CN114257020A - 电动马达冷却套 - Google Patents

电动马达冷却套 Download PDF

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Publication number
CN114257020A
CN114257020A CN202111119318.8A CN202111119318A CN114257020A CN 114257020 A CN114257020 A CN 114257020A CN 202111119318 A CN202111119318 A CN 202111119318A CN 114257020 A CN114257020 A CN 114257020A
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electric motor
cooling jacket
housing
bus bar
bar assembly
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D·J·齐斯科夫斯基
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Dana Heavy Vehicle Systems Group LLC
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Dana Heavy Vehicle Systems Group LLC
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H02K5/203—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium specially adapted for liquids, e.g. cooling jackets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K11/00—Arrangement in connection with cooling of propulsion units
    • B60K11/02—Arrangement in connection with cooling of propulsion units with liquid cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
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    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/22—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs
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    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/42—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by the architecture of the hybrid electric vehicle
    • B60K6/48—Parallel type
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
    • H02K5/225—Terminal boxes or connection arrangements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K2001/003—Arrangement or mounting of electrical propulsion units with means for cooling the electrical propulsion units
    • B60K2001/006—Arrangement or mounting of electrical propulsion units with means for cooling the electrical propulsion units the electric motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/22—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs
    • B60K6/36—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the transmission gearings
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    • B60Y2200/92—Hybrid vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
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    • H—ELECTRICITY
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    • H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
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  • Motor Or Generator Frames (AREA)
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Abstract

本发明涉及提供用于电动马达壳体的***。在一个示例中，***包括相连接外壳，该相连接外壳包括密封在马达引线和多个相线缆连接件之间的汇流条组件。相连接外壳整体地布置在电动马达壳体的冷却套内。

Description

电动马达冷却套
技术领域
本说明书总体上涉及一种具有集成相连接端子盒的电动马达冷却套。
背景技术
对气候变化的担忧导致制造商将能源从化石燃料转换为诸如电能之类的其它能源。这包括各种类别，包括车辆、卡车、船只、摩托车、飞机、火车和其它运输设备。
对电动交通车辆有提高功率输出和行驶里程的性能需求。功率和里程输出的增加也导致热量产生增加以及冷却电动马达和其它电气设备的需求。在构造增加的冷却需求时，噪声、振动和不平顺性可能随着封装约束而增加，这限制了其中可以使用冷却***的许多应用。因此，先前冷却***的示例可能需要修改以适应各种应用，这可能是昂贵且耗时的。
解决电动马达冷却问题的其它示例包括部分被冷却剂通道包围的控制器组件。在美国专利号9,912,207种，史密斯(Smith)等人示出了一种示例方法。其中，史密斯教导了一种电机的控制器组件，该电机的控制器组件部分地被电机的盖的冷却剂通道封围。盖包括凹部，控制器组件的电连接件可延伸穿过该凹部。凹部之一布置在冷却剂通道的空气出口附近。
然而，发明人已发现了上述方法的一些问题。例如，电动马达及其相连接件的径向空间可能增加电机的封装空间。此外，史密斯所示的空气冷却流需要额外的机加工和制造技术，以将空气流引入由诸如油之类的液体冷却的电机。因此，史密斯的设计可能不会利用和/或增强道路车辆上存在的一些预先存在的特征。
发明内容
在一个示例中，该问题可以通过包括用于电动马达的冷却套的***来解决。冷却套围绕密封在马达引线和多个线缆连接件之间的汇流条组件。这样，汇流条可整体地形成在冷却套中，以减少制造约束并降低制造成本。
作为一个示例，提供了一种用于电动马达的低轮廓连接件，该连接件构造成密封马达引线和相线缆连接件之间的汇流条，以减轻通过线缆和/或连接件的油芯吸。可以减少电动马达相线缆连接件所需的径向空间。相连接盒被集成到冷却套铸造/机加工中，这可以消除对单独的相连接盒组件的需要，同时还将端子块(terminal block)集成到冷却套壳体中。
应当理解，提供以上发明内容是为了以简化的形式介绍在详细描述中进一步描述的概念的选择。这并不意味着确定所要求保护的主题的关键或必要特征，所要求保护的主题的范围由所附权利要求书唯一地限定。此外，所要求保护的主题不限于解决以上或在本公开的任何部分中指出的任何缺点的实施方式。
附图说明
图1示出了混合动力车辆架构；
图2示出了具有集成的相连接盒的电动马达冷却套的等距视图；
图3示出了电动马达冷却套的螺栓连接盒；
图4示出了电动马达冷却套的集成的连接盒；
图5示出了螺栓连接盒实施例的高度；
图6示出了集成的连接盒实施例的高度；以及
图7示出了集成的连接盒的分解图。
具体实施方式
以下描述涉及用于电动马达冷却套的***。如图1所示，电动马达冷却套可以整体地布置在混合动力车辆的电动马达壳体中。图2和图3示出了电动马达冷却套的各种视图。图4示出了电动马达冷却套的剖视图。图5和6示出了集成的连接盒的各种视图。图7示出了集成的连接盒的分解图。
现在转到图1，其示出了包括第一轴102和第二轴112的车辆100。第一轴102可以构造成驱动第一组车轮104，而第二轴112可以构造成驱动第二组车轮114。在一个示例中，第一轴102布置成靠近车辆100的前部，而第二轴112布置成靠近车辆100的后部。
