WO2025088188A1

WO2025088188A1 - A drive system for vehicles, and a vehicle

Info

Publication number: WO2025088188A1
Application number: PCT/EP2024/080333
Authority: WO
Inventors: Zhichao CHU; Huipeng LI; Hoaqin WEI
Original assignee: Valeo Eautomotive Germany Gmbh
Priority date: 2023-10-27
Filing date: 2024-10-25
Publication date: 2025-05-01
Also published as: CN119898180A

Abstract

The present disclosure provides a drive system for a vehicle, and a vehicle. The drive system comprises a first housing, provided with a first cooling channel; and a first cooling channel connection structure, integrally formed with the first housing and connected to the first cooling channel. The first cooling channel connection structure comprises a first interface which opens in a first direction and a second interface which opens in a second direction different from the first direction, one of the first interface and the second interface being selectively closable.

Description

A drive system for vehicles, and a vehicle

Technical Field

The present disclosure relates to a drive system for a vehicle, and a vehicle.

Background

As vehicles gradually develop, the space inside vehicles is becoming ever more compact. As an important motive power system of vehicles, electric drive systems are subject to ever higher requirements in terms of becoming more lightweight, smaller, more integrated and multifunctional, and lower in cost. An electric drive system mainly comprises an electric motor, a motor controller assembly and a gearbox assembly, etc., wherein the motor controller assembly provides electric power conversion and battery charging/discharging functions.

In known solutions, the motor controller assembly is generally integrated to form an all-in-one product, thereby meeting the requirements regarding integration and multifunctionality, etc. In these solutions, connections between cooling channels of different products are generally realized in the form of external pipelines, i.e. hoses. There is not much restriction on the use of hoses for cooling channel inlet/outlet structures of products, and they are convenient to arrange, so this is a commonly used connection method at present. However, this connection method will increase the cost of the system and reduce the degree of integration thereof, and is accompanied by the problems of corrosion and ageing of hoses due to the vehicle environment in which they are located; this further increases costs. In other solutions, cooling channels are integrated within the product housing; although this method has a high degree of integration and reduces the external connection structure, it places high demands on internal space, resulting in a larger overall system size.

Thus, there is a need in the art for a drive system capable of solving the above- mentioned problems.

Summary of the Invention i Thus, an objective of the present disclosure is to provide a drive system for a vehicle, and a vehicle, wherein the drive system realizes connections in different directions by means of cooling channel connection structures formed integrally with housings, thus avoiding the use of hoses, resulting in high flexibility, long life and low costs.

The abovementioned objective is achieved through a drive system for a vehicle, and a vehicle, which are described below.

The present disclosure provides a drive system for a vehicle, the drive system comprising: a first housing, provided with a first cooling channel; and a first cooling channel connection structure, integrally formed with the first housing and connected to the first cooling channel, wherein the first cooling channel connection structure comprises a first interface which opens in a first direction and a second interface which opens in a second direction different from the first direction, one of the first interface and the second interface being selectively closable.

In an embodiment, the drive system further comprises: a second housing, provided with a second cooling channel; and a second cooling channel connection structure, integrally formed with the second housing and connected to the second cooling channel, wherein the second cooling channel connection structure is joined to the first interface of the first cooling channel connection structure in a sealed manner, and the second interface of the first cooling channel connection structure is closed.

In an embodiment, the drive system further comprises a transfer component joined to the second interface of the first cooling channel connection structure, and the first interface of the first cooling channel connection structure is closed.

In an embodiment, the drive system further comprises: a third housing, provided with a third cooling channel; a third cooling channel connection structure, integrally formed with the third housing and connected to the third cooling channel; and a first additional cooling channel connection structure, integrally formed with the first housing and connected to the first cooling channel, wherein the first additional cooling channel connection structure comprises a third interface which opens in a third direction and a fourth interface which opens in a fourth direction different from the third direction, and the third cooling channel connection structure is joined to the third interface in a sealed manner, and the fourth interface is closed.

In an embodiment, a first sealing ring is provided between the first cooling channel connection structure and the second cooling channel connection structure; and/or a second sealing ring is provided between the first additional cooling channel connection structure and the third cooling channel connection structure.

In an embodiment, the first cooling channel connection structure and the first additional cooling channel connection structure take the form of slots, and the second cooling channel connection structure and the third cooling channel connection structure take the form of protruding connectors which are insertable in and matched to the slots.

In an embodiment, the first sealing ring and the second sealing ring are respectively positioned, in an elastically deformed manner, between an outer wall of the corresponding protruding connector and an inner wall of the corresponding slot.

