CN221250556U - Electric automobile all-in-one actuating system - Google Patents

Abstract

The utility model discloses an electric automobile all-in-one driving system which comprises a motor controller, a high-voltage power distribution module, a power module, a quick charging module, a driving motor and a speed reducer, wherein the motor controller is connected with the high-voltage power distribution module; the motor controller is arranged above the driving motor and the speed reducer and is fixedly connected through bolts; the motor controller comprises a box body, and the high-voltage power distribution module, the power supply module and the quick charging module are integrated in the box body of the motor controller; the motor shell of the driving motor is internally provided with a motor heat dissipation water channel cavity of a Z-shaped rotary structure, the box body of the motor controller is internally provided with a controller heat dissipation water channel cavity formed by a diamond heat dissipation structure, the power module is internally provided with a power source heat dissipation water channel cavity of a three-dimensional flat structure, and the heat dissipation water channel cavities of the driving motor, the motor controller and the power module are communicated through a shared water pipe. The utility model reduces the use of the whole vehicle to the cable, the high-voltage connector and the cooling water pipe by integrating the devices and the modules, and reduces the cost and the arrangement complexity.

Description

Electric automobile all-in-one actuating system

Technical Field

The utility model belongs to the technical field of new energy electric automobiles, and particularly relates to an electric automobile all-in-one driving system.

Background

The statements herein merely provide background information related to the present disclosure and may not necessarily constitute prior art.

In recent years, new energy automobiles are developing at a high speed, and many host factories are issuing plans for canceling fuel vehicles, so that the trend of electric automobiles is not blocked. The power battery system, the electric drive system, the power supply system, the power distribution system and the like in the new energy automobile are all core components of the electric automobile, the currently common electric automobile driving (electric drive for short) system mainly comprises a three-in-one driving system which is composed of a driving motor, a motor controller and a speed reducer, the three-in-one electric drive system, the power supply system, the power distribution system and the like are usually arranged separately, a large number of connecting parts such as high-voltage cables, high-voltage connectors, low-voltage cables, low-voltage connectors, cooling pipelines and fixed brackets are still needed, the arrangement of the whole automobile is relatively complex, and the cost control of the whole automobile is not facilitated by using the connecting parts. In addition, the common fast charging relay for the electric automobile is basically arranged inside the power battery, so that the discharging and charging of the power battery can be necessarily caused to be respectively connected in a loop by using different high-voltage connectors, and the cost of parts of the electric automobile is increased.

With the development of new energy automobiles, power electronics increasingly move to integration, modularization and platfonn, and the existing three-in-one driving system cannot meet the requirements of the new energy automobiles on the modularization, the less-part and the platfonn of driving system products and the requirements of the new energy automobiles on cost control.

Disclosure of utility model

Aiming at the problems and defects in the prior art, the utility model provides an all-in-one driving system for an electric automobile, which meets the requirements of the electric automobile on high reliability, modularization and platformization of the driving system and solves the problems of high cost of the driving system of the electric automobile, complex arrangement in a power cabin of the whole automobile and complex assembly maintenance.

In order to achieve the above purpose, the present utility model adopts the following technical scheme:

An all-in-one driving system of an electric automobile comprises a motor controller, a high-voltage power distribution module, a power module, a quick charging module, a driving motor and a speed reducer;

The motor controller is arranged above the driving motor and the speed reducer, and the driving motor and the motor controller are fixedly connected through bolts and are connected through copper bars; the driving motor is fixedly connected with the speed reducer through a bolt, and a motor shaft in the driving motor is connected with an input shaft of the speed reducer through a spline; the motor controller comprises a box body, and the high-voltage power distribution module, the power supply module and the quick charging module are integrated in the box body of the motor controller;

The motor shell of the driving motor is internally provided with a motor heat dissipation water channel cavity of a Z-shaped rotary structure, the box body of the motor controller is internally provided with a controller heat dissipation water channel cavity formed by a diamond heat dissipation structure, the power module is internally provided with a power source heat dissipation water channel cavity of a three-dimensional flat structure, and the heat dissipation water channel cavities of the driving motor, the motor controller and the power module are communicated through a shared water pipe.

According to a further technical scheme, a water inlet pipe communicated with a heat dissipation water channel cavity of the motor controller is arranged on a box body of the motor controller; a water outlet pipe communicated with the cavity of the motor heat dissipation water channel is arranged on the motor shell of the driving motor; the inlet tube sets up on motor controller's box, is provided with radial O type circle between inlet tube and the box.

According to a further technical scheme, the motor controller further comprises an upper cover plate, a fuse box cover plate, a bus junction box cover plate and a water channel cover plate, wherein the upper cover plate is used for sealing a box body and is assembled above the box body, the fuse box cover plate is used for sealing the box body and is assembled above the upper cover plate, the bus junction box cover plate is used for sealing the box body, and the water channel cover plate is assembled below the box body and is used for sealing a controller heat dissipation water channel cavity at the bottom of the box body;

The fuse box cover plate is provided with a fuse box cover opening protection switch which is fixed on the fuse box cover plate through bolts and is connected with the box body inner control board assembly through a signal wire harness;

The bus junction box cover plate is arranged on the side surface of the box body, a groove is formed in the matching installation surface of the bus junction box cover plate, and a bus junction box cover plate sealing ring is arranged in the groove;

The water channel cover plate is connected with the lower surface of the box body through a friction stir welding process.

According to a further technical scheme, a direct-current bus high-voltage connector, a slow-charging high-voltage connector, a fast-charging high-voltage connector, an AC high-voltage connector, a PTC high-voltage connector, a low-voltage signal plug-in unit, a box grounding point and a 12V low-voltage output port are sequentially arranged on the periphery of the outer portion of the box body.

The high-voltage distribution module comprises a direct-current bus high-voltage connector, a magnetic ring fixing seat filtering component, a copper bar wiring seat, a PTC relay, a fuse fixing seat, a PTC fuse, an AC fuse, an OBC fuse, a slow-charging high-voltage connector, a slow-charging opening magnetic ring component, an AC high-voltage connector, a PTC high-voltage connector and a laminated copper bar component.

Further technical scheme, quick charge module includes anodal quick charge relay, negative pole quick charge relay, quick charge high voltage connector, quick charge anodal copper bar, quick charge negative pole copper bar.