发动机110可以联接到第一齿轮箱111，而电动马达120可以联接到第二齿轮箱121。第一齿轮箱111和第二齿轮箱121中的每一个可以将动力传递到布置在第一轴102上的第一差速器103和布置在第二轴112上的第二差速器113。在一个示例中，发动机110和电动马达120布置成动力串联混合动力构造。然而，本领域普通技术人员将理解，车辆100的混合动力构造可以是任何形式而不脱离本公开的范围。
电动马达120构造为从电池130接收能量。电动马达120和发动机110流体地联接到共用冷却***140。在一个示例中，冷却***140使诸如油冷却剂、水等之类的液体流动到发动机110和电动马达120中的每一个的冷却剂通道。
在此，车辆100是至少部分地电驱动的。在一个示例中，车辆100是全电动车辆，其包括用于为一个或多个电动马达供电以驱动车辆的一个或多个电池。在一个示例中，车辆100是全电动客车。
现在转向图2，其示出了具有集成的相连接盒的电动马达冷却套的等距视图200。图3示出了本公开的电动马达的连接盒上的螺栓的视图300。图4示出了沿图2所示的切割平面截取的剖视图400。图5和图6分别示出了描绘本公开的实施例和先前示例的实施例之间的高度差的视图500和600。图7示出了相连接盒的分解图700。可以在本文中串行地描述图2-7。
图2、3和7示出了包括三个轴的轴***290，即平行于水平方向的x轴、平行于竖直方向的y轴和垂直于x轴和y轴的z轴图4、5和6包括轴***490，其包括轴***290的y轴和z轴。图2-7是按比例绘制的，但也可以使用其它相对尺寸。
视图200示出了电动马达120的第一侧，而视图300示出了电动马达120的第二侧。电动马达120包括壳体202，壳体202容纳多个电动马达部件，包括定子、绕组、风扇、轴的至少一部分、转子等。壳体202可以经由多个紧固件204物理地联接到电动马达120。在一些示例中，附加地或替代地，壳体202可以经由焊接、熔合、粘合剂或其它类似的联接元件物理地联接。
壳体202可以包括一个或多个安装元件，比如第一安装元件210。壳体202还包括多个第二安装元件212。安装元件可以将壳体202固定地联接到车辆的框架。
壳体202还构造成接纳冷却套220。在一个示例中，冷却套220布置在壳体202的第一部分和第二部分之间。如上所述，冷却套220包括与其集成地布置的连接盒230。关于图4示出冷却套220和连接盒230的详细剖视图。在一个示例中，相连接盒230被集成到冷却套铸造/机加工中，这可以消除对单独的相连接盒组件的需要，同时还将端子块集成到冷却套壳体中。连接盒可以以α角定位在成角度的表面上，在该示例中，该角在与水平面成40-80度的范围内。由于盒子的高度和马达构造的圆形特性，成角度定位能够改进包装构造。连接盒的定位也有利地相对于安装元件210横跨竖直轴线y相对，安装元件210与其加强的延伸部突出超过壳体外周边。具体地，安装元件210具有向下延伸到马达壳体轴线的中心的升高的轮廓，其中壳体被不对称升高的轮廓550进一步加强。在图5中示出的、与连接盒和安装元件相关的这些升高区域的特定定位能够在保持足够的冷却和结构刚度的同时减少壳体的整体封装空间。
连接盒230包括汇流条组件402。汇流条组件402包括在汇流条组件402的第一端处的马达引线连接件404。汇流条组件402还包括在汇流条组件402的第一端相对的第二端处的一个或多个凸耳406。一个或多个凸耳406可以从汇流条组件402径向突出并进入连接盒230的相应凹部432中。
如图3所示，冷却入口和出口(272、274)可定位在壳体的侧部上。入口/出口与连接盒230定位在同一侧上，以再次利用盒所需的包装空间。图3还示出了相对于竖直轴线在壳体的底部处的各种加强肋276。
如图2所示，电气盒盖201遮蔽了冷却入口272，而冷却出口274仍然暴露。在图3的示例中，省略了电气盒盖，从而暴露了冷却入口。
马达引线连接件404可以包括马达的接收器和相连接线缆之间的电连接件。在一个示例中，可以在汇流条组件402中布置多个马达引线连接件，其中每个马达引线连接件对应于电机的不同相位。在一个示例中，马达是三相马达并且存在三个马达引线连接件。
汇流条组件402还可以包括多个密封件410。第一密封件412可以布置在马达引线连接件404附近。第二密封件414可以布置在第一密封件和一个或多个凸耳406之间。在一个示例中，第一密封件412的直径可以小于第二密封件414的直径。因此，第一密封件412可以密封汇流条组件402的内径，而第二密封件414可以密封汇流条组件402的外径。第一密封件412和第二密封件414中的每一个可以构造为阻止冷却液接触马达引线连接件404。
其中布置有集成的相连接盒230的冷却套220还包括螺纹连接件420。在一个示例中，螺纹连接件420是螺纹凸耳连接件。螺纹连接件420可以是连接盒230和冷却套220之间的联接件。
