Busbar assembly, motor, electric driving system and vehicle

Abstract

The utility model discloses a busbar assembly, a motor, an electric driving system and a vehicle. The busbar assembly comprises a conducting bar and a support. The conducting bar is fixed on the bracket; the conducting bar comprises a pin section, the support is provided with a through groove, and a part of the wall surface of the pin section and at least part of the inner wall of the through groove are enclosed to form a limiting hole for a connecting wire to pass through. The structural design of the busbar assembly is beneficial to reducing the complexity of assembling with an electrical component and improving the reliability of electrical connection with the electrical component.

Description

Technical Field

[0001] This application relates to the field of bus technology, and in particular to a bus assembly, a motor, an electric drive system, and a vehicle. Background Technology

[0002] In related technologies, the assembly of the copper busbar assembly and the stator winding of the motor requires positioning using tooling before welding, which is quite complex. In addition, due to the springback characteristics of the stator winding, there is a risk of cracking at the solder joints between the stator winding leads and the copper busbar.

[0003] Similar issues exist with other buses used for electrical connections. Utility Model Content

[0004] The purpose of this application is to provide a bus assembly, a motor, an electric drive system, and a vehicle. The structural design of the bus assembly helps to reduce the complexity of assembling with electrical components and improves the reliability of electrical connections with electrical components.

[0005] To address the aforementioned technical problems, this application provides a bus assembly, including a conductive bus and a support;

[0006] The conductive busbar is fixed on the bracket;

[0007] The conductive bus includes a pin segment, the bracket has a through groove, and a portion of the wall of the pin segment and at least a portion of the inner wall of the through groove form a limiting hole through which a connecting wire can pass.

[0008] In one feasible embodiment, the bus assembly includes three or more conductive buses, each of which includes two or more phase buses and a neutral bus, with each phase bus and the neutral bus at the same horizontal level.

[0009] In one feasible embodiment, the bus assembly includes three or more conductive buses, each of which includes two or more phase busbars and a neutral busbar. The phase busbars are spaced apart along a first arc segment, and the neutral busbar extends along a second arc segment. The first arc segment and the second arc segment are concentric, and the radius of the first arc segment is different from the radius of the second arc segment.

[0010] In one feasible embodiment, the support is arc-shaped, with each of the phase busbars arranged close to the outer peripheral wall of the support, and the neutral busbar arranged close to the inner peripheral wall of the support.

[0011] In one feasible embodiment, the pin segments of both the phase busbar and the neutral busbar extend upward along the axial direction of the bracket, and the phase busbar includes a connecting segment extending out of the outer peripheral wall of the bracket.

[0012] In an implementation, the conductive row further comprises a body segment connected with the pin segment, the bracket has a mounting cavity, the body segment is embedded in the mounting cavity, and the through slot is communicated with the mounting cavity.

[0013] In an implementation, the bracket is integrated with the conductive row as an integral structure.

[0014] In an implementation, the bracket is a plastic bracket, and the plastic bracket is integrally molded with the conductive row as an integral structure.

[0015] In an implementation, the bracket comprises a plurality of wall portions, and each wall portion has a thickness of 1.5 mm to 2 mm.

[0016] The application further provides an electric machine comprising a stator winding and a busbar, the busbar being any one of the busbars described above, and a connecting wire of the stator winding passing through the limiting hole and being welded with the pin segment.

[0017] The application further provides an electric drive system comprising the electric machine described above.

[0018] The application further provides a vehicle comprising the electric drive system described above.

[0019] The busbar assembly provided by the embodiments of the application can be applied to an electric machine to realize electrical connection between a stator winding of the electric machine and a controller of the electric machine. The conductive row of the busbar assembly is fixed on the bracket, and the conductive row and the through slot of the bracket enclose a limiting hole through which a connecting wire can pass. In this way, when the busbar assembly is assembled with an electrical component to be connected, the connecting wire of the electrical component can be positioned through the limiting hole. Part of the hole wall of the limiting hole is part of the wall surface of the pin segment. After the connecting wire passes through the limiting hole, the relative position of the connecting wire and the pin segment can be fixed, and the connecting wire and the pin segment can be conveniently welded, so that the assembly complexity is reduced. Moreover, after welding, the welding point of the connecting wire and the pin segment is not prone to cracking due to the limitation of the hole wall of the limiting hole, and the connection reliability is improved. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 A structure diagram of a busbar assembly provided in an embodiment of the application Figure 1 ;