In an embodiment, the outer wall of the protruding connector is provided with an annular groove for installing the corresponding sealing ring.

In an embodiment, the transfer component has one end joined to the second interface of the first cooling channel connection structure, and another end joined to another cooling device of the vehicle.

In an embodiment, at least one of the first cooling channel connection structure, the second cooling channel connection structure, the first additional cooling channel connection structure and the third cooling channel connection structure is arranged on an outer side of the corresponding housing.

In an embodiment, the first housing contains a motor controller, the second housing contains a voltage converter, an on-board charger and a power distribution unit, and the third housing contains an electric motor and a gearbox.

In an embodiment, a second cooling channel outlet is provided on the second housing, and a third cooling channel inlet is provided on the third housing, the second cooling channel outlet and the third cooling channel inlet being connected by an additional pipeline.

In an embodiment, the first cooling channel is arranged on a bottom wall of the first housing and corresponds to the motor controller.

In an embodiment, the second cooling channel is arranged on a side wall and a bottom wall of the second housing.

In an embodiment, a cooling medium flows through the third cooling channel, the first cooling channel and the second cooling channel sequentially in a circulating manner.

The present disclosure further provides a vehicle, comprising the drive system described above.

Embodiments of the present disclosure have the following advantages: as a result of providing the cooling channel connection structures having interfaces that open in different directions, the drive system of the present disclosure has higher flexibility, is suitable for different housing arrangements, and can be custom-made according to requirements, so that the system is platformized and the development cycle is shortened; joining the cooling channel sealing structures of different housings directly in a sealed manner avoids the use of hoses, thus solving the problems of corrosion and ageing, and thereby reducing costs and increasing service life; joining the cooling channel sealing structures directly also reduces the pressure drop during coolant circulation; integrating the cooling channel sealing structures with the housings increases the degree of integration of the drive system and reduces external connection structures, reducing the size of the system; and arranging the cooling channel sealing structures on the outer sides of the housings further reduces the size of the system.

Brief Description of the Drawings

A better understanding of the advantages and objective of the present disclosure can be gained from the preferred embodiments of the present disclosure de- scribed in detail below with reference to the drawings. To better illustrate the relationships among components in the drawings, the drawings are not drawn to scale. In the drawings:

Fig. 1 shows a highly schematic drawing of a drive system for a vehicle according to an embodiment of the present disclosure;

Fig. 2 shows a partial schematic drawing of a drive system according to an embodiment of the present disclosure;

Fig. 3 shows a sectional schematic drawing of part of the drive system according to Fig. 2;

Fig. 4 shows a partial schematic drawing of a drive system according to an embodiment of the present disclosure;

Fig. 5 shows a partial schematic drawing of a drive system according to another embodiment of the present disclosure; and

Fig. 6 shows a sectional schematic drawing of a drive system according to another embodiment of the present disclosure.

Detailed Description of Embodiments

In order to clarify the objective, technical solutions and advantages of the present disclosure, the technical solutions of embodiments of the present disclosure are described clearly and completely below in conjunction with the drawings accompanying particular embodiments of the present disclosure. In the drawings, identical reference numerals denote identical components. It must be explained that the embodiments described are some, not all, of the embodiments of the present disclosure. All other embodiments obtained by those skilled in the art based on the described embodiments of the present disclosure without the need for inventive effort shall fall within the scope of protection of the present disclosure.

Unless otherwise defined, the technical or scientific terms used herein shall have the common meanings understood by those skilled in the art. The words "first", "second", and the like used in the description and claims of the patent application disclosed herein do not indicate any order, quantity or importance, being merely used to distinguish different component parts. Likewise, words such as "a" or "one" do not necessarily represent a quantity limit. Words such as "comprising", "including” or "having" mean that the element or object preceding the word covers the elements or objects and equivalents thereof listed after the word, without excluding other elements or objects. Words such as "connection” or "communication”, rather than being limited to the physical or mechanical connection or communication shown in a drawing, may include connection or communication equivalent thereto, irrespective of whether it is direct or indirect. "Upper", "lower", "left", "right", etc. are only intended to indicate a relative positional relationship, and when the absolute position of a described object changes, the relative positional relationship may also change accordingly.

Various embodiments of the present disclosure will be described in detail below with reference to Figs. 1 to 6.

