Flat wire motor end connection device and flat wire motor

Abstract

The present invention relates to the technical field of flat wire motors, and in particular to a flat wire motor end connection device and a flat wire motor, wherein the flat wire motor end connection device comprises a first copper bar, a second copper bar and a three-phase parallel copper bar, wherein the first copper bar is connected to the three-phase lead wires of the stator winding and the second copper bar respectively, and the second copper bar is used to connect to the controller DC bus; the three-phase parallel copper bar is connected to the neutral point lead wire of the stator winding, and the three-phase parallel copper bar is used to reduce the current density per unit cross section, and a sensor fixing rod for fixing a temperature sensor is provided on the three-phase parallel copper bar, and the temperature sensor is used to monitor the temperature of the first copper bar, the second copper bar, the three-phase parallel copper bar and the stator winding. The flat wire motor end connection device and the flat wire motor provided by the present invention have a simple structure, and while monitoring the temperature of the stator winding, the current density per unit cross section is reduced, thereby improving the problem of circulating current and heating through the flat wire motor when a large current is present.

Description

Technical Field

[0001] The present invention relates to the technical field of flat wire motors, and in particular to a flat wire motor end connection device and a flat wire motor. Background Art

[0002] The difference between flat wire motors and round wire motors lies in the way the copper wire is formed. Flat wire is conducive to improving the slot fill rate of the motor. Generally, the slot fill rate of round wire motors is about 40%, while the slot fill rate of flat wire motors can reach more than 60%. The increase in slot fill rate means that more copper wire can be filled in without changing the space, generating a stronger magnetic field strength and improving power density.

[0003] With the development of new energy vehicle drive motor technology, the demand for flat wire motors is becoming more and more intense. Flat wire motors are becoming the hot spot in the field of new energy drive motors due to their high power density, low cost, and good temperature performance. However, the difficulty in manufacturing the stator end connection device of the flat wire motor and its poor precision restrict the large-scale use of flat wire motors in new energy vehicles.

[0004] In the prior art, the flat wire motor stator end connection device adopts enameled flat copper wire bending or copper bar connection, but the enameled flat copper wire bending is difficult to manufacture and will damage the paint and insulation performance. The copper bar is a better choice due to its good manufacturability, but its connection method is limited by the space at the end, and the ability to pass large current under the winding of multiple branches is limited, causing heat to damage insulation and even burn the motor. Although the Chinese patent application (publication number CN111245135A) discloses a flat wire motor winding end connection device, which reduces the complexity of manufacturing the flat wire motor end connection device, the technical solution disclosed in it still does not improve the problem of heat generation caused by large current passing. Summary of the invention

[0005] In order to solve the problem of heat generation caused by large current passing through the copper busbar at the end of the flat wire motor in the above-mentioned prior art, the flat wire motor end connection device and the flat wire motor provided by the present invention can improve the large current passing capacity of the copper busbar in a limited space and avoid motor burning and damage.

[0006] The present invention provides a flat wire motor end connection device, comprising a first copper bar, a second copper bar and a three-phase parallel copper bar, wherein the first copper bar is respectively connected to the three-phase lead-out wires of the stator winding and the second copper bar, and the second copper bar is used to be connected to a controller DC bus; the three-phase parallel copper bar is connected to the neutral point lead-out wire of the stator winding, and the three-phase parallel copper bar is used to reduce the current density per unit cross-section, and a sensor fixing rod for fixing a temperature sensor is provided on the three-phase parallel copper bar, and the temperature sensor is used to monitor the temperature of the first copper bar, the second copper bar, the three-phase parallel copper bar and the stator winding.

[0007] Furthermore, the first copper busbar includes a winding connection pin, a lead wire connection surface and a busbar connected in a mountain shape, and the lead wire connection surface protrudes relatively from the winding connection pin and the busbar; the winding connection pin is connected to the three-phase lead wire of the stator winding, the lead wire connection surface is used to connect to the second copper busbar, and the busbar is used for the current of the stator winding to pass through.

[0008] Furthermore, the second copper busbar includes a first copper busbar connector and a lead-out wire connector connected by a flexible connector, the first copper busbar connector is connected to the lead-out wire connection surface, and the lead-out wire connector is provided with a terminal for connecting a DC busbar of a controller.

[0009] Furthermore, the flexible connector is made of laminated soft copper material, and the flexible connector is arc-shaped.