According to a further technical scheme, a power supply module is arranged in the box body, and an isolation structure is arranged around the power supply module; the power module comprises an alternating current input positive electrode, an alternating current input negative electrode, a DCDC/OBC shared positive electrode, a DCDC/OBC shared negative electrode, a DCDC output positive electrode and a power module low-voltage signal plug-in unit;

The DCDC output positive electrode is connected with the 12V low-voltage output port, the alternating current input positive electrode is connected with the live wire interface of the slow-charging high-voltage connector through a wire harness, and the alternating current input negative electrode is connected with the zero wire interface of the slow-charging high-voltage connector through a wire harness;

The DCDC/OBC common positive electrode is connected with one end of an OBC fuse through a wire harness, the other end of the OBC fuse is connected with an OBC terminal of the laminated positive electrode copper bar through the wire harness, and the DCDC/OBC common negative electrode is connected with an OBC terminal of the laminated negative electrode copper bar through the wire harness;

The low-voltage signal plug-in of the power module is connected with the control panel assembly through a wire harness.

According to a further technical scheme, a magnetic ring fixing seat filtering assembly, a copper bar wiring seat, a slow-charging port magnetic ring assembly, an anode fast-charging relay, a cathode fast-charging relay, a PTC relay, a fuse fixing seat, a PTC fuse, an AC fuse, an OBC fuse, a control panel assembly, a supporting capacitor, a driving panel assembly, an IGBT power module, a three-phase copper column and three-phase copper bar fixing seat assembly and a laminated copper bar assembly for connecting components are sequentially arranged from a front end bus junction box cover plate to the rear end in a box body.

Further technical scheme, the outside of driving motor includes motor casing, motor rear end cap, changes visor, outlet pipe and common water pipe soon, and driving motor's inside includes stator core, stator winding, motor shaft, rotor core, rotor clamp plate, rotor clamping ring, motor front bearing spring wave pad, motor front bearing jump ring, motor front bearing, motor rear bearing jump ring, motor rear bearing clamp plate, changes the stator soon, changes the rotor soon and three-phase sealing washer soon.

According to a further technical scheme, the speed reducer comprises a speed reducer left shell, a speed reducer right shell, an input shaft left bearing, an input shaft right bearing, a high-speed oil seal and a spline O-shaped ring.

Compared with the prior art, the utility model has the following beneficial effects:

The utility model provides an all-in-one driving system of an electric automobile, which integrates a motor controller, a high-voltage power distribution module, a power supply module and a quick charging module in a box body of the motor controller, integrates a driving motor, the motor controller and a speed reducer at the outer part, and shares the driving motor, the motor controller and an internal water channel of the power supply module to form the all-in-one driving system, so that the use of a whole automobile on a high-voltage cable, a high-voltage connector and a cooling water pipe is reduced, the purpose of reducing the cost is achieved, and the problem of high cost of the driving system is solved; meanwhile, the integrated scheme reduces the complexity of the whole vehicle arrangement, optimizes the high-voltage circuit topology architecture of the whole vehicle, and can realize better platform application.

Drawings

The accompanying drawings, which are included to provide a further understanding of the utility model and are incorporated in and constitute a part of this specification, illustrate embodiments of the utility model and together with the description serve to explain the utility model.

FIG. 1 is a schematic view of an isometric view of a front view of an all-in-one drive system for an electric vehicle according to the present utility model;

FIG. 2 is a schematic view of an isometric view of a reverse side view of an all-in-one drive system for an electric vehicle according to the present utility model;

Fig. 3 is a schematic diagram of a front view structure of an all-in-one driving system of an electric vehicle according to the present utility model;

FIG. 4 is a schematic view of a rear view angle structure of the all-in-one driving system of the electric vehicle according to the present utility model;

FIG. 5 is a schematic diagram of a right side view of the all-in-one drive system of the electric vehicle according to the present utility model;

fig. 6 is a schematic diagram of a top view structure of the electric vehicle all-in-one driving system according to the present utility model, with a fuse box cover removed;

FIG. 7 is a schematic top view structure diagram of the all-in-one driving system of the electric vehicle according to the present utility model, with an upper cover plate removed;

FIG. 8 is a schematic view of an isometric structure of an electric vehicle all-in-one drive system with motor controller removed according to the present utility model;

Fig. 9 is a schematic structural view of an internal heat dissipation water channel extraction water channel cavity of the all-in-one driving system of the electric vehicle;

FIG. 10 is a schematic front cross-sectional view of the electric vehicle all-in-one drive system of the present utility model;

fig. 11 is an exploded view of the electric vehicle all-in-one driving system according to the present utility model.

1, A motor controller; 1-1, a box body; 1-1-1, a central fixing bolt at the lower part of the box body; 1-2, an upper cover plate; 1-2-1, fixing a bolt at the center of an upper cover plate; 1-3, fuse box cover plate; 1-3-1, a fuse box cover opening protection switch; 1-3-2, sealing ring of fuse box cover plate; 1-4, a bus junction box cover plate; 1-4-1, a bus junction box cover plate sealing ring; 1-5, a water channel cover plate; 1-6, a water inlet pipe; 1-6-1, radial O-shaped ring; 1-7, a controller radiating water channel cavity; 1-8, low voltage signal plug-ins; 1-9, a box body grounding point; 1-10, a ventilation valve; 1-11, 12V low pressure output port; 1-12, a supporting capacitor; 1-12-1, mounting support legs; 1-12-2, supporting the positive electrode of the capacitor input end; 1-12-3, supporting the negative electrode of the capacitor input end; 1-12-4, a positive electrode of an output end of the supporting capacitor; 1-12-5, supporting the negative electrode of the output end of the capacitor; 1-12-6, a grounding copper bar; 1-13, a control panel assembly; 1-13-1, a signal plug-in of a control panel power module; 1-13-2, a control board driving signal plug-in; 1-14, a drive plate assembly; 1-14-1, a U-phase on-board current sensor; 1-14-2, a W-phase on-board current sensor; 1-14-3, a drive board low voltage signal plug-in; 1-15, IGBT power module; 1-15-1, an IGBT power module is input into the anode; 1-15-2, and inputting an IGBT power module into a cathode; 1-15-3, and outputting a U phase by the IGBT power module; 1-15-4, and outputting a V phase by the IGBT power module; 1-15-5, and outputting a W phase by the IGBT power module; 1-15-6, IGBT signal pins; 1-16, three-phase copper columns; 1-17, a three-phase copper bar fixing seat assembly; 1-17-1, U-phase copper bars; 1-17-2, V-phase copper bars; 1-17-3, W phase copper bars;

