The present disclosure relates to the vehicle field and, more particularly, to an electric drive assembly system, a vehicle including the electric drive assembly system and an assembly method of an electric drive assembly system.
The electric drive assembly system is an integral part of a vehicle and includes an electric machine, a gearbox assembly and an electric machine controller. In a known solution, the electric connection assembly between the electric machine controller and the electric machine is disposed at the non-drive end of the rotor shaft of the electric machine, and the connection between the electric machine and the gearbox assembly is disposed at the drive end of the rotor shaft of the electric machine.
The electric machine length or power is determined by the length between the drive and the non-drive ends of the rotor shaft of the electric machine. Various devices are assembled at both the drive and the non-drive ends of the rotor shaft of the electric machine. For example, the electric connection assembly between the electric machine and the electric machine controller (for example, inverter) is disposed at the non-drive end. For a known electric drive assembly system, any change in the electric machine length will affect the electric connection assembly between the electric machine and the inverter. Therefore, the electric connection assembly needs to be redesigned if the electric machine length is to be changed.
Additionally, the electric connection assembly disposed at the non-drive end of the rotor shaft of the electric machine is cooled by air, so the cooling efficiency is low.
Furthermore, the total length of a known electric drive assembly system is large and there is generally no enough space to install such a long electric drive assembly system, so it is generally disposed off the centre of the vehicle. This causes an increased length difference between the left and the right drive shafts of the vehicle and even an additional shaft needs to be provided between the left and the right drive shafts to balance the length difference.
Therefore, an electric drive assembly system that can solve the above-mentioned problems is needed in this field.
Therefore, the purpose of the present disclosure is to provide an electric drive assembly system, a vehicle including the electric drive assembly system and an assembly method of an electric drive assembly system. In the electric drive assembly system, the electric connection assembly between the electric machine control device and the electric machine is installed at the drive end of the rotor shaft of the electric machine such that the electric machine length can be changed without the need of redesigning the electric connection assembly. Additionally, the electric connection assembly in the electric drive assembly system is cooled by the cooling oil of the gearbox assembly, so the cooling efficiency is high. Furthermore, the electric drive assembly system reduces the length difference between the left and the right drive shafts of the vehicle.
In one aspect, the present disclosure provides an electric drive assembly system. The electric drive assembly system comprises:
In one embodiment, the electric connection assembly comprises a plurality of busbars, an injection moulding part and a seal, the injection moulding part is disposed on the busbars and closes the opening, and the seal is disposed between the injection moulding part and the first wall.
In one embodiment, the injection moulding part is formed on the plurality of busbars by injection moulding.
In one embodiment, the busbars pass through the opening and comprise first sections connected to the stator and second sections connected to the electric machine control module.
In one embodiment, the cover comprises a gearbox cover, an electric machine cover, and a control module cover, wherein the first sections are located within a third accommodating space limited by the body of the housing and the electric machine cover, and at least partially extends in the direction transverse to the gear input shaft, and the second sections are located within a second accommodating space limited by the body of the housing and the control module cover.
In one embodiment, the body is provided with other opening in a second wall protruded at the drive end of the rotor shaft, and the other opening expose at least a part of the first sections.
In one embodiment, the electric connection assembly is fixed to the body by using a connector.
In one embodiment, the electric machine control module comprises a plurality of output terminals corresponding to the plurality of busbars, and the arrangement direction of the plurality of output terminals is in parallel with the extension direction of the gear input shaft.
In one embodiment, the electric machine control module comprises a plurality of output terminals corresponding to the plurality of busbars, and the arrangement direction of the plurality of output terminals is perpendicular to the extension direction of the gear input shaft.
In one embodiment, the first sections extend in a direction perpendicular to the gear input shaft, and the second sections extend between the first sections and the output terminals corresponding to the first sections.
In one embodiment, the first sections and/or the second sections are arranged side by side in their respective width directions or at least partially arranged side by side in their respective thickness directions.
In one embodiment, the plurality of busbars pass through the same opening or corresponding plurality of openings in the first wall.
In one more aspect, the present disclosure provides a vehicle. The vehicle comprises the above-mentioned electric drive assembly system.
In another aspect, the present disclosure provides an assembly method of an electric drive assembly system. The assembly method comprises:
In one embodiment of the method, the electric drive assembly system is configured as described above.
To clearly describe the technical solution in the embodiments of the present disclosure, the drawings of the embodiments of the present disclosure will be briefly introduced below. The drawings are only used to show some embodiments of the present disclosure and do not limit all embodiments of the present disclosure here. In the drawings:
The technical solutions of the embodiments of the present invention will be clearly and completely described below by referring to the drawings of the particular embodiments of the present disclosure so that the purposes of the technical solutions, the technical solutions and the advantages of the present invention are clearer. In the drawings, identical reference numerals denote identical parts. It is important to note that the embodiments described are only some of embodiments of the present disclosure and are not all embodiments. All other embodiments obtained by those of ordinary skill in the art based on the described embodiments of the present disclosure without any creative work fall within the scope of protection of the present disclosure.