[0010] Furthermore, the first copper bar, the first copper bar connector and the three-phase parallel copper bar are all coated with insulating powder.

[0011] Furthermore, the three-phase parallel copper bar includes a horizontal three-phase parallel copper bar and a vertical three-phase parallel copper bar. The horizontal three-phase parallel copper bar is horizontally arranged compared to the stator winding end; the vertical three-phase parallel copper bar is vertically arranged compared to the stator winding end.

[0012] Furthermore, the horizontal three-phase parallel copper busbar includes connected horizontal winding connection feet, a horizontal busbar and a first sensor fixing rod, the horizontal winding connection feet are connected to the neutral point lead-out line of the stator winding, and the horizontal busbar is used for the current of the stator winding to pass through.

[0013] Furthermore, the vertical three-phase parallel copper busbar includes connected vertical winding connecting feet, a vertical busbar and a second sensor fixing rod, the vertical winding connecting feet are connected to the neutral point lead-out line of the stator winding, and the vertical busbar is used for the current of the stator winding to pass through.

[0014] Further, the sensor fixing rod comprises the first sensor fixing rod and the second sensor fixing rod, and the temperature sensor is arranged on the first sensor fixing rod and / or the second sensor fixing rod through a fixing sleeve.

[0015] The present invention further provides a flat wire motor, comprising a stator, wherein the ends of the stator adopt a flat wire motor end connection device as described in any one of the above items.

[0016] Compared with the prior art, the present invention provides a flat wire motor end connection device and a flat wire motor, which have a simple structure. A first copper bar is respectively connected to the three-phase lead-out wires of the stator winding and the second copper bar, the second copper bar is connected to the DC bus of the controller, and the three-phase parallel copper bar is connected to the neutral point lead-out wire of the stator winding. The three-phase parallel copper bar reduces the current density per unit cross-section, and the temperature sensor is fixed on the sensor fixing rod of the three-phase parallel copper bar. While monitoring the temperatures of the first copper bar, the second copper bar, the three-phase parallel copper bar and the stator winding, the problem of large current circulating and heating through the flat wire motor can be improved, thereby avoiding burning and damage to the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0018] Figure 1 A schematic diagram of the structure of the flat wire motor end connection device provided by the present invention;

[0019] Figure 2 An exploded view of the flat wire motor end connection device provided by the present invention;

[0020] Figure 3 A schematic structural diagram of a first copper busbar provided by the present invention;

[0021] Figure 4 A schematic diagram of the structure of a second copper busbar provided by the present invention;

[0022] Figure 5 A schematic diagram of the structure of a horizontally placed three-phase parallel copper busbar provided by the present invention;

[0023] Figure 6 This is a schematic structural diagram of the vertical three-phase parallel copper busbar provided by the present invention.

[0024] Reference numerals:

[0025] 10 first copper bar 11 winding connection foot 12 lead wire connection surface

[0026] 13 busbar 20 second copper bar 21 flexible connector

[0027] 22 first copper bar connector 23 lead wire connector 24 protective sleeve

[0028] 30 three-phase parallel copper bar 31 horizontal three-phase parallel copper bar 311 horizontal winding connection foot

[0029] 312 horizontal busbar 313 first sensor fixing rod 32 vertical three-phase parallel copper busbar

[0030] 321 vertical winding connection foot 322 vertical busbar 323 second sensor fixing rod

[0031] 40 stator winding 50 temperature sensor 51 fixed sleeve DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0033] In the description of the present invention, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0034] Figure 1 The schematic diagram of the structure of the flat wire motor end connection device provided by the present invention is as follows: Figure 1 As shown, a flat wire motor end connection device provided by the present invention includes a first copper bar 10, a second copper bar 20 and a three-phase parallel copper bar 30, wherein the first copper bar 10 is respectively connected to the three-phase lead-out wires of the stator winding 40 and the second copper bar 20, and the second copper bar 20 is used to be connected to the controller DC bus; the three-phase parallel copper bar 30 is connected to the neutral point lead-out wire of the stator winding 40, and the three-phase parallel copper bar 30 is used to reduce the current density per unit cross-section, and a sensor fixing rod for fixing a temperature sensor 50 is provided on the three-phase parallel copper bar 30, and the temperature sensor 50 is used to monitor the temperature of the first copper bar 10, the second copper bar 20, the three-phase parallel copper bar 30 and the stator winding 40.