冷却套220包括与定子442和绕组444相邻布置的冷却剂通道430。冷却剂通道430可以包括弯曲形状，其中流过冷却剂通道430的冷却剂以C形流动。换言之，冷却剂在冷却剂通道430中在第一方向上流动，转为在冷却剂通道430中在第二方向上朝向汇流条402流动，并且转为在与第二方向正交且与第一方向相反的第三方向上离开。多个密封件410可以阻止冷却剂直接接触汇流条402和/或马达引线连接件404。
检修面板450可以紧固到冷却套220的最外面部分。检修面板450可以经由多个紧固件452紧固，当电动马达120完全组装好时，这些紧固件452对于用户来说是可接近的。
图5和图6示出了电动马达120的当前示例500与电动马达602的先前示例600之间的比较。当前示例500包括冷却套220和连接盒230。结果，当前示例中的连接盒230的径向突出部小于先前示例600中的连接盒的径向突出部。在一个示例中，先前示例600的连接盒604延伸的径向距离是连接盒230的两倍。因此，先前示例的封装尺寸大于电动马达120的封装尺寸。在一个示例中，附加地或替代地，连接盒230径向向外延伸的距离等于连接盒604的径向距离的20％或更少。
在一个示例中，本公开的从电动马达的中心到连接盒230的最外部分(例如，到检修面板450)测量的径向距离可以小于300mm。附加地或替代地，径向距离可以小于285mm。在一个示例中，径向距离等于272.5mm。先前示例的从电动马达的中心到连接盒604的最外部分测量的径向距离可以大于300mm。在一个示例中，连接盒604距电动马达分中心的径向距离为323.75mm。
如图所示，在当前示例500和先前示例600中的每一个中的用于冷却套的壳体相对紧凑。由于这些封装约束和布置在其中的冷却剂，将连接盒集成在其中相对困难。因此，图5的实施例提供了一种增强的马达壳体和冷却套，其中连接盒整体地布置在其中，这减少了混合动力车辆的电动马达的封装约束。此外，可以增强连接盒和其中的电连接件的冷却，这可以增加寿命和导电性。
在一个示例中，连接盒的定位可以使得虽然它仍然可以经由电动马达的冷却剂通道中的冷却剂进行热调节，但连接盒在冷却剂通道的径向外侧，使得不需要重新设计冷却剂通道。因此，由于连接盒整体地布置在电动马达冷却套中时，可以保持冷却剂通道的预先存在的构造。
冷却套铸件可能比先前示例更大，以便支承连接盒。此外，可以使用附加的铸芯来减少对连接盒腔(例如，图4的凹部432)的机加工，同时也在铸造过程期间减少较厚的部分。
转向图7，其示出了冷却套(例如，图2的冷却套220)外部的连接盒230的分解图700。连接盒230包括块壳体710，比如端子块壳体，其可以与汇流条组件402和检修面板450中的每一个接口。
汇流条组件402包括用于将马达连接到逆变器的三相AC线缆安装件702。三相AC线缆安装件702可以是如图所示的凸耳和压盖构造，或者可以是如图3所示的快速连接构造。凸耳和压盖构造可包括第一多个凸耳742和第二多个凸耳744。第一多个凸耳742在平行于z轴的方向上延伸，而第二多个凸耳744在平行于y轴的方向上延伸。在一个示例中，第一多个凸耳742延伸穿过邻近马达引线404的第一压盖743。第二多个凸耳744可以延伸穿过第二压盖，其中第二压盖布置得比第一压盖更靠近检修面板450。来自定子组件(例如，图4的定子442)的马达引线404可以物理地联接到汇流条组件402，同时允许马达的三相操作。在一个示例中，马达引线404在平行于x轴的方向上物理联接到汇流条组件402，而三相AC线缆安装件702在平行于y轴并正交于马达引线404的方向上联接到逆变器。
第一垫圈722可以布置在汇流条组件402和块壳体710之间。第一垫圈722可以包括弹性体材料，该弹性材料构造成阻挡汇流条组件402和块壳体710之间的界面之间的冷却剂流动。
维修面板450可以物理地联接到块壳体710。在一个示例中，汇流条组件402物理地联接到端子块壳体710的侧面，而维修面板450物理地联接到块壳体710的顶面。侧面可以平行于一平面，该平面正交于顶面所平行的平面。
多个紧固件732可以将检修面板450物理地联接到块壳体710。第二垫圈724可以布置在检修面板450和块壳体710之间。第二垫圈724的材料和形状可以与第一垫圈722相同。
在图7的示例中，检修面板450包括布置在外部面上的标签752。在一个示例中，标签752可以从外部面突出。这样，标签752不与外部面齐平。标签752可以包括诸如闪电之类的符号，从而可以通知操作员在块壳体710中存在电连接件。
这样，相连接盒和汇流条可以整体地布置在电动马达壳体的冷却套中。一个或多个密封件可围绕汇流条布置以阻止冷却剂泄漏到电连接件和相连接盒的部分中。将相连接盒集成到冷却套中的技术效果是增强了电连接件的温度控制，同时还减小了电动马达壳体的封装尺寸。
