A new energy vehicle electric compressor motor stator winding connection plate

Abstract

The present invention proposes a stator winding connection plate for an electric compressor motor of a new energy vehicle, including a connection plate, a neutral point connection piece, a W-phase connection piece, a V-phase connection piece, and a U-phase connection piece; wherein the connection plate is in a circular ring shape, and the W-phase connection piece, the V-phase connection piece, and the U-phase connection piece of the same structure are overlapped in sequence inside the connection plate; 4 groups of neutral point connection pieces are respectively arranged on the outside of the W-phase connection piece, the V-phase connection piece, and the U-phase connection piece, and the neutral points of each phase are connected in parallel. The present invention can fully realize insulation, realize insulation of the connection part through subsequent potting, ensure the withstand voltage insulation performance of the motor, simplify the motor connection method, improve the consistency of the product, make the production process independent, specialized, and standardized, and ensure the accuracy and reliability of the motor assembly.

Description

Technical Field

[0001] The invention relates to a stator winding connection plate of an electric compressor motor of a new energy vehicle, belonging to the technical field of automotive electrical equipment. Background Art

[0002] New energy vehicles refer to vehicles that use advanced technologies in power control and driving of integrated vehicles, use unconventional vehicle fuels as power sources, or use conventional vehicle fuels but with new vehicle power devices, including pure electric vehicles, fuel cell electric vehicles, hybrid vehicles, hydrogen engine vehicles, etc. Most new energy vehicles are powered by electricity, using electric motors instead of fuel engines, so the requirements for the insulation and pressure resistance of the vehicle's internal environment are much higher than those of ordinary vehicles, in order to avoid the failure of the high voltage of the entire vehicle due to internal circuit insulation failure and the inability to drive.

[0003] In the current electric compressor structure, the connection of the motor stator winding is usually made by extending the enameled wire from each phase winding as the lead wire, which is then tied after being covered with an insulating tube to ensure the relative fixation of the lead wire. In today's automobile production workshops, the above process is usually carried out manually, which is difficult to automate and is not conducive to improving the production efficiency of the motor; and the manual connection accuracy is poor, and the consistency of the product is relatively low. As a result, in the current market, the copper bars or terminals of the existing conventional stator winding connection plates are exposed, which cannot meet the relatively high requirements of the electric compressor motors of new energy vehicles for withstand voltage insulation. Summary of the invention

[0004] The purpose of the present invention is to overcome the performance defects of the motor stator winding of the existing automobile electric compressor, and to propose a new energy automobile electric compressor motor stator winding connection plate to meet the higher voltage resistance insulation requirements of the new energy automobile electric compressor motor, improve the efficiency of winding connection, and lay the foundation for the automated production of motor windings.

[0005] The technical solution of the present invention is: a new energy vehicle electric compressor motor stator winding connecting plate, whose structure includes a connecting plate, a neutral point connector, a W-phase connector, a V-phase connector, and a U-phase connector; wherein the connecting plate is in a circular ring shape, and the W-phase connector, the V-phase connector and the U-phase connector with the same structure are overlapped in sequence inside the connecting plate; 4 groups of neutral point connectors are respectively arranged on the outside of the W-phase connector, the V-phase connector and the U-phase connector, and the neutral points of each phase are connected in parallel.

[0006] Furthermore, the W-phase connector, V-phase connector, and U-phase connector have the same structure and are stamped from a whole copper bar, and their structure includes terminals, lead wire pads, terminal wire bridges, and connecting bridges; wherein the connecting bridge is an overall 3 / 4 arc-shaped structure, and the four terminal wire bridges are arranged in sequence at equal distances along the outer edge of the connecting bridge, and a terminal is provided at the top of each terminal wire bridge; the lead wire pad is arranged at the inner edge of the connecting bridge.

[0007] Furthermore, the neutral point connector is stamped from a whole copper bar, and its structure includes a terminal and a neutral point connection bridge; wherein the neutral point connection bridge is arc-shaped, and three terminals are arranged in sequence and at equal distances along the inner edge of the neutral point connection bridge.