[0035] When implementing it, Figure 1 , Figure 2As shown, the first copper bar 10 is connected to the three-phase lead-out wires of the stator winding 40 and the second copper bar 20 respectively, the second copper bar 20 is used to be connected to the controller DC bus, the three-phase parallel copper bar 30 is connected to the neutral point lead-out wire of the stator winding 40, and the three-phase parallel copper bar 30 is also provided with a sensor fixing rod for fixing the temperature sensor 50. The temperature sensor 50 is used to monitor the temperatures of the first copper bar 10, the second copper bar 20, the three-phase parallel copper bar 30 and the stator winding 40. The three-phase parallel copper bar 30 is used to reduce the current density per unit cross-section to change the circulating current and heating phenomenon of the flat wire motor.

[0036] like Figure 1 , Figure 2 , Figure 3 As shown, the first copper bar 10 is vertically arranged relative to the end of the stator winding 40, and there are multiple first copper bars 10. The first copper bar 10 includes a winding connection foot 11, a lead wire connection surface 12 and a busbar 13 connected to each other. Specifically, the winding connection foot 11, the lead wire connection surface 12 and the busbar 13 are in a mountain shape, and the lead wire connection surface 12 protrudes relatively from the winding connection foot 11 and the busbar 13. The winding connection foot 11 is connected to the three-phase lead wire of the stator winding 40, and the lead wire connection surface 12 is connected to the second copper bar 20. The busbar 13 is used for the current of the stator winding to pass. Preferably, the number of the first copper bars 10 in this embodiment is three, the winding connection foot 11 is welded to the three-phase lead wire of the stator winding 40, and the lead wire connection surface 12 is welded to the second copper bar 20.

[0037] Specifically, Figure 1 , Figure 2 , Figure 4 As shown, the second copper busbar 20 includes a first copper busbar connector 22 and a lead-out wire connector 23 connected by a flexible connector 21. The first copper busbar connector 22 is connected to the lead-out wire connecting surface 23. The lead-out wire connector 23 is provided with a connecting terminal for connecting the DC bus of the controller. The shape of the connecting terminal can be a round hole or a square hole. The flexible connector 21 is made of soft copper material laminated, and the flexible connector 21 is arc-shaped. The second copper busbar 20 including the flexible connector 21 can effectively unload the assembly stress.

[0038] Preferably, in the present embodiment, the number of the second copper bars 20 matches the first copper bars 10, the first copper bar connector 22 and the lead wire connector 23 are rigid copper bars, the first copper bar connector 22 is welded to the lead wire connection surface 12, and a protective sleeve 24 is provided at the welding connection position between the first copper bar connector 22 and the lead wire connection surface 12, and the protective sleeve 24 is used to protect the welding connection position and insulate it; the first copper bar connector 22 and the lead wire connection surface 12 are both vertically arranged relative to the end of the stator winding 40, the lead wire connector 23 is horizontally arranged relative to the end of the stator winding 40, and the end of the lead wire connector 23 relatively away from the flexible connector 21 is provided with a circular hole-shaped connecting terminal.

[0039] Preferably, the first copper busbar 10, the first copper busbar connector 22 and the three-phase parallel copper busbar 30 are all coated with insulating powder. The insulating powder can be the common insulating powder in the prior art and will not be described here. The insulating powder coating can eliminate the insulating isolation piece, thereby reducing the processing and manufacturing cost as well as the mold opening cost.

[0040] like Figure 1 , Figure 2 As shown, the three-phase parallel copper bar 30 includes a horizontal three-phase parallel copper bar 31 and a vertical three-phase parallel copper bar 32. The horizontal three-phase parallel copper bar 31 is horizontally arranged compared to the end of the stator winding 40, and the vertical three-phase parallel copper bar 32 is vertically arranged compared to the end of the stator winding 40. The horizontal three-phase parallel copper bar 31 and the vertical three-phase parallel copper bar 32 are both connected to the neutral point lead-out line of the stator winding 40. The horizontal three-phase parallel copper bar 31 and the vertical three-phase parallel copper bar 32 separate the convergence of the neutral point of the stator winding 40 by multiple branches, effectively reducing the current density per unit cross-section, thereby improving the problem of large current circulation and heat generation through the flat wire motor.