[0021] Figure 2 A structure diagram of a busbar assembly provided in an embodiment of the application Figure 2 ;

[0022] Figure 3 A structure diagram of a busbar provided in an embodiment of the application Figure 1 ;

[0023] Figure 4 For Figure 1 Structure diagram of the bracket;

[0024] Figure 5 For Figure 1 Structure diagram of the busbar assembly after being installed on the stator winding.

[0025] Explanation of reference signs:

[0026] Bracket 10, outer peripheral wall 101, inner peripheral wall 102, first mounting cavity 11, second mounting cavity 12, third mounting cavity 13, neutral mounting cavity 14, first limiting hole 151, second limiting hole 152, third limiting hole 153, fourth limiting hole 154;

[0027] U-phase busbar 20, U-phase body segment 21, U-phase pin segment 22, U-phase connecting segment 23;

[0028] V-phase busbar 30, V-phase body segment 31, V-phase pin segment 32, V-phase connecting segment 33;

[0029] W-phase busbar 40, W-phase body segment 41, W-phase pin segment 42, W-phase connecting segment 43;

[0030] Neutral busbar 50, neutral body segment 51, first pin segment 521, second pin segment 522, third pin segment 523;

[0031] Stator winding 60, connecting wire 61. DETAILED DESCRIPTION

[0032] In order to make the person skilled in the art better understand the scheme of the present application, the present application will be further described in detail below in combination with the drawings and specific embodiments.

[0033] The ordinal numbers such as first, second, etc. used herein are used to distinguish different parts with the same name, and do not represent a specific order or primary and secondary relationship. The plural used herein means two or more, including two.

[0034] Please refer to Figures 1 to 4 , Figure 1 Structure diagram of the busbar assembly provided in an embodiment of the present application Figure 1 , Figure 2 Structure diagram of the busbar assembly provided in an embodiment of the present application Figure 2 , Figure 3 For Figure 1 Structure diagram of the guide flow bar, Figure 4 For Figure 1 Structure diagram of the bracket. Among them, Figure 1 and Figure 2 Structure of the busbar assembly in two different perspectives.

[0035] The busbar assembly provided by the embodiment can be applied to an electric machine to realize electrical connection between stator windings of the electric machine and a controller of the electric machine. The busbar assembly can also be applied to other electrical connection scenarios, for example, to realize electrical connection between a circuit board and a controller.

[0036] In the embodiment, the busbar assembly includes a conductive bar and a bracket 10, the conductive bar is fixed on the bracket 10, the conductive bar includes a pin segment, and the bracket has a through groove, and a part of walls of the pin segment and at least part of groove walls of the through groove enclose a limiting hole through which a connecting wire can pass.

[0037] After the above arrangement, when the busbar assembly is assembled with electrical components to be connected, the connecting wire of the electrical component can be positioned through the limiting hole, a part of hole walls of the limiting hole are a part of walls of the pin segment, and after the connecting wire passes through the limiting hole, the relative position of the connecting wire and the pin segment can be fixed, and the connecting wire and the pin segment are conveniently welded, the assembly complexity is reduced, and after welding, the welding point of the connecting wire and the pin segment is not easy to crack due to the limitation of the hole walls of the limiting hole, which is conducive to improving the connection reliability.

[0038] In some examples, the pin segment can be located in the through groove as a whole or in part, and the walls of the pin segment facing the through groove and part of groove peripheral walls of the through groove enclose the limiting hole.

[0039] In other examples, the through groove can also have an opening side, the pin segment is located at the opening side of the through groove and blocks the opening side of the through groove, and the walls of the pin segment facing the through groove and the entire groove peripheral walls of the through groove enclose the limiting hole.