2. A high voltage power distribution module; 2-1, a direct current bus high-voltage connector; 2-1-1, an anode bus cable; 2-1-2, a negative bus cable; 2-2, a magnetic ring fixing seat filtering assembly; 2-2-1, a direct current bus positive copper bar; 2-2-2, a direct current bus negative copper bar; 2-2-3, an on-board Y capacitor assembly; 2-3, a copper bar wiring seat; 2-4, PTC relay; 2-5, fuse fixing seat; 2-5-1, PTC fuse; 2-5-2, AC fuses; 2-5-3, OBC fuse; 2-6, a slow-charging high-voltage connector; 2-6-1, a fire wire interface of a slow charging high-voltage connector; 2-6-2, a zero line interface of a slow charging high-voltage connector; 2-6-3, a ground wire interface of the slow-charging high-voltage connector; 2-6-4, a grounding terminal in the box body; 2-7, a slow filling port magnetic ring assembly; 2-8, AC high voltage connectors; 2-8-1, positive electrode of AC high-voltage connector; 2-8-2, negative electrode of AC high-voltage connector; 2-9, PTC high voltage connector; 2-9-1, positive electrode of PTC high-voltage connector; 2-9-2, negative electrode of PTC high-voltage connector; 2-10, laminating a copper bar assembly; 2-10-1, laminating positive electrode copper bars; 2-10-2, laminating negative electrode copper bars; 2-10-3, insulating coating; 2-10-4, a stacked negative copper bar PTC terminal; 2-10-5, a laminated negative electrode copper bar AC terminal; 2-10-6, a laminated negative copper bar OBC terminal; 2-10-7, a laminated positive copper bar OBC terminal;

3. A power module; 3-1, alternating current input positive electrode; 3-2, alternating current is input into the cathode; 3-3, a DCDC/OBC shared positive electrode; 3-4, the DCDC/OBC shares a cathode; 3-5, a DCDC output positive electrode; 3-6, a low-voltage signal plug-in unit of the power module; 3-7, a power supply heat dissipation water channel cavity;

4. A quick-charging module; 4-1, an anode fast charging relay; 4-2, a negative pole fast charging relay; 4-3, a quick-charging high-voltage connector; 4-3-1, positive electrode of quick-charging high-voltage connector; 4-3-2, a fast-charging high-voltage connector negative electrode; 4-4, quick-charging the positive electrode copper bar; 4-5, quick-charging a negative electrode copper bar;

5. A driving motor; 5-1, a motor shell; 5-2, a motor heat dissipation water channel cavity; 5-3, a motor rear end cover; 5-3-1, a rear bearing chamber of the motor; 5-3-2, a supporting point a of a rear end cover of the motor; 5-3-3, a supporting point b of a rear end cover of the motor; 5-3-4, a supporting point c of a rear end cover of the motor; 5-4, a rotary protective cover; 5-5, a water outlet pipe; 5-6, sharing a water pipe; 5-7, a stator core; 5-8, stator windings; 5-9, a motor shaft; 5-10, rotor core; 5-11, a rotor pressing plate; 5-12, a rotor pressing ring; 5-13, a motor front bearing spring wave pad; 5-14, a motor front bearing snap spring; 5-15, a motor front bearing; 5-16, a motor rear bearing; 5-17, a motor rear bearing snap spring; 5-18, a motor rear bearing pressing plate; 5-19, a swirl stator; 5-20, a rotary rotor; 5-21, a three-phase sealing ring; 5-22, a rotary cover plate sealing ring;

6. A speed reducer; 6-1, a left shell of the speed reducer; 6-1-1, a left shell fixing bracket of the speed reducer; 6-1-2, a bearing chamber of a left shell of the speed reducer; 6-2, a right shell of the speed reducer; 6-2-1, a left bearing chamber of a right shell of the speed reducer; 6-2-2, a motor-side bearing chamber of the right housing of the speed reducer; 6-3, an input shaft; 6-4, an input shaft left bearing; 6-5, an input shaft right bearing; 6-6, high-speed oil sealing; 6-7, spline O-shaped ring.

Detailed Description

It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the application. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present application. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.

The utility model discloses an all-in-one driving system of an electric automobile, which is shown in fig. 1 and 2, and comprises a motor controller 1, a high-voltage power distribution module 2, a power supply module 3, a quick charging module 4, a driving motor 5 and a speed reducer 6, wherein the motor controller 1, the driving motor 5 and the speed reducer 6 are all external components of the driving system, the motor controller 1 comprises a box body 1-1, and the high-voltage power distribution module 2, the power supply module 3 and the quick charging module 4 are integrated in the box body 1-1 of the motor controller 1.

Further, the motor controller 1 is arranged above the driving motor 5 and the speed reducer 6; the driving motor 5 and the motor controller 1 are fixedly connected through bolts, and the interior of the driving motor is connected through copper bars for power transmission; the driving motor 5 and the speed reducer are fixedly connected through bolts, and a motor shaft in the driving motor 5 and an input shaft of the speed reducer are connected through splines to transmit power.

Specifically, as shown in fig. 5 and 8, the motor controller 1 is disposed above the driving motor 5 and the decelerator 6, and is mounted on a motor rear end cover supporting point a5-3-2, a motor rear end cover supporting point b5-3-3, a motor rear end cover supporting point c5-3-4, and a decelerator left housing fixing bracket 6-1-1 of the decelerator 6 of the driving motor 5 by bolts; as shown in fig. 3 and 4, the decelerator 6 is disposed at the left side of the driving motor 5, and the driving motor 5 and the decelerator 6 are connected by bolts.