图1-7示出了具有各个部件的相对定位的示例构造。如果示出为彼此直接接触或直接联接，则至少在一个示例中，这样的元件可以分别称为直接接触或直接联接。类似地，至少在一个示例中，示出为彼此连续或相邻的元件可以分别是彼此连续或彼此相邻的。作为示例，放置为彼此共面地接触的组件可以称为共面地接触。作为另一示例，在至少一个示例中，定位成彼此间隔开、其间仅具有间隔而没有其他部件的元件可以被如此称呼。作为又一示例，彼此上/下、彼此相对侧或彼此左/右地示出的元件可以相对于彼此如此称呼。此外，如附图中所示，在至少一个示例中，最顶上的元件或元件的位置可称为部件的“顶部”，而最底下的元件或元件的位置可称为部件的“底部”。如本文所使用的，顶部/底部、上部/下部、上方/下方可以是相对于附图的竖直轴线并且用于描述附图中的元件相对于彼此的定位。这样，在一个示例中，在其它元件上方示出的元件垂直地位于其它元件上方。作为又一示例，在附图中描绘的元件的形状可称为具有如此形状(例如，诸如圆形的、直线的、平面的、弯曲的、圆滑的、倒角的、成角度的，等等)。此外，在至少一个示例中，示出为彼此相交的元件可以被称为相交元件或彼此相交。更进一步，在一个示例中，示出为在另一个元件内或在另一个元件外的元件可以如此称呼。可以理解的是，被称为“基本上相似和/或相同”的一个或多个部件根据制造公差(例如，在1-5％的偏差内)彼此不同。
要注意的是，本文包括的示例控制和估计例程可以与各种发动机和/或车辆***构造一起使用。本文公开的控制方法和例程可以作为可执行指令存储在非暂时性存储器中，并且可以由包括与各种传感器、致动器和其它发动机硬件结合的控制器的控制***来执行。本文描述的特定例程可以代表任何数量的诸如事件驱动、中断驱动、多任务、多线程等的处理策略中的一个或多个。这样，所示出的各种动作、操作和/或功能可以以所示出的顺序、并行地来执行，或者在某些情况下被省去。同样，实现本文描述的示例实施例的特征和优点的处理顺序不是必要的，而是为了便于说明和描述而提供。取决于被使用的特定策略，可以重复地执行所示的动作、操作和/或功能中的一个或多个。此外，所描述的动作、操作和/或功能可以图形地表示待编程到引擎控制***中的计算机可读存储介质的非暂时性存储器中的代码，其中所描述的动作通过在包括各种发动机硬件部件并且与电子控制器结合在一起的***中执行指令来执行。
应当理解的是，本文公开的构造和例程本质上是示例性的，并且这些具体实施例不应被认为是限制性的，因为可以进行多种变化。例如，以上技术可以应用于V-6、I-4、I-6、V-12、对置4(opposed 4)以及其它发动机类型。本公开的主题包括本文公开的各种***和构造以及其它特征、功能和/或特性的所有新颖且非显而易见的组合和子组合。
如本文所使用的，除非另外指明，否则术语“大约”解释为表示该范围的正负百分之五。
所附权利要求书特别指出了被认为是新颖且非显而易见的某些组合和子组合。这些权利要求书可能涉及“一个”元件或“第一”元件或其等同物。应当将这样的权利要求书理解为包括一个或多个这样的元件的结合，既不需要也不排除两个或多个这样的元件。在本申请或相关申请中，可以通过修改本权利要求书或通过提出新权利要求书来主张所公开的特征、功能、元件和/或特性的其他组合和子组合。这样的权利要求书，无论是在范围上与原始权利要求书相比更宽、更窄、相同或不同，都被认为包括在本公开的主题范围内。

Claims (15)

1.一种电动马达，包括：
相连接外壳，所述相连接外壳包括密封在马达引线和多个相线缆连接件之间的汇流条组件。
2.如权利要求1所述的电动马达，其特征在于，所述汇流条组件包括多个凸耳。
3.如权利要求1所述的电动马达，其特征在于，螺纹凸耳连接件定位在所述相连接外壳内。
4.如权利要求1所述的电动马达，其特征在于，所述相连接外壳包括立方体或矩形棱柱形状。
5.如权利要求1所述的电动马达，其特征在于，所述汇流条组件与所述电动马达的冷却套壳体的冷却剂通道直接接触。
6.如权利要求5所述的电动马达，其特征在于，所述冷却套壳体布置在电动马达壳体内。
7.如权利要求5所述的电动马达，其特征在于，所述冷却剂通道与所述电动马达的定子直接接触。
8.一种电动马达冷却套，包括：
冷却剂通道，所述冷却剂通道构造成使冷却剂在定子和相连接盒之间的冷却套壳体的一部分中流动，其中，所述相连接盒整体地布置在所述冷却套壳体中。
9.如权利要求8所述的电动马达冷却套，其特征在于，汇流条组件和多个凸耳连接件布置在所述冷却套壳体内。
10.如权利要求9所述的电动马达冷却套，其特征在于，在所述汇流条组件、马达引线和所述相连接盒之间布置有密封件。
11.如权利要求8所述的电动马达冷却套，其特征在于，所述相连接盒集成到冷却套铸件中。
12.如权利要求8所述的电动马达冷却套，其特征在于，所述相连接盒通过检修面板在外部密封。
13.如权利要求12所述的电动马达冷却套，其特征在于，在所述相连接盒和所述检修面板之间布置有垫圈。
14.如权利要求8所述的电动马达冷却套，其特征在于，马达引线从定子螺栓到汇流条组件，以提供马达的三相控制。
15.如权利要求8所述的电动马达冷却套，其特征在于，所述相连接盒的汇流条组件构造成经由凸耳和压盖联接将逆变器电联接到马达。
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