Integrated drive and motor assemblies

Patent metadata

Field	Value
Publication number	US-10644571-B2
Application number	US-201615764827-A
Country	US
Kind code	B2
Filing date	Sep 23, 2016
Priority date	Sep 29, 2015
Publication date	May 5, 2020
Grant date	May 5, 2020

Abstract

Integrated drive and motor assemblies are described herein. An example integrated drive and motor assembly includes an electric motor having a winding that concentrically surrounds an input drive shaft, an inverter for delivering power to the electric motor, a gearbox assembly coupled to the input drive shaft and an output drive shaft, the gearbox assembly having a planetary gear that includes a plurality of helical gears that couple with the input drive shaft and a ring gear. The planetary gear also includes a carrier that is rotatably coupled to the plurality of helical gears and transfers rotational forces to the output drive shaft. The assembly includes a housing that encloses the electric motor, the gearbox assembly, and the output shaft in co-axial alignment with respect to a central axis.

First claim

What is claimed is:

1. An integrated drive and motor assembly for a motor vehicle, the integrated drive and motor assembly comprising:
an electric motor;
an inverter for delivering power to the electric motor;
a gearbox assembly coupled to the electric motor;
an output shaft coupled to the gearbox assembly; and
a housing comprising:
a central section that retains the electric motor, the gearbox assembly, and
the output shaft in co-axial relationship to one with respect to a central axis;
a lower reservoir disposed on a bottom end of the central section; and
an inverter enclosure extending from a sidewall of the central section, the inverter enclosure configured to receive the inverter.

2. The integrated drive and motor assembly according to claim 1 , wherein the electric motor comprises a motor winding that is concentric to an input driveshaft of the electric motor.

3. The integrated drive and motor assembly according to claim 2 , wherein the gearbox assembly comprises a planetary gear that comprises a plurality of helical gears that transfer rotational forces from the input drive shaft of the electric motor to the output shaft.

4. The integrated drive and motor assembly according to claim 3 , wherein the gearbox assembly further comprises a ring gear that is fixedly coupled with a cover of the central section.

5. The integrated drive and motor assembly according to claim 4 , wherein the electric motor is directly electrically coupled with the inverter by a three phase bus bar of the inverter.

6. The integrated drive and motor assembly according to claim 5 , wherein the central section comprises a cooling compartment formed by a rearward opening of the housing enclosed with a cover plate.

7. The integrated drive and motor assembly according to claim 6 , wherein an interior portion of the inverter enclosure is in fluid communication with a cooling cavity of the central section using an inlet path and an outlet path.

8. The integrated drive and motor assembly according to claim 7 , further comprising a coolant interface and a lubricant interface.

9. The integrated drive and motor assembly according to claim 8 , further comprising a heat exchanger that thermally processes a lubricant circulated through the electric motor and the gearbox, wherein the lubricant collects within the lower reservoir, and wherein the heat exchanger thermally processes a coolant that circulates through the inverter enclosure.

10. The integrated drive and motor assembly according to claim 9 , wherein the lubricant is circulated using the lubricant interface and the coolant through the inverter enclosure using the coolant interface.

11. An integrated drive and motor assembly for a motor vehicle, the integrated drive and motor assembly comprising:
an electric motor;
an inverter for delivering power to the electric motor;
a gearbox assembly rotatably coupled to the electric motor;
an output shaft coupled to the gearbox assembly; and
a housing comprising:
a cylindrical section that retains the electric motor, the gearbox assembly, and the output shaft in co-axial relationship to one another along a central axis;
a lower reservoir disposed on a bottom end of the cylindrical section, the lower reservoir comprising a lubricant for the electric motor and gearbox assembly; and
an inverter enclosure extending from a sidewall of the cylindrical section, the inverter enclosure configured to receive the inverter, the inverter enclosure comprising an interior portion that comprises a coolant for cooling the inverter.

12. The integrated drive and motor assembly according to claim 11 , wherein the lower reservoir is disposed perpendicularly to the inverter enclosure.

13. The integrated drive and motor assembly according to claim 12 , wherein the lower reservoir and the interior portion of the inverter enclosure are in fluid communication with a cooling compartment disposed rearwardly of the cylindrical section.

14. The integrated drive and motor assembly according to claim 13 , wherein a distal portion of the inverter enclosure is sealed to prevent the coolant from entering the distal portion.

15. The integrated drive and motor assembly according to claim 14 , wherein the interior portion and the distal portion are separated by a dividing wall.

16. An integrated drive and motor assembly for a motor vehicle, the integrated drive and motor assembly comprising:
an electric motor having a winding that concentrically surrounds an input drive shaft;
an inverter for delivering power to the electric motor;
a gearbox assembly coupled to the input drive shaft and an output drive shaft, the gearbox assembly comprising a planetary gear that comprises a plurality of helical gears that couple with the input drive shaft and a ring gear, the planetary gear also comprising a carrier that is rotatably coupled to the plurality of helical gears and transfers rotational forces to the output drive shaft; and
a housing that encloses the electric motor, the gearbox assembly, and the output shaft in co-axial alignment with respect to a central axis.

17. The integrated drive and motor assembly according to claim 16 , wherein the electric motor is directly electrically coupled with the inverter by symmetrical output tabs of a three phase bus bar of the inverter.

18. The integrated drive and motor assembly according to claim 17 , wherein the housing comprises a cooling compartment formed by a rearward opening of the housing, which is enclosed with a cover plate.

19. The integrated drive and motor assembly according to claim 18 , wherein an interior portion of the inverter enclosure is in fluid communication with a cooling cavity of the central section using an inlet path and an outlet path.

20. The integrated drive and motor assembly according to claim 19 , wherein a transmission fluid is circulated within the housing and a coolant is circulated within an inverter enclosure of the housing.

Assignees

• Faraday&Future Inc
• Faraday & Future Inc

Inventors

• Hatch Erik

Classifications

• F16H57/0417

  Heat exchangers adapted or integrated in the gearing · CPC title

• H02K11/33

  Drive circuits, e.g. power electronics (H02K11/38 takes precedence) · CPC title

• H02K1/30

  using intermediate parts, e.g. spiders · CPC title

• F16H57/031

  characterised by covers or lids for gearboxes · CPC title

• F16H57/0452

  Oil pans · CPC title