As shown in fig. 9, the driving motor 5, the motor controller 1 and the power module 3 are water-cooled components, and a motor heat dissipation water channel cavity 5-2 of a Z-shaped rotary structure is arranged in a motor shell 5-1 of the driving motor 5, and the Z-shaped structure can improve the heat dissipation area of the motor shell and reduce the water channel flow resistance; the inside of the box body 1-1 of the motor controller 1 is provided with a controller radiating water channel cavity 1-7 formed by a diamond radiating structure, the diamond structure can greatly increase the radiating area of the internal water channel of the controller, and can effectively take away the heat generated by the power module, so that the motor controller can operate efficiently, and the service life of the controller is prolonged; the power supply module 3 is internally provided with the power supply heat dissipation water channel cavity 3-7 with a three-dimensional flat structure, and the flat design can improve the heat dissipation area of the water channel and the heat dissipation efficiency of the power supply module 3.

Further, the driving motor 5, the motor controller 1 and the radiating water channel cavity in the power module 3 are communicated through a common water pipe 5-6. In addition, a water inlet pipe 1-6 communicated with the heat dissipation water channel cavity is arranged on a box body 1-1 of the motor controller 1, a water outlet pipe 5-5 communicated with the heat dissipation water channel cavity is arranged on a shell 5-1 of the driving motor 5, the water inlet pipe 1-6 is arranged on the box body 1-1 of the motor controller, and meanwhile, a radial O-shaped ring 1-6-1 is arranged between the water inlet pipe 1-6 and the box body 1-1 and is assembled with the box body to seal the heat dissipation water channel cavity 1-7 of the controller.

As shown in fig. 1, 3, 6 and 9, the motor controller 1 includes a housing 1-1, an upper cover plate 1-2 for closing the housing 1-1 and fitted over the housing 1-1, a fuse box cover plate 1-3 for closing the housing 1-1 and fitted over the upper cover plate 1-2, a bus bar junction box cover plate 1-4 for closing the housing 1-1, and a waterway cover plate 1-5 fitted under the housing 1-1 for closing a controller heat dissipation waterway cavity 1-7 at the bottom of the housing 1-1. Furthermore, a controller radiating water channel cavity 1-7 formed by diamond stitch shapes is arranged on one surface of the water channel cover plate 1-5 facing the inside of the box body 1-1. As shown in fig. 6 and 11, a high-voltage distribution module 2, a power supply module 3, and a quick-charge module 4, and components for realizing the functions of a motor controller, and the like are arranged in the case 1-1.

The upper cover plate 1-2 is connected with the upper surface of the box body 1-1 through bolts, meanwhile, an upper cover plate center fixing bolt 1-2-1 is specially arranged between the middle position of the upper cover plate 1-2 and the box body 1-1, the structural rigidity of the upper cover plate 1-2 can be greatly improved through the arrangement of the upper cover plate center fixing bolt 1-2-1, the vibration performance of the all-in-one driving system at the local position of the upper cover plate 1-2 is reduced, and the noise effect of the all-in-one driving system can be further improved; the upper cover plate 1-2 and the box body 1-1 can carry out glue spraying treatment on the joint surface before assembly, and the upper cover plate 1-2 and the box body 1-1 are sealed through sealant.

The fuse box cover plate 1-3 is arranged above the upper cover plate 1-2 and is connected through bolts; the upper cover plate 1-2 and the fuse box cover plate 1-3 are combined and provided with grooves, the grooves are internally provided with fuse box cover plate sealing rings 1-3-2, and the fuse box cover plate sealing rings 1-3-2 are arranged in the grooves of the upper cover plate 1-2 to play a role in sealing cavities formed between the upper cover plate 1-2 and the fuse box cover plate 1-3.

The fuse box cover plate 1-3 is provided with a fuse box cover opening protection switch 1-3-1, the fuse box cover opening protection switch 1-3-1 is fixed on the fuse box cover plate 1-3 through bolts, the fuse box cover opening protection switch 1-3-1 is connected with a control panel assembly 1-13 in the controller box body 1-1 through a signal wire harness, a transmission signal is transmitted to the control panel assembly 1-13 to detect the opening and closing of the fuse box cover plate 1-3, and then the all-in-one driving system can control high voltage in a high-voltage circuit in the whole vehicle, so that the safety of personnel is protected.

The bus junction box cover plate 1-4 is arranged on the side face of the box body 1-1, the box body 1-1 is provided with a groove on the matching installation face of the bus junction box cover plate 1-4, and the groove is internally provided with the bus junction box cover plate sealing ring 1-4-1, so that a cavity formed between the box body 1-1 and the bus junction box cover plate 1-4 is sealed.

The water channel cover plate 1-5 is connected with the lower surface of the box body 1-1 through a friction stir welding process, the friction stir welding process plays a role in connecting and fixing the water channel cover plate 1-5 and the box body 1-1, and simultaneously plays a role in sealing a cavity formed between the box body 1-1 and the water channel cover plate 1-5.

Further, a fixed support structure is arranged outside the box body 1-1, and the box body is respectively connected with the driving motor and the speed reducer through bolts at the fixed support structure around the outside. Meanwhile, a box lower center fixing bolt 1-1-1 is specially arranged between the middle position below the box 1-1 and the motor shell 5-1 of the driving motor 5, and the arrangement of the box lower center fixing bolt 1-1-1 can greatly improve the structural rigidity of the box 1-1, reduce the vibration performance of the all-in-one driving system at the local position of the box 1-1, and further improve the noise effect of the all-in-one driving system.

As shown in fig. 11, two ventilation valves 1-10 are arranged at the positions of the three-phase copper bar fixing seat assemblies 1-17 outside the box body 1-1, and the ventilation valves 1-10 play a role in balancing the air pressure inside the motor controller 1; the DC bus high-voltage connector 2-1, the slow-charging high-voltage connector 2-6, the fast-charging high-voltage connector 4-3, the AC high-voltage connector 2-8, the PTC high-voltage connector 2-9, the low-voltage signal plug-in unit 1-8, the box grounding point 1-9 and the 12V low-voltage output port 1-11 are sequentially arranged on the periphery outside the box body 1-1, and the DC bus high-voltage connector 2-1, the slow-charging high-voltage connector 2-6, the fast-charging high-voltage connector 4-3, the AC high-voltage connector 2-8, the PTC high-voltage connector 2-9, the low-voltage signal plug-in unit 1-8, the box grounding point 1-9 and the 12V low-voltage output port 1-11 are all connected with the box body 1-1 through bolts. Further, as shown in fig. 3, a positive bus cable 2-1-1 and a negative bus cable 2-1-2 are arranged in the direct current bus high voltage connector 2-1, and the positive bus cable 2-1-1 and the negative bus cable 2-1-2 are respectively connected with a direct current bus positive copper bar 2-2-1 and a direct current bus negative copper bar 2-2-2 through bolts.