[0040] In the embodiment, the busbar assembly includes three or more conductive bars, the three or more conductive bars include two or more phase busbars and a neutral busbar 50, each phase busbar and the neutral busbar 50 are at the same horizontal height, each phase busbar is arranged along a first circular arc segment, the neutral busbar 50 extends along a second circular arc segment, the first circular arc segment and the second circular arc segment are concentric, and the radius of the first circular arc segment is smaller than the radius of the second circular arc segment.

[0041] After the above arrangement, each phase busbar and the neutral busbar 50 are in the same horizontal plane. It can be understood that each phase busbar and the neutral busbar 50 are at the same layer in the vertical direction, and each phase busbar and the neutral busbar 50 are on circular arc segments of different radii. In this way, the arrangement of the conductive bars is relatively simple, and it is conducive to reducing the occupied space of the busbar assembly.

[0042] In a specific implementation, the bracket 10 has an arc shape, the bracket 10 has an arc-shaped outer peripheral wall 101 and an arc-shaped inner peripheral wall 102, each phase busbar is arranged close to the outer peripheral wall 101 of the bracket 10, and the neutral busbar 50 is arranged close to the inner peripheral wall 102.

[0043] After the above setting, the setting positions of the phase bus bars and the neutral bus bar 50 can be taken as reference bases of the arc-shaped bracket 10, facilitating the arrangement of the bus bars and the neutral bus bar 50.

[0044] In a specific implementation, the pin segments of the phase bus bars and the neutral bus bar 50 extend upward along the axial direction of the bracket 10, and the phase bus bar further includes a connecting segment extending out of the outer peripheral wall 101 of the bracket 10. In this way, the phase bus bars of the busbar assembly are facilitated to be connected to two electrical components to be connected, and the orderly arrangement of the wire harness is also facilitated.

[0045] In a specific implementation, the conductive bar includes a body segment connected with the pin segment, the bracket 10 has a mounting cavity, the body segment is fixedly embedded in the mounting cavity, and the through groove is in communication with the mounting cavity. In this way, the relative position of the conductive bar and the bracket 10 can be defined by the relative position of the pin segment and the through groove.

[0046] Next, taking the busbar assembly provided with four conductive bars, three phase bus bars and one neutral bus bar 50 as an example, the busbar assembly is used for a motor, and the busbar assembly is combined with the motor to be described in detail. Figures 1 to 4

[0047] In an embodiment, the busbar assembly includes three phase bus bars, which are a U-phase bus bar 20, a V-phase bus bar 30, and a W-phase bus bar 40. The U-phase bus bar 20, the V-phase bus bar 30, and the W-phase bus bar 40 are sequentially arranged.

[0048] The U-phase bus bar 20, the V-phase bus bar 30, and the W-phase bus bar 40 are sequentially arranged along the circumferential direction of the bracket 10. The U-phase bus bar 20 and the V-phase bus bar 30 are spaced apart by a certain distance, and the V-phase bus bar 30 and the W-phase bus bar 40 are spaced apart by a certain distance. The spacing distance is based on ensuring electrical safety, and can be determined according to actual application needs.

[0049] The U-phase bus bar 20 includes a U-phase body segment 21, a U-phase pin segment 22, and a U-phase connecting segment 23. The U-phase body segment 21 is in an arc shape. The U-phase pin segment 22 is arranged at one end of the U-phase body segment 21 away from the V-phase bus bar 30, and is formed by extending upward along the axial direction of the bracket 10 from the top surface of the U-phase body segment 21. The U-phase connecting segment 23 is arranged at one end of the U-phase body segment 21 close to the V-phase bus bar 30, and extends outward along the radial direction of the bracket 10. The U-phase connecting segment 23 penetrates through the outer peripheral wall 101 of the bracket 10. The U-phase pin segment 22 of the U-phase bus bar 20 is used to be welded with a connection wire of a stator winding of the motor, and the U-phase connecting segment 23 of the U-phase bus bar 20 is used to be electrically connected with a connection wire of a motor controller.