[0008] Furthermore, the upper surface of the connecting plate is provided with 4 glue filling grooves, each of which is provided with 6 through holes, each of which is provided with an enameled wire of a motor winding, and the enameled wire is also covered with a sealant, which cooperates with the through hole to seal the through hole; the inner side of the connecting plate is provided with A refrigerant flow channel and B refrigerant flow channel; the connecting plate also includes a lead wire glue filling groove and a wire groove, wherein the lead wire glue filling groove covers the top of the lead wire pads of the W phase connector, the V phase connector and the U phase connector, and the wire groove is provided on the inner edge of the connecting plate, and a wire groove is provided corresponding to the position of each through hole.

[0009] Furthermore, the enameled wire of the motor winding is installed inside the terminal, and the terminal structure specifically includes the following types:

[0010] 1) The terminal is connected to the connection bridge through the terminal wire bridge; the top of the terminal is provided with a symmetrical terminal clamp formed by bending the copper bar, and the enameled wire passes through the terminal clamp. The inner side of the terminal clamp has teeth to increase the connection effect. The terminal clamps on both sides form an angle β, 20°≤β≤60°; the size of the copper bar at the root of the terminal clamp is slightly larger than the diameter of the enameled wire.

[0011] 2) The terminal is formed directly by bending the end of the connecting bridge. The direction of the terminal is perpendicular to the surface of the connecting bridge and parallel to the enameled wire. The enameled wire is stripped and installed on the side of the terminal and connected to the terminal by resistance welding or brazing.

[0012] 3) The terminal is made by stamping and bending a copper busbar. A through hole is punched out on the copper busbar, and the material at the through hole is bent vertically downward on both sides of the through hole to form teeth. During assembly, the enameled wire passes through the through hole, and the teeth are crimped with the enameled wire to increase the contact area between the terminal and the enameled wire. The connection between the terminal and the enameled wire is strengthened by resistance welding, laser welding, and brazing.

[0013] 4) The terminal is formed by stamping and bending a part of the terminal clamp structure of the copper bar at the end of the connecting bridge. The terminal is parallel to the enameled wire so that the terminal clamp forms an angle with the copper bar.

[0014] Advantages of the present invention:

[0015] 1) The copper connecting bridge is injection molded inside, which can achieve complete insulation. The exposed part of the terminal is in the potting groove, and the insulation of the connecting part can be achieved through subsequent potting, ensuring the voltage resistance and insulation performance of the motor;

[0016] 2) Simplify the motor connection method and improve product consistency;

[0017] 3) The production process is independent, specialized and standardized to ensure the accuracy and reliability of motor assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Attached Figure 1 It is a schematic diagram of the overall structure of the stator winding connection plate of the electric compressor motor of a new energy vehicle.

[0019] Attached Figure 2 It is a schematic diagram of the electrical structure of the stator winding connection board of the electric compressor motor of a new energy vehicle.

[0020] Attached Figure 3 It is a schematic diagram of the structure of the W phase connector.

[0021] Attached Figure 4 It is a structural diagram of the neutral point connection.

[0022] Attached Figure 5a~5d Schematic diagram of the terminal structure of each embodiment.

[0023] In the figure, 1 is a connecting plate, 11 is a glue pouring groove, 12 is a through hole, 13 is a lead wire glue pouring groove, 14 is a wire groove, 15 is A refrigerant flow channel, 16 is B refrigerant flow channel; 2 is a neutral point connector; 3 is a W phase connector, 31 is a lead wire pad, 32 is a terminal wire bridge; 4 is a V phase connector; 5 is a U phase connector; 6 is an enameled wire; 7 is a terminal, 711 is a terminal clamp, 712 is a side, 713 is a copper busbar, 714 is a tooth, 715 is a copper busbar, and 716 is a through hole. DETAILED DESCRIPTION

[0024] The technical solution of the present invention is further explained below in conjunction with the accompanying drawings. Examples of the embodiments are shown in the accompanying drawings, in which the same or similar reference numerals throughout represent the same or similar elements or elements with the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limitations on the present invention. With regard to the concentrated winding motor stator solution, each embodiment of this patent uses a 12-slot, "Y"-type connection scheme motor stator for illustration. In fact, the stator structure solution of the present invention is not limited, and can be an integral type, a block type, or a tooth yoke separation type. The connecting plate can meet the higher voltage resistance and insulation requirements of the electric compressor motor of new energy vehicles, without copper bars or exposed terminals.