The high-voltage power distribution module 2 is composed of a direct-current bus high-voltage connector 2-1, a magnetic ring fixing seat filter assembly 2-2, a copper bar wiring seat 2-3, a PTC relay 2-4, a fuse fixing seat 2-5, a PTC fuse 2-5-1, an AC fuse 2-5-2, an OBC fuse 2-5-3, a slow charging high-voltage connector 2-6, a slow charging magnetic ring assembly 2-7, an AC high-voltage connector 2-8, a PTC high-voltage connector 2-9, a laminated copper bar assembly 2-10, related accessories and the like. Wherein, the slow charging high-voltage connector 2-6 is provided with a slow charging magnetic ring component 2-7 at the outlet position at the inner side of the box body 1-1, and when the slow charging function is started, the electromagnetic compatibility effect of the all-in-one driving system can be improved; the slow filling port magnetic ring component 2-7 is arranged in the box body 1-1; the wire harness of the outlet wire of the low-charging high-voltage connector 2-6 passes through the round hole in the low-charging magnetic ring assembly 2-7. Four grooves are formed in the fuse fixing seat 2-5, and the PTC fuse 2-5-1, the AC fuse 2-5-2 and the OBC fuse 2-5-3 are installed in the grooves of the fuse fixing seat 2-5, and meanwhile a fuse installation position is reserved.

As shown in fig. 7, the internal components of the motor controller 1 are sequentially provided with a magnetic ring fixing seat filtering assembly 2-2, a copper bar wiring seat 2-3, a slow charging port magnetic ring assembly 2-7, a positive fast charging relay 4-1, a negative fast charging relay 4-2, a PTC relay 2-4, a fuse fixing seat 2-5, a PTC fuse 2-5-1, an AC fuse 2-5-2, an OBC fuse 2-5-3, a control board assembly 1-13, a supporting capacitor 1-12, a driving board assembly 1-14, an IGBT power module 1-15, a three-phase copper column 1-16, a three-phase copper bar fixing seat assembly 1-17, and a laminated copper bar assembly 2-10 for connecting the components from the front end bus wiring box cover plate 1-4 to the rear end inside the box body 1-1.

The magnetic ring fixing seat filter assembly 2-2 is arranged in the box body 1-1 and fixedly connected with the box body 1-1 through bolts, the magnetic ring fixing seat filter assembly 2-2 is provided with an onboard Y capacitor assembly 2-2-3, a direct current bus positive copper bar 2-2-1 and a direct current bus negative copper bar 2-2-3, the onboard Y capacitor assembly 2-2-3 is arranged on the box body 1-1, and meanwhile, the onboard Y capacitor assembly 2-2-3 is respectively connected with the direct current bus positive copper 2-2-1 and the direct current bus negative copper bar 2-2-2 through bolts; the direct current bus positive copper 2-2-1 and the direct current bus negative copper bar 2-2-2 are directly connected with the magnetic ring fixing seat filter assembly 2-2 in an integral injection molding mode, meanwhile, the magnetic ring and the X capacitor are integrated in the magnetic ring fixing seat filter assembly 2-2, a first-stage EMC filter structure of the all-in-one driving system is formed, and the electromagnetic compatibility effect of the all-in-one driving system can be improved.

The positive bus cable 2-1-1 in the direct current bus high-voltage connector 2-1 is connected with the direct current bus positive copper bar 2-2-1, and the positive bus cable 2-1-1 in the direct current bus high-voltage connector 2-1 is connected with the direct current bus positive copper bar 2-2-1; the direct current bus positive copper 2-2-1 and the direct current bus negative copper bar 2-2 are connected with the laminated copper bar assembly 2-10 through the copper bar wiring seat 2-3.

The laminated copper bar assembly 2-10 is provided with a laminated positive electrode copper bar 2-10-1, a laminated negative electrode copper bar 2-10-2 and an insulating coating film 2-10-3, and the insulating coating film 2-10-3, the laminated positive electrode copper bar 2-10-1 and the laminated negative electrode copper bar 2-10-2 form an integrated assembly structure through an integrated forming process; the laminated positive electrode copper bar 2-10-1 is connected with one end of the positive electrode quick charging relay 4-1; the other end of the positive pole quick charge relay 4-1 is connected with the positive pole 4-3-1 of the quick charge high voltage connector through a quick charge positive pole copper bar 4-4; the laminated negative electrode copper bar 2-10-2 is connected with one end of the negative electrode quick charging relay 4-2; the other end of the negative pole fast charge relay 4-2 is connected with the negative pole 4-3-2 of the fast charge high voltage connector through a fast charge negative pole copper bar 4-5; one end of the laminated positive electrode copper bar is connected with the positive electrode of the input end of the supporting capacitor; one end of the laminated negative electrode copper bar is connected with the negative electrode of the input end of the supporting capacitor; one end of a laminated anode copper bar 2-10-1 is commonly connected with a PTC fuse 2-5-1 and an AC fuse 2-5-2, the PTC fuse 2-5-1 is connected with a PTC relay 2-4 through a wire harness, the PTC relay 2-4 is connected with a PTC high-voltage connector anode 2-9-1 through a wire harness, a PTC high-voltage connector cathode 2-9-2 is connected with a laminated cathode copper bar PTC terminal 2-10-4 through a wire harness, an AC fuse 2-5-2 is connected with an AC high-voltage connector anode 2-8-1 through a wire harness, and an AC high-voltage connector cathode 2-8-2 is connected with a laminated cathode copper bar AC terminal 2-10-5 through a wire harness; the stacked negative electrode copper bar PTC terminal 2-10-4 is connected with the stacked negative electrode copper bar 2-10-2 through bolts, and the stacked negative electrode copper bar AC terminal 2-10-5 is connected with the stacked negative electrode copper bar 2-10-2 through bolts; the right side position of the PTC relay 2-4 inside the box body 1-1 is reserved with a relay installation space and an installation hole position, and the PTC module connection control requirement of the multi-gear function can be met.