[0050] ​The V-phase busbar 30 includes a V-phase body segment 31, a V-phase pin segment 32, and a V-phase connecting segment 33. The V-phase body segment 31 also has an arc shape. The V-phase pin segment 32 is formed by extending upward from an inner side end of the V-phase body segment 31 along the axial direction of the bracket 10. The V-phase connecting segment 33 is formed by extending downward from an outer side end of the V-phase body segment 31 along the axial direction of the bracket 10. The inner side end of the V-phase body segment 31 refers to an end close to the inner peripheral wall 102 of the bracket 10. The outer side end of the V-phase body segment 31 refers to an end close to the outer peripheral wall 101 of the bracket 10. Part of the V-phase body segment 31 and the V-phase connecting segment 33 extend out of the outer peripheral wall 101 of the bracket 10. The V-phase pin segment 32 of the V-phase busbar 30 is used for welding with the connecting wire of the stator winding of the motor. The V-phase connecting segment 33 of the V-phase busbar 30 is used for electrical connection with the connecting wire of the motor controller.

[0051] The W-phase busbar 40 includes a W-phase body segment 41, a W-phase pin segment 42, and a W-phase connecting segment 43. The W-phase body segment 41 also has an arc shape. The W-phase pin segment 42 is arranged at an end of the W-phase body segment 41 away from the V-phase busbar 30. The W-phase pin segment 42 is formed by extending upward from a top surface of the W-phase body segment 41 along the axial direction of the bracket 10. The W-phase connecting segment 43 is arranged at an end of the W-phase body segment 41 close to the V-phase busbar 30. The W-phase connecting segment 43 extends substantially outward along the radial direction of the bracket 10. The W-phase connecting segment 43 penetrates through the outer peripheral wall 101 of the bracket 10. The W-phase pin segment 42 of the W-phase busbar 40 is used for welding with the connecting wire of the stator winding of the motor. The W-phase connecting segment 43 of the W-phase busbar 40 is used for electrical connection with the connecting wire of the motor controller.

[0052] In the illustrated example, the U-phase body segment 21 and the W-phase body segment 41 have a relatively long arc length, and the V-phase body segment 31 has a relatively short arc length. The U-phase busbar 20 and the W-phase busbar 40 are structurally symmetrical relative to the V-phase busbar 30. In other embodiments, the specific shapes, sizes, and the like of the U-phase busbar 20, the V-phase busbar 30, and the W-phase busbar 40 can be set according to application requirements.

[0053] The neutral busbar 50 includes a neutral body segment 51, a first pin segment 521, a second pin segment 522, and a third pin segment 523. The neutral body segment 51 has an arc shape. The first pin segment 521, the second pin segment 522, and the third pin segment 523 all extend upward from a top surface of the neutral body segment 51 along the axial direction of the bracket 10.

[0054] In the radial direction of the bracket 10, the first pin segment 521 corresponds in position to the U-phase pin segment 22, the second pin segment 522 corresponds in position to the V-phase pin segment 32, and the third pin segment 523 corresponds in position to the W-phase pin segment 42.

[0055] In actual applications, the U-phase busbar 20, the V-phase busbar 30, the W-phase busbar 40, and the neutral busbar 50 can all be made of copper bars, or can be made of aluminum bars or other conductive materials.

[0056] In the illustrated example, the pin segments of the U-phase busbar 20, the V-phase busbar 30 and the W-phase busbar 40 are each provided with two, and correspondingly, the neutral busbar 50 is provided with two first pin segments 521, two second pin segments 522 and two third pin segments 523. In this way, in the illustrated example, the busbar assembly is provided with a total of 12 pin segments, and correspondingly, the support 10 has 12 through grooves that are matched one by one with the 12 pin segments to form 12 limiting holes.

[0057] In other embodiments, the number of pin segments of the busbar assembly is set according to application needs, and the number of through grooves on the support 10 is set in matching with the pin segments.

[0058] In a specific implementation, the support 10 has a first mounting cavity 11, a second mounting cavity 12, a third mounting cavity 13 and a neutral mounting cavity 14, which are respectively used for mounting the U-phase busbar 20, the V-phase busbar 30, the W-phase busbar 40 and the neutral busbar 50.

[0059] On the basis of the illustrated structure of the U-phase busbar 20, the V-phase busbar 30, the W-phase busbar 40 and the neutral busbar 50, the mounting cavities and the through grooves of the support 10 can be set as follows.