Fig. 1 shows a drive system comprised in a vehicle according to the present disclosure in highly schematic form. This may be an electric drive assembly system. The boxes shown in the figure show schematically the main parts of the drive system and the approximate positions of various components, but do not represent a real situation; the arrangement of an actual system may be changed as required. The drive system may comprise a first housing 1, a second housing 2 and a third housing 3, the three housings having their own cooling channels. Of course, the drive system of the present disclosure could also comprise only the first housing 1 and the third housing 3. Comprising one of the abovementioned housings of the present disclosure is also a possibility; the present disclosure imposes no restrictions in this respect. In some examples, the first housing 1 contains a motor controller, e.g. an inverter. The second housing 2 contains a voltage converter, an on-board charger and a power distribution unit. The third housing 3 contains an electric motor and a gearbox. The third housing 3, first housing 1 and second housing 2 are arranged in sequence in the vertically upward direction in Fig. 1. Specifically, the first housing 1 is mounted on a top end of the third housing 3 by means of a threaded connection member for example, and the second housing 2 is mounted on a top end of the first housing 1 by means of a threaded connection member. In other examples, the first housing 1 and second housing 2 may be mounted side by side on the top end of the third housing 3.

As shown schematically in Fig. 1, the first housing 1 is provided with a first cooling channel 6, the second housing 2 is provided with a second cooling channel 7, and the third housing 3 is provided with a third cooling channel 8. In the figure, the positions of the cooling channels are merely schematic, or only partially shown.

The drive system of the present disclosure further comprises a first cooling channel connection structure 11, which is integrally formed with the first housing 1 and connected to the first cooling channel 6. In addition, the first cooling channel connection structure 11 is located on an outer side of the first housing 1, i.e. protrudes from an outer surface of the first housing 1. As shown in Fig. 3, the first cooling channel connection structure 11 comprises a first interface 20 which opens in a first direction (only the position of the interface being shown schematically) and a second interface 21 which opens in a second direction different from the first direction. During actual use, one of the first and second interfaces may be selectively closed. In Fig. 3, the first direction is vertically upward, and the second direction is horizontally leftward. For example, the first direction and the second direction are perpendicular to each other, but the present disclosure imposes no restrictions in this respect.

The drive system of the present disclosure further comprises a second cooling channel connection structure 12, which is integrally formed with the second housing 2 and connected to the second cooling channel 7. In addition, the second cooling channel connection structure 12 is located on an outer side of the second housing 2, i.e. protrudes from an outer surface of the second housing 2. As shown in Figs. 2 and 3, the second cooling channel connection structure 12 is joined in a sealed manner to the first interface 20 of the first cooling channel connection structure 11, and the second interface 21 of the first cooling channel connection structure 11 is closed. For example, the second interface 21 of the first cooling channel connection structure 11 is closed by a first plug 17. Similarly, the second cooling channel connection structure 12 also has two interfaces, one of which may be selectively closed. Specifically, the second cooling channel connection structure 12 in Fig. 3 has an interface which opens in a vertically downward direction, and an interface which opens in a horizontally leftward direction, wherein the interface which opens in the horizontally leftward direction is closed by a second plug 18.

The situation described above is one in which the first housing 1 and the second housing 2 are stacked vertically; in a situation in which the first housing 1 and the second housing 2 are arranged side by side, the second cooling channel connection structure 12 is joined to the second interface 21 in a sealed manner, and the first interface 20 is closed by a plug.

As shown in Fig. 3, a first sealing ring 15 is provided between the first cooling channel connection structure 11 and the second cooling channel connection structure 12. For example, the first cooling channel connection structure 11 takes the form of a slot, and the second cooling channel connection structure 12 takes the form of a protruding connector which is insertable in and matched to the slot. The first sealing ring 15 is positioned, in an elastically deformed manner, between an outer wall of the second cooling channel connection structure 12 which is a protruding connector, and an inner wall of the first cooling channel connection structure 11 which is a slot, as shown in the sectional drawing in Fig. 3. An annular groove for installing the first sealing ring 15 is provided on the outer wall of the second cooling channel connection structure 12 which is a protruding connector.

As shown by the black arrow in Fig. 3, coolant flows from the first cooling channel connection structure 11 towards the second cooling channel connection structure 12.

In other embodiments, as shown in Figs. 5 and 6, the drive system of the present disclosure further comprises a transfer component 4 joined to the second interface 21 of the first cooling channel connection structure 11, and the first interface 20 of the first cooling channel connection structure 11 is closed. As shown in Fig. 6, the first interface 20 of the first cooling channel connection structure 11 may be closed by a first additional plug 19 or a stopper, and coolant leaves the first housing 1 via the transfer component 4. It should be noted that the first interface 20 could also be realized by adjusting a processing depth of a mould and not running through the first cooling channel connection structure 11 during processing.