The supporting capacitor 1-12 is provided with four mounting support legs 1-12-1, a positive electrode 1-12-2 of an input end of the supporting capacitor, a negative electrode 1-12-3 of an input end of the supporting capacitor, a positive electrode 1-12-4 of an output end of the supporting capacitor and a negative electrode 1-12-5 of an output end of the supporting capacitor, wherein the mounting support legs 1-12-1 are connected with the box body 1-1 through bolts, and one of the four mounting support legs 1-12-1 is provided with a grounding copper bar 1-12-6; the Y-shaped capacitor device and the magnetic ring component are integrated in the supporting capacitor 1-12, the Y-shaped capacitor integrated in the supporting capacitor is grounded to the box body 1-1 through the grounding copper bar 1-12-6 to form a second-level EMC filter structure, and the electromagnetic compatibility effect of the all-in-one driving system can be greatly improved by combining the second-level EMC filter structure with the first-level EMC filter structure; the positive electrode 1-12-4 of the output end of the supporting capacitor is connected with the input positive electrode 1-15-1 of the IGBT power module through bolts, and the negative electrode 1-12-5 of the output end of the supporting capacitor is connected with the input negative electrode 1-15-2 of the IGBT power module through bolts.

The control panel assembly 1-13 is arranged above the supporting capacitor 1-12 and is connected and installed on the box body 1-1 through bolts; the low-voltage signal plug-in 1-8 is welded on the control board assembly 1-13; the control panel assembly 1-13 is provided with a control panel power module signal plug-in 1-13-1, a control panel driving signal plug-in 1-13-2 and other related signal plug-ins, the control panel power module signal plug-in 1-13-1 is connected with a power module low voltage signal plug-in 3-6, and the control panel driving signal plug-in 1-13-2 is connected with a driving panel low voltage signal plug-in 1-14-3 through a wire harness.

The IGBT power module 1-15 is arranged above an internal water channel of the box body 1-1 and is connected with the box body 1-1 through bolts, the IGBT power module 1-15 is provided with an IGBT power module input positive electrode 1-15-1, an IGBT power module input negative electrode 1-15-2, an IGBT power module output U phase 1-15-3, an IGBT power module output V phase 1-15-4, an IGBT power module output W phase 1-15-5 and an IGBT signal pin 1-15-6, a three-phase copper column 1-16 is arranged above the IGBT power module output V phase 1-15-4 and the IGBT power module output W phase 1-15-5, and the three-phase copper column 1-16 is connected with one end of the U-phase copper bar 1-17-1, the V-phase copper bar 1-17-2 and the W-phase copper bar 1-17-3 on the three-phase copper bar fixing seat assembly 1-17 through the three-phase copper column 1-16 bolts.

The driving plate assembly 1-14 is fixed on the IGBT power module 1-15 through bolts and is connected with the IGBT signal pins 1-15-6 through welding; the driving board assembly 1-14 is provided with a U-phase onboard current sensor 1-14-1, a W-phase onboard current sensor 1-14-2 and a driving board low-voltage signal plug-in unit 1-14-3, wherein the U-phase onboard current sensor 1-14-1 is used for detecting U-phase winding current of a driving motor, and the W-phase onboard current sensor 1-14-2 is used for detecting W-phase winding current of the driving motor; the drive board low voltage signal plug-in 1-14-3 is connected with the control board drive signal plug-in 1-13-2 through a wire harness.

The three-phase copper bar fixing seat assembly 1-17 is arranged on the box body 1-1, the U-phase copper bar 1-17-1, the V-phase copper bar 1-17-2 and the W-phase copper bar 1-17-3 are arranged on the three-phase copper bar fixing seat assembly 1-17, the U-phase copper bar 1-17-1, the V-phase copper bar 1-17-2 and the W-phase copper bar 1-17-3 are integrally injection molded with the three-phase copper bar fixing seat assembly 1-17, and the other ends of the U-phase copper bar 1-17-1, the V-phase copper bar 1-17-2 and the W-phase copper bar 1-17-3 are connected with the stator winding 5-8 of the driving motor through bolts.

The quick charging module 4 consists of a positive quick charging relay 4-1, a negative quick charging relay 4-2, a quick charging high-voltage connector 4-3, a quick charging positive copper bar 4-4, a quick charging negative copper bar 4-5 and related accessories.

The power module 3 is arranged inside the box body 1-1, and the box body 1-1 is provided with an isolation structure around the power module 3; the power module 3 is a two-in-one component integrating a DCDC function and an OBC function, and the power module 3 is provided with an alternating current input positive electrode 3-1, an alternating current input negative electrode 3-2, a DCDC/OBC shared positive electrode 3-3, a DCDC/OBC shared negative electrode 3-4, a DCDC output positive electrode 3-5 and a power module low-voltage signal plug-in unit 3-6.

The DCDC output anode 3-5 is connected with the 12V low-voltage output port 1-11, the DCDC output cathode in the power module 3 is directly connected with the box body through the power module shell, and the box body grounding points 1-9 are shared; the alternating current input anode 3-1 is connected with the live wire interface 2-6-1 of the slow charging high voltage connector through a wire harness, the alternating current input cathode 3-2 is connected with the zero wire interface 2-6-2 of the slow charging high voltage connector through a wire harness, and the ground wire interface 2-6-3 of the slow charging high voltage connector is directly connected with the grounding terminal 2-6-4 in the box body through a wire harness;

The DCDC/OBC shared positive electrode 3-3 is connected with one end of the OBC fuse 2-5-3 through a wire harness; the other end of the OBC fuse 2-5-3 is connected with a laminated positive copper bar OBC terminal 2-10-7 through a wire harness, and a DCDC/OBC common negative electrode 3-4 is connected with a laminated negative copper bar OBC terminal 2-10-6 through a wire harness; the power module low voltage signal plug-in 3-6 is connected with the control board assembly through a wire harness, namely is connected with the control board power module signal plug-in 1-13-1 in the control board assembly.

As shown in fig. 8, 9 and 10, the driving motor 5 comprises a motor shell 5-1, a motor rear end cover 5-3, a rotary protective cover 5-4, a water outlet pipe 5-5 and a common water pipe 5-6, and the driving motor comprises main components such as a stator iron core 5-7, a stator winding 5-8, a motor shaft 5-9, a rotor iron core 5-10, a rotor pressing plate 5-11, a rotor pressing ring 5-12, a motor front bearing spring wave pad 5-13, a motor front bearing clamp spring 5-14, a motor front bearing 5-15, a motor rear bearing 5-16, a motor rear bearing clamp spring 5-17, a motor rear bearing clamp plate 5-18, a rotary stator 5-19, a rotary stator 5-20, a three-phase sealing ring 5-21 and the like.

