US-12620872-B2 - Integrated electric drive system and electric vehicle

Abstract

A drive system includes a motor, a speed reducer, a controller, and a housing. The housing includes: a first accommodation space for accommodating the controller; a second accommodation space configured for accommodating the motor; and a third accommodation space configured for accommodating the speed reducer. The controller is connected with the motor, and an output shaft of the motor is connected with the speed reducer. In a length direction of the output shaft, an absolute value of a difference between a mounting width and a width of the first accommodation space is no greater than a first difference threshold. In a direction perpendicular to the length direction of the output shaft and parallel to a horizontal plane, an absolute value of a difference between a length of the first accommodation space and a length of the third accommodation space is no greater than a second difference threshold.

Inventors

• Heping Ling
• Zhen Zhai
• Lei Hu
• Yuchao XIONG

Assignees

• BYD COMPANY LIMITED

Dates

Publication Date

20260505

Application Date

20230330

Priority Date

20200930

Claims (20)

1. 1 . A drive system, comprising a motor, a speed reducer, a controller, and a housing, wherein the housing comprises a first accommodation space having a first opening and configured for accommodating the controller; a second accommodation space configured for accommodating the motor; and a third accommodation space configured for accommodating the speed reducer, the second accommodation space and the third accommodation space of the housing are disposed below the first accommodation space; the controller is connected with the motor; and an output shaft of the motor is connected with the speed reducer; in a length direction of the output shaft of the motor, an absolute value of a difference between a mounting width value and a width value of the first accommodation space is less than or equal to a first difference threshold; and the mounting width value is a sum of a width value of the second accommodation space and a width value of the third accommodation space; in a direction perpendicular to the length direction of the output shaft of the motor and parallel to a horizontal plane, an absolute value of a difference between a length value of the first accommodation space and a length value of the third accommodation space is less than or equal to a second difference threshold; and in a projection onto the horizontal plane, a substantial area of a projection of the second accommodation space overlaps with a projection of the first opening, and a substantial area of a projection of the third accommodation space overlaps with the projection of the first opening.
2. 2 . The drive system according to claim 1 , wherein, in the direction perpendicular to the length direction of the output shaft of the motor and parallel to the horizontal plane, an absolute value of a difference between a half of the length value of the first accommodation space and the length value of the second accommodation space is less than or equal to a third difference threshold.
3. 3 . The drive system according to claim 2 , wherein the first difference threshold is zero.
4. 4 . The drive system according to claim 2 , wherein the second difference threshold is zero.
5. 5 . The drive system according to claim 2 , wherein the third difference threshold is zero.
6. 6 . The drive system according to claim 1 , further comprising an air conditioning compressor and a support mounted on a surface of the speed reducer away from the second accommodation space, wherein the air conditioning compressor is mounted to the support and connected with the controller.
7. 7 . The drive system according to claim 6 , further comprising a water pump mounted on the support and connected with the controller.
8. 8 . The drive system according to claim 7 , wherein the support comprises a vertical plate and a transverse plate connected with an upper end of the vertical plate; the vertical plate is mounted to a surface of the speed reducer away from the motor; the water pump is mounted below the transverse plate; and the air conditioning compressor is mounted to a side of the vertical plate away from the speed reducer and is located above the transverse plate.
9. 9 . The drive system according to claim 1 , wherein the controller comprises a capacitor, an insulated-gate bipolar transistor (IGBT), a three-phase copper bar, a DC bus, an on-board charger, and a DC converter; the on-board charger and the DC converter are connected with a vehicle power battery; the capacitor, the IGBT, the three-phase copper bar, the on-board charger, and the DC converter are mounted in the first accommodation space; the capacitor is connected with the vehicle power battery through the DC bus mounted to the housing; the three-phase copper bar is connected with a three-phase terminal of the motor; and the vehicle power battery drives the motor to rotate through the DC bus, the capacitor, the IGBT, and the three-phase copper bar connected in sequence.
10. 10 . The drive system according to claim 9 , wherein the on-board charger and the DC converter comprise a heat dissipator, an electric control element driver, and a heating element driver; the heating element driver is mounted to the heat dissipator; and the electric control element driver is mounted to an end of the heating element driver away from the heat dissipator.