[0025] In the description of the present invention, it is necessary to understand that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0026] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0027] like Figure 1-Figure 2 As shown, a new energy vehicle electric compressor motor stator winding connection plate, whose structure includes a connection plate 1, a neutral point connector 2, a W-phase connector 3, a V-phase connector 4, and a U-phase connector 5; wherein the connection plate 1 is in a circular ring shape, and the W-phase connector 3, the V-phase connector 4 and the U-phase connector 5 with the same structure are overlapped in sequence inside the connection plate 1, and all the connectors are in an arc shape as a whole, and are distributed in parallel in concentric circles on the same plane, which can save space as much as possible, and are connected to the motor winding through terminals; 4 groups of neutral point connectors 2 are respectively arranged on the outside of the W-phase connector 3, the V-phase connector 4 and the U-phase connector 5, and the neutral points of each phase are connected in parallel.

[0028] The upper surface of the connecting plate 1 is provided with 4 glue pouring grooves 11, and each glue pouring groove 11 is provided with 6 through holes 12. The number of the glue pouring grooves 11 can be adjusted according to the structural design of the connecting plate 1 to cover all the through holes 12, so that after the connection is completed, the connecting part can be isolated from the outside world by filling the potting material in the glue pouring groove 12 to achieve sealing. In actual use, the enameled wire 6 of the motor winding passes through the connecting plate 1 through the through hole 12, and the enameled wire 6 is also covered with a seal, which cooperates with the through hole 12 of the connecting plate 1 to seal the through hole 12. The connecting plate 1 in the figure is applied to a 12-phase concentrated winding motor solution. If the connecting plate is used for other solutions, if the motor has N phases, then the neutral point connectors 2 should have N / 3. The connecting plate in the figure is applied to a 12-phase concentrated winding motor solution, and the winding is connected in a "Y" shape, and the windings of each phase are connected in parallel, so there are a total of 24 through holes, 2 for each phase.

[0029] The inner side of the connecting plate 1 is provided with a refrigerant flow channel A 15 and a refrigerant flow channel B 16; during the operation of the compressor, the refrigerant can pass through the motor stator winding through the refrigerant flow channel A 15 and the refrigerant flow channel B 16 to cool the stator winding.

[0030] like Figure 3 As shown, the W-phase connector 3, the V-phase connector 4, and the U-phase connector 5 have the same structure; taking the W-phase connector 3 as an example, the W-phase connector 3 is formed by stamping a whole copper bar, and its structure includes a terminal 7, a lead wire pad 31, a terminal wire bridge 32, and a connecting bridge 33; wherein the connecting bridge 33 is a 3 / 4 arc structure as a whole, and the four terminal wire bridges 32 are arranged in sequence and at equal distances along the outer edge of the connecting bridge 33, and a terminal 7 is arranged at the top of each terminal wire bridge 32; the lead wire pad 31 is arranged at the inner edge of the connecting bridge 33. In actual use, the four W-phase ends of the motor are connected in parallel through the four terminals 7.

[0031] like Figure 4 As shown, the neutral point connector 2 is formed by stamping a whole copper bar, and its structure includes a terminal 7 and a neutral point connection bridge 21; wherein the neutral point connection bridge 21 is arc-shaped, and three terminals 7 are arranged in sequence and at equal distances along the inner edge of the neutral point connection bridge 21. In actual use, the four neutral point connectors 2 respectively connect the neutral points of the U, V, and W phase windings connected in the motor in parallel.