Specifically, the motor shell 5-1 is arranged between the speed reducer 6 and the motor rear end cover 5-3, and the motor shell 5-1 is connected with the motor rear end cover 5-3 and the speed reducer 6 through bolts. The motor shell 5-1 is of a water jacket shell structure, a motor radiating water channel cavity 5-2 of a Z-shaped rotary structure is designed in the motor shell, and the motor radiating water channel cavity 5-2 is connected with a controller radiating water channel cavity 1-7 through a common water pipe 5-6; the common water pipe 5-6 is a water pipe structure with a steel skeleton designed inside and sealing rubber covered outside, and has other sealing functions on the motor radiating water channel cavity 5-2 and the controller radiating water channel cavity 1-7, and the inside of the motor shell 5-1 is connected with the stator iron core 5-7 in an interference fit manner; the motor rear end cover 5-3 is connected with the motor shell 5-1 through bolts, the motor rear end cover 5-3 is connected with the motor controller box body 1-1 to play a supporting role on the motor controller 1, and a three-phase sealing ring 5-21 is arranged at the joint of the motor rear end cover 5-3 and the box body 1-1; a motor rear bearing chamber 5-3-1 is arranged in the motor rear end cover 5-3, so that the motor rear bearing 5-16 is supported; the motor shaft 5-9 is an internal spline shaft which is matched with an external spline of the input shaft 6-3; the rotor pressing plates 5-11 are arranged on two sides of the rotor iron core 5-10, the rotor iron core 5-10 is extruded and kept through the rotor pressing rings 5-12, and the rotor pressing rings 5-12 are connected with the motor shaft 5-9 through threads; the motor front bearing 5-15 is arranged in the motor side bearing chamber 6-2-2 of the right shell of the speed reducer, and the motor front bearing spring wave pad 5-13 is arranged at the root of the motor side bearing chamber 6-2-2 of the right shell of the speed reducer, so that an axial pre-tightening force is exerted on a motor rotor bearing, and the rotor bearing is enabled to normally operate; the motor front bearing snap spring 5-14 and the motor rear bearing snap spring 5-17 are respectively arranged in the motor axial snap spring groove, and play an axial limiting role on the motor front bearing and the motor rear bearing; the motor rear bearing pressing plate 5-18 is fixed on the motor rear end cover 5-3 through bolts, and plays a role in fixing an outer ring of the motor rear bearing 5-16; the rotary stator 5-19 is arranged in the motor rear end cover 5-3 and is connected with the motor rear end cover 5-3 through bolts; the motor shaft on which the rotary rotor 5-20 is arranged is connected with the motor shaft through bolts.

The rotary protective cover 5-4 is arranged on the motor rear end cover 5-3, a rotary cover plate sealing ring 5-22 is arranged between the rotary protective cover 5-4 and the motor rear end cover 5-3, the rotary cover plate sealing ring 5-22 is arranged in a groove of the motor rear end cover 5-3, and a cavity formed between the rotary protective cover 5-4 and the motor rear end cover 5-3 is sealed.

The water outlet pipe 5-5 is arranged on the motor shell 5-1, and a radial O-shaped ring is arranged between the water outlet pipe 5-5 and the motor shell 5-1, so that the motor heat dissipation water channel cavity 5-2 is sealed.

As shown in fig. 8 and 10, the speed reducer 6 is a separate assembly comprising a left speed reducer housing 6-1, a right speed reducer housing 6-2, an input shaft 6-3, a left input shaft bearing 6-4, a right input shaft bearing 6-5, a high speed oil seal 6-6, a splined O-ring 6-7, and other gear shaft components.

Specifically, a fixed bracket 6-1-1 is arranged above the left casing 6-1 of the speed reducer and is used for supporting the motor controller 1; the left shell 6-1 of the speed reducer is provided with a left shell bearing chamber 6-1-2 of the speed reducer, and the left bearing 6-4 of the input shaft of the speed reducer is arranged in the left shell bearing chamber 6-1-2 of the speed reducer; the left side of the right shell 6-2 of the speed reducer is connected with the left shell 6-1 of the speed reducer through bolts, the right side of the right shell 6-2 of the speed reducer is connected with the motor shell 5-1 through bolts, a left bearing chamber 6-2-1 is arranged in the right shell 6-2 of the speed reducer, a right bearing 6-5 of an input shaft of the speed reducer is arranged in the left bearing chamber 6-2-1 of the right shell of the speed reducer, a motor bearing chamber 6-2-2 is arranged in the right shell 6-2 of the speed reducer, the motor bearing chamber 6-2-2 of the right shell of the speed reducer is an embedded steel bearing chamber which is integrally cast with the right shell 6-2 of the speed reducer, and a front bearing 5-15 of the motor is arranged in the motor bearing chamber 6-2-2 of the right shell of the speed reducer; the input shaft 6-3 of the speed reducer is connected with the left and right shells of the speed reducer through left and right bearings of the input shaft, and meanwhile, the input shaft 6-3 of the speed reducer is provided with external splines which are in spline fit connection with the motor shaft 5-9; the high-speed oil seal 6-6 is arranged between the right shell 6-2 of the speed reducer and the input shaft 6-3 of the speed reducer and is used for sealing the internal cavity of the speed reducer, so that lubricating oil in the speed reducer cannot enter the internal cavity of the motor when the all-in-one driving system operates; the spline O-shaped ring 6-7 is arranged in a groove on the left side of the spline of the input shaft 6-3 and is used for sealing lubricating grease for spline matching, so that the grease is ensured not to leak out, and normal meshing operation of the spline is ensured.

In summary, the multiple components are deeply integrated into the multiple-in-one driving system for the electric automobile, the structural arrangement is compact, the layers are clear, the multiple components share the cooling water channel, meanwhile, a more reasonable water channel heat dissipation structure is designed based on the size and the arrangement, a good heat dissipation effect can be achieved, a multi-stage and multi-position EMC filtering structure is designed, the electromagnetic compatibility is excellent, the whole volume is small, and the reliability is high; the whole vehicle arrangement is greatly facilitated, the whole vehicle assembly process is reduced, and the platform requirement of the whole vehicle is met.