[0060] The first mounting cavity 11, the second mounting cavity 12 and the third mounting cavity 13 are arranged close to the outer peripheral wall 101 of the support 10.

[0061] The first mounting cavity 11 extends along the circumference of the support 10 and is an arc-shaped cavity. An end of the first mounting cavity 11 close to the second mounting cavity 12 penetrates the outer peripheral wall 101 of the support 10 to form an open end. In this way, after the U-phase body segment 21 of the U-phase busbar 20 is embedded in the first mounting cavity 11, the U-phase connecting segment 23 connected to the U-phase body segment 21 can extend out of the outer peripheral wall 101 of the support 10 from the open end of the first mounting cavity 11. The support 10 further has a first through groove 161 that communicates with the first mounting cavity 11. The first through groove 161 penetrates the top wall and the bottom wall of the support 10. After the U-phase body segment 21 of the U-phase busbar 20 is embedded in the first mounting cavity 11, the U-phase lead segment 22 and the first through groove 161 enclose a first limiting hole 151.

[0062] The outer side wall of the bracket 10 has a through hole communicating with the second mounting cavity 12, at least part of the V-phase body segment 31 of the V-phase busbar 30 passes through the through hole of the outer side wall of the bracket 10, and the V-phase pin segment 31 of the V-phase busbar 30 is located in the second mounting cavity 12. The bracket 10 can be provided with two second mounting cavities 12, which are matched with two V-phase pin segments 32 of the V-phase busbar 30 respectively. The bracket 10 also has a second through groove 162 communicating with the second mounting cavity 12, the second through groove 162 penetrates the top wall and the bottom wall of the bracket 10, and the V-phase pin segment 31 located behind the second mounting cavity 12 forms a second limiting hole 152 together with the second through groove 162.

[0063] The third mounting cavity 13 extends along the circumference of the bracket 10 and is an arc-shaped cavity. The third mounting cavity 13 has an open end penetrating the outer peripheral wall 101 of the bracket 10 at one end close to the second mounting cavity 12, so that the W-phase body segment 41 of the W-phase busbar 40 is embedded in the third mounting cavity 13, and the W-phase connecting segment 43 connected with the W-phase body segment 41 can extend out of the outer peripheral wall 101 of the bracket 10 from the open end of the third mounting cavity 13. The bracket 10 also has a third through groove 163 communicating with the third mounting cavity 13, the third through groove 163 penetrates the top wall and the bottom wall of the bracket 10, and the W-phase body segment 41 of the W-phase busbar 40 embedded in the third mounting cavity 13 forms a third limiting hole 153 together with the third through groove 163.

[0064] The neutral mounting cavity 14 is arranged close to the inner peripheral wall 102 of the bracket 10 and is an arc-shaped cavity. The arc length of the neutral mounting cavity 14 matches the arc length of the neutral body segment 51. The bracket 10 is provided with a fourth through groove 164 at positions corresponding to the first pin segment 521, the second pin segment 522 and the third pin segment 523, so that the first pin segment 521, the second pin segment 522 and the third pin segment 523 can form a fourth limiting hole 154 together with the corresponding fourth through groove 164 after the neutral body segment 51 is embedded in the neutral mounting cavity 14.

[0065] In the embodiment, the bracket 10 is integrated with the conductive busbar, i.e., the bracket 10 is integrated with the aforementioned phase busbars and the neutral busbar 50.

[0066] In specific implementation, the bracket 10 is made of plastic, which can reduce cost while playing an insulating role.

[0067] For example, the bracket 10 and the conductive busbar are integrally injection molded.

[0068] In specific implementation, the bracket 10 includes a plurality of wall portions, which can be cavity walls forming the aforementioned mounting cavities, groove walls forming the aforementioned through grooves, or rib walls playing a reinforcing role.

[0069] In the application, the thickness of each wall of the support 10 is 1.5mm-2mm, which balances the structure performance of the support 10 while ensuring the insulation performance of the support 10.

[0070] Please refer to Figure 5 , Figure 5 for Figure 1 the partial structure diagram of the busbar assembly after being installed on the stator winding.