[0032] The connecting plate 1 further comprises a lead wire glue potting groove 13 and a wire groove 14, wherein the lead wire glue potting groove 13 covers the lead wire pads 31 of the W-phase connector 3, the V-phase connector 4 and the U-phase connector 5, and the wire groove 14 is arranged at the inner edge of the connecting plate 1, and a wire groove 14 is arranged corresponding to the position of each through hole 12. After the connection is completed, the connection part is isolated from the outside by filling the potting material in the neutral point potting groove 13 to achieve sealing. The potting material includes but is not limited to plastic injection molding, epoxy resin, polyurethane, etc.

[0033] The terminal 7 is internally mounted with the enameled wire 6 of the motor winding. Figure 5a~Figure 5d Shown are schematic structural diagrams of different embodiments of the terminal 7.

[0034] Example 1

[0035] Reference Figure 5a , the terminal 7 is connected to the connection bridge 33 through the terminal wire bridge 32; the top of the terminal 7 is provided with a symmetrical terminal clamp 711 formed by bending a copper bar, and the enameled wire 6 passes through the terminal clamp 711. The inner side of the terminal clamp 711 has teeth to increase the connection effect. The terminal clamps 711 on both sides form an angle β, 20°≤β≤60°. The size of the copper bar 713 at the root of the terminal clamp 711 is slightly larger than the diameter of the enameled wire 6. The terminal structure is connected to the enameled wire 6 by resistance welding, and the enameled wire 6 can be de-painted or not.

[0036] Example 2

[0037] Reference Figure 5b The terminal 7 is directly formed by bending the end of the connecting bridge 33. The direction of the terminal 7 is perpendicular to the surface of the connecting bridge 33 and parallel to the enameled wire 6. The enameled wire 6 is installed on the side 712 of the terminal 7 and is connected to the terminal 7 by resistance welding, brazing, etc. When matching this terminal, the enameled wire 6 needs to be depainted.

[0038] Example 3

[0039] Reference Figure 5c The terminal 7 is made by stamping and bending a copper bar 715, punching a through hole 716 on the copper bar 715, and the material at the through hole 716 is automatically bent to both sides of the through hole to form teeth 714 vertically downward; during assembly, the enameled wire 6 passes through the through hole 716, and the teeth 714 are crimped with the enameled wire 6 to increase the contact area between the terminal 7 and the enameled wire 6. The connection between the terminal 7 and the enameled wire 6 can be strengthened by resistance welding, laser welding, brazing, etc.

[0040] Example 4

[0041] Reference Figure 5d The terminal 7 is formed by stamping and bending a portion of the copper bar 713 at the end of the connecting bridge 33, and the terminal 7 is parallel to the enameled wire 6, so that the terminal clamp 711 and the copper bar 713 form an angle α, 0<α<90°. When connecting, the clamp 711 and the copper bar 713 are pressed tightly against the enameled wire 6 by crimping, and the connection is strengthened by resistance welding. When using this type of terminal 7 structure, the enameled wire 6 can be depainted or not.

[0042] The above embodiments are only preferred implementations of the present invention, but the implementations of the present invention are not limited thereto. Any other changes, modifications, substitutions, and simplifications that do not deviate from the principles of the present invention are equivalent replacement methods and are included in the protection scope of the technical solution of the present invention.

Claims

1. A new energy vehicle electric compressor motor stator winding connection plate, characterized in that The invention comprises a connecting plate (1), a neutral point connecting piece (2), a W-phase connecting piece (3), a V-phase connecting piece (4), and a U-phase connecting piece (5); wherein the connecting plate (1) is in the shape of a ring, and the W-phase connecting piece (3), the V-phase connecting piece (4), and the U-phase connecting piece (5) having the same structure are sequentially overlapped and arranged inside the connecting plate (1); and four groups of neutral point connecting pieces (2) are respectively arranged outside the W-phase connecting piece (3), the V-phase connecting piece (4), and the U-phase connecting piece (5), and the neutral points of the phases are connected in parallel; The upper surface of the connecting plate (1) is provided with four glue pouring grooves (11), each of the glue pouring grooves (11) is provided with six first through holes (12), each of the first through holes (12) is provided with an enameled wire (6) of a motor winding, and a sealing member is also sleeved on the enameled wire (6), and the sealing member cooperates with the first through hole (12) to seal the first through hole (12); the inner side of the connecting plate (1) is provided with a refrigerant flow channel A (15) and a refrigerant flow channel B (16); The W-phase connector (3), the V-phase connector (4), and the U-phase connector (5) have the same structure and are formed by stamping a whole copper bar. The structure comprises a terminal (7), a lead wire pad (31), a terminal wire bridge (32), and a connecting bridge (33); wherein the connecting bridge (33) is in a 3 / 4 arc shape as a whole, and the four terminal wire bridges (32) are arranged in sequence at equal distances along the outer edge of the connecting bridge (33), and a terminal (7) is arranged at the top of each terminal wire bridge (32); and the lead wire pad (31) is arranged at the inner edge of the connecting bridge (33).