While the foregoing description of the embodiments of the present utility model has been presented in conjunction with the drawings, it should be understood that it is not intended to limit the scope of the utility model, but rather, it is intended to cover all modifications or variations within the scope of the utility model as defined by the claims of the present utility model.

Claims (10)

1. The all-in-one driving system of the electric automobile is characterized by comprising a motor controller, a high-voltage power distribution module, a power module, a quick charging module, a driving motor and a speed reducer;

The motor controller is arranged above the driving motor and the speed reducer, and the driving motor and the motor controller are fixedly connected through bolts and are connected through copper bars; the driving motor is fixedly connected with the speed reducer through a bolt, and a motor shaft in the driving motor is connected with an input shaft of the speed reducer through a spline; the motor controller comprises a box body, and the high-voltage power distribution module, the power supply module and the quick charging module are integrated in the box body of the motor controller;

The motor shell of the driving motor is internally provided with a motor heat dissipation water channel cavity of a Z-shaped rotary structure, the box body of the motor controller is internally provided with a controller heat dissipation water channel cavity formed by a diamond heat dissipation structure, the power module is internally provided with a power source heat dissipation water channel cavity of a three-dimensional flat structure, and the heat dissipation water channel cavities of the driving motor, the motor controller and the power module are communicated through a shared water pipe.

2. The all-in-one driving system of the electric automobile as claimed in claim 1, wherein a water inlet pipe communicated with a heat dissipation water channel cavity of the controller is arranged on a box body of the motor controller; a water outlet pipe communicated with the cavity of the motor heat dissipation water channel is arranged on the motor shell of the driving motor; the inlet tube sets up on motor controller's box, is provided with radial O type circle between inlet tube and the box.

3. The electric vehicle all-in-one drive system of claim 1, wherein the motor controller further comprises an upper cover plate for closing the case and assembled above the case, a fuse box cover plate for closing the case and assembled above the upper cover plate, a bus junction box cover plate for closing the case, and a water channel cover plate assembled below the case for closing a controller heat dissipation water channel cavity at the bottom of the case;

The fuse box cover plate is provided with a fuse box cover opening protection switch which is fixed on the fuse box cover plate through bolts and is connected with the box body inner control board assembly through a signal wire harness;

The bus junction box cover plate is arranged on the side surface of the box body, a groove is formed in the matching installation surface of the bus junction box cover plate, and a bus junction box cover plate sealing ring is arranged in the groove;

The water channel cover plate is connected with the lower surface of the box body through a friction stir welding process.

4. The electric vehicle all-in-one driving system according to claim 1, wherein the dc bus high-voltage connector, the slow-charging high-voltage connector, the fast-charging high-voltage connector, the AC high-voltage connector, the PTC high-voltage connector, the low-voltage signal plug-in unit, the box grounding point and the 12V low-voltage output port are sequentially arranged around the outside of the box body.

5. The electric vehicle all-in-one drive system of claim 1, wherein the high voltage distribution module comprises a direct current bus high voltage connector, a magnetic ring fixing seat filter assembly, a copper bar wiring seat, a PTC relay, a fuse fixing seat, a PTC fuse, an AC fuse, an OBC fuse, a slow charging high voltage connector, a slow charging magnetic ring assembly, an AC high voltage connector, a PTC high voltage connector, and a laminated copper bar assembly.

6. The electric vehicle all-in-one drive system of claim 1, wherein the fast charging module comprises a positive fast charging relay, a negative fast charging relay, a fast charging high voltage connector, a fast charging positive copper bar, and a fast charging negative copper bar.

7. The electric vehicle all-in-one driving system according to claim 1, wherein the power module is installed in the case, and an isolation structure is provided around the power module; the power module comprises an alternating current input positive electrode, an alternating current input negative electrode, a DCDC/OBC shared positive electrode, a DCDC/OBC shared negative electrode, a DCDC output positive electrode and a power module low-voltage signal plug-in unit;

The DCDC output positive electrode is connected with the 12V low-voltage output port, the alternating current input positive electrode is connected with the live wire interface of the slow-charging high-voltage connector through a wire harness, and the alternating current input negative electrode is connected with the zero wire interface of the slow-charging high-voltage connector through a wire harness;

The DCDC/OBC common positive electrode is connected with one end of an OBC fuse through a wire harness, the other end of the OBC fuse is connected with an OBC terminal of the laminated positive electrode copper bar through the wire harness, and the DCDC/OBC common negative electrode is connected with an OBC terminal of the laminated negative electrode copper bar through the wire harness;

The low-voltage signal plug-in of the power module is connected with the control panel assembly through a wire harness.

8. The electric vehicle all-in-one driving system according to claim 1, wherein the internal components of the motor controller are sequentially provided with a magnetic ring fixing seat filtering assembly, a copper bar wiring seat, a slow charging port magnetic ring assembly, a positive fast charging relay, a negative fast charging relay, a Positive Temperature Coefficient (PTC) relay, a fuse fixing seat, a Positive Temperature Coefficient (PTC) fuse, an Alternating Current (AC) fuse, an on-board chip (OBC) fuse, a control board assembly, a supporting capacitor, a driving board assembly, an Insulated Gate Bipolar Transistor (IGBT) power module, a three-phase copper column and three-phase copper bar fixing seat assembly and a laminated copper bar assembly for connecting the components from a front end bus junction box cover plate to a rear end in the box body.

9. The electric vehicle integrated drive system of claim 1, wherein the exterior of the drive motor comprises a motor housing, a motor rear end cap, a spin-on protective cap, a water outlet pipe and a common water pipe, and the interior of the drive motor comprises a stator core, a stator winding, a motor shaft, a rotor core, a rotor pressing plate, a rotor pressing ring, a motor front bearing spring wave pad, a motor front bearing clamping spring, a motor front bearing, a motor rear bearing clamping spring, a motor rear bearing pressing plate, a spin-on stator, a spin-on rotor and a three-phase sealing ring.

10. The electric vehicle integrated drive system of claim 1, wherein the reducer comprises a reducer left housing, a reducer right housing, an input shaft left bearing, an input shaft right bearing, a high-speed oil seal, and a spline O-ring.