11. 11 . The drive system according to claim 9 , wherein the first accommodation space comprises a first internal space and a second internal space both having a rectangular shape and adjacent to each other; and the capacitor, the IGBT, and the three-phase copper bar are mounted in the first internal space; the on-board charger and the DC converter are mounted in the second internal space; and the DC bus is located on a side of the first internal space facing away from the second internal space.
12. 12 . The drive system according to claim 9 , wherein the housing comprises a first cooling water channel, a second cooling water channel, a water channel inlet, and a water channel outlet; the first cooling water channel is arranged at a position in the housing opposite to the IGBT; and the second cooling water channel is arranged at a position in the housing opposite to the on-board charger and the DC converter; and a first end of the water channel inlet is connected with a water inlet device; a second end of the water channel inlet is connected with the first cooling water channel and the second cooling water channel; and the water channel outlet is connected with an end of the first cooling water channel and an end of the second cooling water channel away from the water channel inlet.
13. 13 . The drive system according to claim 12 , wherein the motor comprises an outer enclosure connected with the speed reducer and an inner enclosure inserted in the outer enclosure; a cooling space is formed between an inner wall of the outer enclosure and an outer wall of the inner enclosure; a water inlet and a water outlet in communication with the cooling space are disposed on the outer enclosure; and an end of the water channel outlet away from the first cooling water channel is in communication with the water inlet.
14. 14 . The drive system according to claim 13 , wherein a plurality of ribbed flow guide plates are disposed on the outer wall of the inner enclosure in a circumferential direction of the output shaft of the motor.
15. 15 . The drive system according to claim 1 , wherein the speed reducer comprises a main shaft, an intermediate shaft, an output shaft, a driving gear, an output gear, an intermediate driving gear, and an intermediate driven gear; the main shaft is connected with the output shaft of the motor; the driving gear is mounted to the main shaft; the intermediate driving gear and the intermediate driven gear are mounted to the intermediate shaft; the output gear is mounted to the output shaft of the speed reducer; the intermediate driving gear is meshed with the driving gear; and the intermediate driven gear is meshed with the output gear; and on a plane perpendicular to an axis of the main shaft, an axis of the intermediate shaft is higher than the axis of the main shaft and an axis of the output shaft of the speed reducer; and an included angle between the horizontal plane and a line connecting a center point of the main shaft to a center point of the output shaft of the speed reducer is less than or equal to a preset angle.
16. 16 . The drive system according to claim 1 , wherein a battery mounting space configured for mounting a battery is disposed on a surface of the housing facing away from the first opening.
17. 17 . The drive system according to claim 1 , further comprising a housing cover adaptively connected with the first opening.
18. 18 . An electric vehicle, comprising a drive system, wherein the drive system comprises a motor, a speed reducer, a controller, and a housing, wherein the housing comprises a first accommodation space having a first opening and configured for accommodating the controller; a second accommodation space configured for accommodating the motor; and a third accommodation space configured for accommodating the speed reducer, the second accommodation space and the third accommodation space of the housing are disposed below the first accommodation space; the controller is connected with the motor; and an output shaft of the motor is connected with the speed reducer; in a length direction of the output shaft of the motor, an absolute value of a difference between a mounting width value and a width value of the first accommodation space is less than or equal to a first difference threshold; and the mounting width value is a sum of a width value of the second accommodation space and a width value of the third accommodation space; in a direction perpendicular to the length direction of the output shaft of the motor and parallel to a horizontal plane, an absolute value of a difference between a length value of the first accommodation space and a length value of the third accommodation space is less than or equal to a second difference threshold; and in a projection onto the horizontal plane, a substantial area of a projection of the second accommodation space overlaps with a projection of the first opening, and a substantial area of a projection of the third accommodation space overlaps with the projection of the first opening.
19. 19 . The electric vehicle according to claim 18 , wherein the controller comprises a capacitor, an insulated-gate bipolar transistor (IGBT), a three-phase copper bar, a DC bus, an on-board charger, and a DC converter; the on-board charger and the DC converter are connected with a vehicle power battery; the capacitor, the IGBT, the three-phase copper bar, the on-board charger, and the DC converter are mounted in the first accommodation space; the capacitor is connected with the vehicle power battery through the DC bus mounted to the housing; the three-phase copper bar is connected with a three-phase terminal of the motor; and the vehicle power battery drives the motor to rotate through the DC bus, the capacitor, the IGBT, and the three-phase copper bar connected in sequence.