Fig. 6 shows a situation in which only the first housing 1 and not the second housing 2 is included; in this situation, the components needed for the drive system may be integrated in the first housing 1. In the case where the system uses a single all-in-one product, one end of the transfer component 4 is joined to the second interface 21 of the first cooling channel connection structure 11, for example inserted into the second interface 21 and joined thereto in a sealed manner by an interference fit, and the other end is joined to another cooling device of the vehicle; for example, it may be joined to a cooling system or channel in another region of the vehicle, or to a coolant pump. The transfer component 4 is fixed to the second interface 21 of the first cooling channel connection structure 11 by a fastener 9. The fastener 9 is for example a screw or a bolt, etc., as shown in Fig. 5. The transfer component 4 may be made of a hard material, e.g. the same material as the housing. As shown in the figures, the transfer component 4 has a cylindrical form. In addition, the length of the transfer component 4 may be set or chosen according to needs.

It should be noted that Fig. 5 shows schematically a combination of the embodiment of Figs. 2 and 3 and the embodiment of Fig. 6, to illustrate the fact that the first cooling channel connection structure of the present disclosure may have interfaces leading in different directions, but this does not represent a real use situation. Specifically, in an actual situation, the second housing 2 and the structure on the first cooling channel connection structure which are shown in Fig. 5 may not be present.

As shown in Fig. 1, the drive system of the present disclosure may further comprise a third cooling channel connection structure 13, which is integrally formed with the third housing 3 and connected to the third cooling channel 8. In addition, the third cooling channel connection structure 13 is located on an outer side of the third housing 3, i.e. protrudes from an outer surface of the third housing 3. As shown in Figs. 1 and 4, the drive system of the present disclosure may further comprise a first additional cooling channel connection structure 14, which is integrally formed with the first housing 1 and connected to the first cooling channel 6. It should be noted that although Fig. 1 shows the first additional cooling channel connection structure 14 and the first cooling channel connection structure 11 as being located on two opposite sides of the first housing 1 , the actual situation may be different; the two structures may be located on two adjacent side faces of the first housing 1. Similar to the first cooling channel connection structure 11 and the second cooling channel connection structure 12, the first additional cooling channel connection structure 14 comprises a third interface 22 which opens in a third direction, and a fourth interface 23 which opens in a fourth direction different from the third direction. The third cooling channel connection structure 13 is joined to the third interface 22 in a sealed manner, and the fourth interface 23 is closed. For example, the fourth interface 23 is closed by a fourth plug 24. Similarly, a second sealing ring (not shown in the figures) is provided between the first additional cooling channel connection structure 14 and the third cooling channel connection structure 13. For example, the first additional cooling channel connection structure 14 takes the form of a slot, and the third cooling channel connection structure 13 takes the form of a protruding connector which is insertable in and matched to the slot. The second sealing ring is positioned, in an elastically deformed manner, between an outer wall of the third cooling channel connection structure 13 which is a protruding connector, and an inner wall of the first additional cooling channel connection structure 14 which is a slot. An annular groove for installing the corresponding sealing ring is provided on the outer wall of the third cooling channel connection structure 13 which is a protruding connector.

Again referring to Fig. 2, a second cooling channel outlet 16 may be provided on the second housing 2, and a third cooling channel inlet may be provided on the third housing 3, the second cooling channel outlet 16 and the third cooling channel inlet being connected by an additional pipeline.

Again referring to Fig. 1, the first cooling channel 6 may be arranged on a bottom wall of the first housing 1 and corresponds to a motor controller arranged therein. The second cooling channel 7 may be arranged on a side wall and a bottom wall of the second housing 2.

For example, a cooling medium flows through the third cooling channel, the first cooling channel 6 and the second cooling channel 7 sequentially in a circulating manner. For example, the cooling medium may be water. As stated above, as a result of providing the cooling channel connection structures having interfaces that open in different directions, the drive system of the present disclosure has higher flexibility, is suitable for different housing arrangements, and can be custom-made according to requirements, so that the system is platformized and the development cycle is shortened; joining the cooling channel sealing structures of different housings directly in a sealed manner avoids the use of hoses, thus solving the problems of corrosion and ageing, and thereby reducing costs and increasing service life; joining the cooling channel sealing structures directly also reduces the pressure drop during coolant circulation; integrating the cooling channel sealing structures with the housings increases the degree of integration of the drive system and reduces external connection structures, reducing the size of the system; and arranging the cooling channel sealing structures on the outer sides of the housings further reduces the size of the system.

