冷却油通过相应侧多个出油孔(10)淋向左端定子绕组(12)外侧，并直接流进所述壳体回油通道(8)内，右侧喷油环(5)内的冷却油通过相应侧多个出油孔(10)淋向右端定子绕组(12)外侧，且部分冷却油进入所述端盖总成(3)的集油环(16)内并通过轴承钢嵌件(14)的开孔流入右侧所述轴承(15)表面和内部，以冷却右侧所述轴承(15)，并通过所述端盖总成(3)的回油孔(17)进入所述壳体回油通道(8)。
  15. 根据权利要求13所述的一种电机油冷方法，其特征在于，冷却方式(2)中：冷却 油同时从所述转子进油通道(22)进入所述转子总成的空心轴(18)内，并分别通过相应侧的转子出油孔(24)和进油槽(26)进入相应侧平衡板(20)上的环形油道(25)内，环形油道(25)内的冷却油通过多个铁芯进油通道(27)进入转子铁芯(19)的减重孔，并通过平衡板(20)上的多个避让孔(28)甩到油冷壳体腔体内，进而甩到左右两侧所述轴承(15)上以冷却左右两侧轴承(15)，环形油道(25)内的冷却油还通过多个甩油通道(29)甩到定子绕组(12)内侧，以冷却定子绕组(12)，最后冷却油在重力作用下流进所述壳体回油通道(8)。
PCT/CN2022/116698 2022-03-22 2022-09-02 一种电机油冷系统及电机油冷方法 WO2023178927A1 (zh)

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