20. 20 . The electric vehicle according to claim 19 , wherein the housing comprises a first cooling water channel, a second cooling water channel, a water channel inlet, and a water channel outlet; the first cooling water channel is arranged at a position in the housing opposite to the IGBT; and the second cooling water channel is arranged at a position in the housing opposite to the on-board charger and the DC converter; and a first end of the water channel inlet is connected with a water inlet device; a second end of the water channel inlet is connected with the first cooling water channel and the second cooling water channel; and the water channel outlet is connected with an end of the first cooling water channel and an end of the second cooling water channel away from the water channel inlet.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a Continuation Application of International Patent Application No. PCT/CN2021/121798, filed on Sep. 29, 2021 and entitled “INTEGRATED ELECTRIC DRIVING SYSTEM AND ELECTRIC VEHICLE”, which is based on and claims priority to and benefits of Chinese Patent Application No. 202011063762.8, filed on Sep. 30, 2020. The entire content of all of the above-referenced applications is incorporated herein by reference. FIELD The present disclosure relates to the technical field of electric vehicles, and more specifically, to an integrated electric drive system and an electric vehicle. BACKGROUND An electric drive system is a core component of an electric vehicle. With the continuous development of new energy vehicles, there are increasingly high requirements for the arrangement of the vehicle driving system. The electric drive system is composed of components such as a driving motor, a motor controller, a transmission, an air compressor, a water pump, a vehicle controller, an on-board charger, and a DC converter. In the related art, an integrated control enclosure of the electric drive system is generally mounted on a top of a stator housing of the driving motor, the transmission is mounted to an output shaft end of the driving motor, and the air compressor is hung on the transmission through a support. However, such an integrated electric drive system has disadvantages such as a large overall weight, a low integration level, a large accommodation space, and high costs of molds and materials, and the like. SUMMARY The present disclosure provides an integrated electric drive system and an electric vehicle, to solve the technical problems such as a low integration level and a large accommodation space of the electric drive system in the related art. In a first aspect of the present disclosure, a drive system provided in an embodiment of the present disclosure includes a motor, a speed reducer, a controller, and a housing. The housing includes a first accommodation space having a first opening and configured for accommodating the controller. A second accommodation space is configured for accommodating the motor, and a third accommodation space is configured for accommodating the speed reducer. The second accommodation space and the third accommodation space of the housing are disposed below the first accommodation space. The controller is connected with the motor. An output shaft of the motor is connected with the speed reducer. In a length direction of the output shaft of the motor, an absolute value of a difference between a mounting width value and a width value of the first accommodation space is less than or equal to a first difference threshold; and the mounting width value is a sum of a width value of the second accommodation space and a width value of the third accommodation space. In a direction perpendicular to the length direction of the output shaft and parallel to a horizontal plane, an absolute value of a difference between a length value of the first accommodation space and a length value of the third accommodation space is less than or equal to a second difference threshold. In an embodiment of the present disclosure, in the direction perpendicular to the length direction of the output shaft and parallel to the horizontal plane, an absolute value of a difference between a half of the length value of the first accommodation space and the length value of the second accommodation space is less than or equal to a third difference threshold. In an embodiment of the present disclosure, the first difference threshold is zero. In an embodiment of the present disclosure, the second difference threshold is zero. In an embodiment of the present disclosure, the third difference threshold is zero. In an embodiment of the present disclosure, the drive system further includes an air conditioning compressor and a support mounted on a surface of the speed reducer away from the second accommodation space. The air conditioning compressor is mounted to the support and connected with the controller. In an embodiment of the present disclosure, the drive system further includes a water pump mounted on the support and connected with the controller. In an embodiment of the present disclosure, the support includes a vertical plate and a transverse plate connected with an upper end of the vertical plate. The vertical plate is mounted to a surface of the speed reducer away from the motor, the water pump is mounted above the transverse plate, and the air conditioning compressor is mounted to a side of the vertical plate away from the speed reducer and is located below the transverse plate. In an embodiment of the present disclosure, the controller includes a capacitor, an insulated-gate bipolar transistor (IGBT), a three-phase copper bar, a DC bus, an on-board charger, and a DC converter. The on-board charger and the DC converter are connected with a vehicle power battery. The