[0071] In practical application, Figure 1 the busbar assembly and the stator winding 60 of the motor are installed, and each connection wire 61 led out by the stator winding 60 can pass through the corresponding limiting hole of the support 10 and be welded and fixed with the corresponding pin segment. The structure of the foregoing busbar assembly does not need additional tooling to position the connection wire 61 led out by the stator winding 60 and the position of the pin segment, which reduces the complexity of assembly. After welding, the connection wire 61 is limited by the hole wall of the limiting hole, so even if the stator winding 60 has a rebound characteristic, the limiting hole can also limit the position of the connection wire 61, which reduces the risk of cracking of the welding point position of the connection wire 61 and the pin segment, and improves the connection reliability.

[0072] In addition to the busbar assembly described above, the embodiment of the application also provides a motor, which can be combined Figure 5 understood that the motor includes a stator winding 60 and the busbar assembly introduced in the foregoing embodiment, and the lead-out wire 61 of the stator winding 60 passes through the limiting hole of the support 10 of the busbar assembly and is welded with the pin segment of the conductive row. The motor includes the foregoing busbar assembly and has the corresponding technical effects of the busbar assembly, which will not be repeated here.

[0073] It should be understood that other functional components of the motor can be implemented by using the prior art, which will not be described here.

[0074] The embodiment of the application also provides an electric drive system, which includes the motor described above. The electric drive system includes the motor described above and has the corresponding technical effects of the motor, which will not be repeated here.

[0075] The embodiment of the application also provides a vehicle, which includes the electric drive system described above. The vehicle has the corresponding technical effects of the electric drive system, which will not be repeated here.

[0076] The principles and implementation modes of the application are described by using specific examples in this paper, and the above description of the embodiments is only used to help understand the method and core idea of the application. It should be pointed out that for ordinary skilled persons in the technical field, some improvements and modifications can be made to the application without departing from the principles of the application, and these improvements and modifications also fall within the protection scope of the claims of the application.

Claims

1. A bus assembly, characterized in that, Includes busbars and supports; The conductive busbar is fixed on the bracket; The conductive bus includes a pin segment, the bracket has a through groove, and a portion of the wall of the pin segment and at least a portion of the inner wall of the through groove form a limiting hole through which a connecting wire can pass.

2. The bus assembly according to claim 1, characterized in that, The bus assembly includes three or more conductive buses, each of which includes two or more phase buses and a neutral bus, with each phase bus and the neutral bus at the same horizontal level.

3. The bus assembly according to claim 1 or 2, characterized in that, The bus assembly includes three or more conductive buses, each including two or more phase busbars and a neutral busbar. The phase busbars are spaced apart along a first arc segment, and the neutral busbar extends along a second arc segment. The first arc segment and the second arc segment are concentric, and the radius of the first arc segment is different from the radius of the second arc segment.

4. The bus assembly according to claim 2, characterized in that, The bracket is arc-shaped, with each phase busbar arranged close to the outer peripheral wall of the bracket, and the neutral busbar arranged close to the inner peripheral wall of the bracket.

5. The bus assembly according to claim 2, characterized in that, The pin segments of both the phase busbar and the neutral busbar extend upward along the axial direction of the bracket, and the phase busbar includes a connecting segment extending out of the outer peripheral wall of the bracket.

6. The bus assembly according to claim 1, characterized in that, The conductive bus also includes a body section connected to the pin section, the bracket has a mounting cavity, the body section is fixedly embedded in the mounting cavity, and the through groove communicates with the mounting cavity.

7. The bus assembly according to any one of claims 1-6, characterized in that, The bracket and the conductive busbar are integrated into a single structure.

8. The bus assembly according to claim 7, characterized in that, The bracket is a plastic bracket, and the plastic bracket and the conductive busbar are injection molded into an integral structure.

9. The bus assembly according to claim 8, characterized in that, The support includes multiple wall sections, each with a thickness of 1.5mm to 2mm.

10. An electric motor, characterized in that, It includes a stator winding and a busbar, wherein the busbar is the busbar according to any one of claims 1-9, and the connecting wires led out from the stator winding pass through the limiting hole and are welded to the pin segment.

11. An electric drive system, characterized in that, Including the motor as described in claim 10.

12. A vehicle, characterized in that, Including the electric drive system as described in claim 11.

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