Unless otherwise defined, technical or scientific terms used herein shall have ordinary meanings as understood by those of ordinary skill in the art to which this disclosure belongs. “First”, “second” and similar terms used in the patent application specification and claims of the present disclosure do not indicate any sequence, quantity or importance, and are only used to distinguish different constituent parts. Likewise, terms such as “a” and “one” do not necessarily represent a quantity limit “Comprise”, “include”, “have” or any other similar term means that the element or object preceding the term covers the elements or objects and equivalents thereof listed after the term but does not exclude other elements or objects. A term like “connected” or “linked”, rather than being limited to the physical or mechanical connection or link shown in a drawing, may include a connection or link equivalent thereto, irrespective of whether it is direct or indirect. “Upper”, “lower”, “left”, “right”, etc., are only used to indicate a relative positional relationship, and when the absolute position of the described object has changed, the relative positional relationship may also change accordingly.
Preferred embodiments of an electric drive assembly system for a vehicle according to the present disclosure will be described in detail below with reference to
As shown in
Specifically, the electric machine 2 has a rotor shaft (not shown in the figures). The electric machine 2 may include a rotor and a stator 22. The fixed part of the electric machine is called the stator and the rotating part is called the rotor. For example, the stator consists of a core, windings and a base, and the core is generally formed by stacking silicon steel sheets. The rotor is fixed to the base by using a bearing or shaft sleeve and includes a rotor shaft and a rotor core mounted on the rotor shaft. The electric machine control module 4 is connected to the terminals of the stator to input AC to the stator to generate a rotating magnetic field. The rotor is cut by magnetic lines of force in the rotating magnetic field to generate an output current. Additionally, the wheels of the vehicle can reversely drive the rotor to induce a rotating magnetic field in the other direction, and the electric machine control module 4 that is an inverter transfers power back to the battery.
The gearbox assembly 3 has a gear input shaft 21, and the gear input shaft 21 is connected to the rotor shaft and coaxially arranged to receive a torque from the electric machine. For example, the gear input shaft 21 may be rotatably fixed to the rotor shaft of the electric machine. It should be understood that the rotor shaft and the gear input shaft may be two different shafts rotatably connected by a connecting element (for example, a spline), or the same shaft, and are not limited herein.
The gearbox assembly 3 may further comprise an intermediate shaft engaged with the gear of the gear input shaft 21 and a differential component (for example, the differential 6 shown in
The electric machine control module 4 is configured to control the electric machine 2. The electric machine control module 4 may include various electronic and electrical control elements, for example in the form of a circuit board. By using electronic and electrical control elements to control the IGBT integrated power module, the electric machine control module 4 can output a controllable three-phase sinusoidal AC current, controlling the speed and torque of the electric machine. Because the electric machine control module 4 is common in the art, it is not specifically described herein.
Additionally, the electric machine control module 4 is installed onto a first wall 17 of the body 11 by stacking over the electric machine 2 and/or gearbox assembly 3 in the direction transverse to the gear input shaft 21. As shown in
As shown in
The electric connection assembly 5 is configured to electrically connect the electric machine control module 4 to the stator 22 of the electric machine 2, or rather, terminals of the stator 22. The electric connection assembly 5 is provided to electrically connect to the stator 22 of the electric machine 2 near the gear input shaft 21. The position of the stator 22 is shown in
Arranging the electrical connection component 5 near the drive end of the rotor shaft of the electric machine of the electric drive assembly system allows its non-drive end to be extensible. In other words, the body 11 of the housing 1 is extensible in the direction towards the electric machine cover 13, that is, the length of the electric machine or stator housed therein is changeable and the electric machine control module and the electrical connection component do not need to be redesigned. This allows the electric drive assembly system of the present disclosure to have a flexible application and a low cost.
As shown in
The electric machine control module 4 comprises a plurality of output terminals 41 corresponding to the plurality of busbars 51, as shown in
Specifically, the busbars 51 pass through the opening and comprise first sections 511 connected to the stator 22 and second sections 512 connected to the electric machine control module 4, as shown in
Additionally, as shown in
The left and the right drive shafts of the vehicle are connected to the differential of the gearbox assembly. For example, the electric drive assembly system is not on the centre of the vehicle. In a vehicle of the present disclosure, the electric connection assembly between the electric machine control module and the electric machine in the above-mentioned electric drive assembly system is installed at the drive end of the rotor shaft of the electric machine to reduce the total length of the electric machine such that the electric drive assembly system is disposed closer to the centre of the vehicle, decreasing the length difference between the left and the right drive shafts. This also reduces the probability of or avoids using an additional shaft to balance the length difference between the left and the right drive shafts.
An assembly method of an electric drive assembly system according to the present disclosure comprises: installing the electric machine 2 in the housing 1 of the electric drive assembly system; inserting the electric connection assembly 5 into at least one opening disposed in the first wall 17 of the body 11 in the direction transverse to the rotor shaft (i.e. the direction transverse to the gear input shaft 21) from the outside of the body 11 of the housing 1 at the drive end of the rotor shaft of the electric machine 2; connecting the electric connection assembly 5 to the stator 22 of the electric machine 2 (or rather, terminals of the stator 22); installing the gearbox assembly 3 in the housing 1 and the electric machine control module 4 to the first wall 17; and connecting the electric connection assembly 5 to the electric machine control module 4. The above-mentioned electric drive assembly system may be assembled using the assembly method. For example, the step for inserting the above-mentioned electric connection assembly 5 can be performed in a direction perpendicular to the gear input shaft 21, that is, the vertically downward direction in
The technical features disclosed above are not limited to the combinations of the disclosed features with other features, and according to the purpose of the present invention, those skilled in the art may make other combinations of the technical features, which shall be judged by the purpose of the present disclosure.
Number | Date | Country | Kind |
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202210699993.0 | Jun 2022 | CN | national |