The present disclosure also provides a vehicle, comprising the drive system described above. The vehicle may be an electrified vehicle, such as a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV) or a range-extended electrified vehicle (REEV). The vehicle may also be a hydrogen-powered vehicle. It should be understood that the vehicle of the present disclosure also has the advantages described above in relation to the drive system.

In addition, the technical features disclosed above are not limited to combinations of the disclosed features with other features, and those skilled in the art could combine technical features in other ways according to the objective of the invention, to realize the objective of the present disclosure.

Claims

What is claimed is:

1. A drive system for a vehicle, the drive system comprising: a first housing (1), provided with a first cooling channel (6); and a first cooling channel connection structure (11), integrally formed with the first housing (1) and connected to the first cooling channel (6), wherein the first cooling channel connection structure (11) comprises a first interface (20) which opens in a first direction and a second interface (21) which opens in a second direction different from the first direction, one of the first interface and the second interface being selectively closable.

2. The drive system according to claim 1 , characterized in that the drive system further comprises: a second housing (2), provided with a second cooling channel (7); and a second cooling channel connection structure (12), integrally formed with the second housing (2) and connected to the second cooling channel (7), wherein the second cooling channel connection structure (12) is joined to the first interface (20) of the first cooling channel connection structure (11) in a sealed manner, and the second interface (21) of the first cooling channel connection structure (11) is closed.

3. The drive system according to claim 1, characterized in that the drive system further comprises a transfer component (4) joined to the second interface of the first cooling channel connection structure (11), and the first interface of the first cooling channel connection structure (11) is closed.

4. The drive system according to one of the preceding claims, characterized in that the drive system further comprises: a third housing (3), provided with a third cooling channel (8); a third cooling channel connection structure (13), integrally formed with the third housing (3) and connected to the third cooling channel (8); and a first additional cooling channel connection structure (14), integrally formed with the first housing (1) and connected to the first cooling channel (6), wherein the first additional cooling channel connection structure (14) comprises a third interface (22) which opens in a third direction and a fourth interface (23) which opens in a fourth direction different from the third direction, and the third cooling channel connection structure (13) is joined to the third interface (22) in a sealed manner, and the fourth interface (23) is closed.

5. The drive system according to claim 4, characterized in that a first sealing ring (15) is provided between the first cooling channel connection structure (11) and the second cooling channel connection structure (12); and/or a second sealing ring is provided between the first additional cooling channel connection structure (14) and the third cooling channel connection structure (13).

6. The drive system according to claim 5, characterized in that the first cooling channel connection structure (11) and the first additional cooling channel connection structure (14) take the form of slots, and the second cooling channel connection structure (12) and the third cooling channel connection structure (13) take the form of protruding connectors which are insertable in and matched to the slots.

7. The drive system according to claim 6, characterized in that the first sealing ring (15) and the second sealing ring are respectively positioned, in an elastically deformed manner, between an outer wall of the corresponding protruding connector and an inner wall of the corresponding slot.

8. The drive system according to claim 7, characterized in that the outer wall of the protruding connector is provided with an annular groove for installing the corresponding sealing ring.

9. The drive system according to claim 3, characterized in that the transfer component (4) has one end joined to the second interface (21) of the first cooling channel connection structure (11), and another end joined to another cooling device of the vehicle.

10. The drive system according to one of the claims 4 to 8, characterized in that at least one of the first cooling channel connection structure (11), the second cooling channel connection structure (12), the first additional cooling channel connection structure (14) and the third cooling channel connection structure (13) is arranged on an outer side of the corresponding housing.

11. The drive system according to one of the claims 4 to 8, characterized in that the first housing (1) contains a motor controller, the second housing (2) contains a voltage converter, an on-board charger and a power distribution unit, and the third housing (3) contains an electric motor and a gearbox.

12. The drive system according to claim 11, characterized in that a second cooling channel outlet (16) is provided on the second housing (2), and a third cooling channel inlet is provided on the third housing (3), the second cooling channel outlet (16) and the third cooling channel inlet being connected by an additional pipeline.

13. The drive system according to claim 11 or 12, characterized in that the first cooling channel (6) is arranged on a bottom wall of the first housing (1) and corresponds to the motor controller.

14. The drive system according to one of the claims 11 to 13, characterized in that the second cooling channel (7) is arranged on a side wall and a bottom wall of the second housing (2).

15. The drive system according to one of the claims 11 to 14, characterized in that a cooling medium flows through the third cooling channel, the first cooling channel (6) and the second cooling channel (7) sequentially in a circulating manner.

16. A vehicle, characterized in that the vehicle comprises the drive system according to any one of claims 1 to 15.