2. A new energy vehicle electric compressor motor stator winding connection plate according to claim 1, characterized in that The neutral point connector (2) is formed by stamping a whole copper bar, and its structure includes a terminal (7) and a neutral point connection bridge (21); wherein the neutral point connection bridge (21) is arc-shaped, and the three terminals (7) are arranged in sequence at equal distances along the inner edge of the neutral point connection bridge (21).

3. A new energy vehicle electric compressor motor stator winding connection plate according to claim 1, characterized in that The connecting plate (1) further comprises a lead wire glue potting groove (13) and a wire groove (14), wherein the lead wire glue potting groove (13) covers the lead wire pads (31) of the W-phase connecting piece (3), the V-phase connecting piece (4) and the U-phase connecting piece (5), and the wire groove (14) is arranged at the inner edge of the connecting plate (1), and a wire groove (14) is arranged corresponding to the position of each first through hole (12).

4. A stator winding connection plate for an electric compressor motor of a new energy vehicle according to any one of claim 1, characterized in that The terminal (7) has the enameled wire (6) of the motor winding installed inside.

5. A stator winding connection plate for an electric compressor motor of a new energy vehicle according to any one of claim 1, characterized in that The terminal (7) is connected to the connection bridge (33) via a terminal wire bridge (32); a symmetrical terminal clamp (711) formed by bending a copper bar is provided on the top of the terminal (7); the enameled wire (6) passes through the terminal clamp (711); the inner side of the terminal clamp (711) has teeth to increase the connection effect; the terminal clamps (711) on both sides form an angle β, 20°≤β≤60°; the size of the first copper bar (713) at the root of the terminal clamp (711) is slightly larger than the diameter of the enameled wire (6).

6. A new energy vehicle electric compressor motor stator winding connection plate according to any one of claim 1, characterized in that The terminal (7) is directly formed by bending the end of the connecting bridge (33), and the direction of the terminal (7) is perpendicular to the surface of the connecting bridge (33) and parallel to the enameled wire (6); the enameled wire (6) is depainted and installed on the side (712) of the terminal (7), and is connected to the terminal (7) by resistance welding or brazing.

7. A stator winding connection plate for an electric compressor motor of a new energy vehicle according to any one of claim 1, characterized in that The terminal (7) is formed by stamping and bending a second copper bar (715), a second through hole (716) is stamped out on the second copper bar (715), and the material at the second through hole (716) is bent to both sides of the through hole vertically downward to form teeth (714); during assembly, the enameled wire (6) passes through the second through hole (716), and the teeth (714) are crimped with the enameled wire (6), thereby increasing the contact area between the terminal (7) and the enameled wire (6); the connection between the terminal (7) and the enameled wire (6) is strengthened by resistance welding, laser welding, or brazing.

8. A stator winding connection plate for an electric compressor motor of a new energy vehicle according to any one of claim 1, characterized in that The terminal (7) is formed by stamping and bending a portion of a terminal clamp (711) structure of the first copper bar (713) at the end of the connecting bridge (33); the terminal (7) is parallel to the enameled wire (6), so that the terminal clamp (711) and the first copper bar (713) form an angle α, 0<α<90°.

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