[0041] Specifically, Figure 1 , Figure 2 , Figure 5 , Figure 6 As shown, the horizontal three-phase parallel copper bar 31 includes a horizontal winding connection foot 311, a horizontal busbar 312 and a first sensor fixing rod 313 connected to each other. The horizontal winding connection foot 311, the horizontal busbar 312 and the first sensor fixing rod 313 are all arranged horizontally relative to the end of the stator winding 40. The horizontal winding connection foot 311 and the first sensor fixing rod 313 extend relatively from the horizontal busbar 312. The horizontal winding connection foot 311 is connected to the neutral point lead-out line of the stator winding 40. The horizontal busbar 312 is used for the current of the stator winding 40 to pass through.

[0042] The vertical three-phase parallel copper busbar 32 includes a vertical winding connecting foot 321, a vertical busbar 322 and a second sensor fixing rod 323 which are connected to each other. The vertical winding connecting foot 321, the vertical busbar 322 and the second sensor fixing rod 323 are vertically arranged relative to the end of the stator winding 40. The vertical winding connecting foot 321 and the second sensor fixing rod 323 extend relative to the vertical busbar 322. The vertical winding connecting foot 321 is connected to the neutral point lead-out line of the stator winding 40. The vertical busbar 322 is used for the current passing through the stator winding.

[0043] like Figure 5 , Figure 6 As shown, the sensor fixing rod includes a first sensor fixing rod 313 and a second sensor fixing rod 323. The first sensor fixing rod 313 is arranged on the horizontal three-phase parallel copper busbar 31. Preferably, in this embodiment, the first sensor fixing rod 313 is located at the right end of the horizontal three-phase parallel copper busbar 31, and the second sensor fixing rod 323 is arranged on the vertical three-phase parallel copper busbar 32. Preferably, in this embodiment, the second sensor fixing rod 323 is located at the left end of the vertical three-phase parallel copper busbar 32.

[0044] The temperature sensor 50 is fixed to the first sensor fixing rod 313 and / or the second sensor fixing rod 323 through a fixing sleeve 51. The temperature sensor 50 is used to monitor the temperature and heating conditions of the first copper bar 10, the second copper bar 20, the three-phase parallel copper bar 30 and the stator winding 40. Preferably, the temperature sensor 50 is a common temperature sensor in the prior art and is not described in detail here.

[0045] The present invention provides a flat wire motor end connection device, when actually connected, such as Figures 1 to 6 As shown, first, the horizontal three-phase parallel copper bar 31 is horizontally arranged relative to the end of the stator winding 40, the horizontal winding connecting foot 311 is welded to the neutral point of the stator winding 40, and the vertical three-phase parallel copper bar 32 is vertically arranged relative to the end of the stator winding 40, and the vertical winding connecting foot 321 is welded to the neutral point of the stator winding 40; when the flat wire motor is actually running, the neutral point separation and confluence of the stator winding 40 can effectively reduce the current density per unit cross section, and improve the circulation and heat generation of the flat wire motor;

[0046] The first copper bar 10 is vertically arranged relative to the end of the stator winding 40, the winding connecting foot 11 is welded to the three-phase lead wire of the stator winding 40, the lead wire connecting surface 12 is welded to the first copper bar connector 22, and the connecting terminal on the lead wire connector 23 is used to connect to the controller DC bus; when the flat wire motor is actually running, the current of the stator winding 40 passes through the busbar 13, the horizontal busbar 312 and the vertical busbar 322.

[0047] Next, insulating powder is coated on the first copper bar 10, the first copper bar connector 22, the horizontal three-phase parallel copper bar 31 and the vertical three-phase parallel copper bar 32 to achieve insulation between electrical components, and then a protective sleeve 24 is set on the welding connection position between the lead wire connection surface 12 and the first copper bar connector 22 to protect the welding connection position and insulate it; after the insulating powder coating is completed, the temperature sensor 50 is fixed to the first sensor fixing rod 313 and / or the second sensor fixing rod 323 through the fixing sleeve 51. When the flat wire motor is running, the temperature sensor 50 can monitor the temperature and heating conditions of the first copper bar 10, the second copper bar 20, the horizontal three-phase parallel copper bar 31, the vertical three-phase parallel copper bar 32 and the stator winding 40, so as to make timely warnings or processing.

[0048] Compared with the prior art, the flat wire motor end connection device provided by the present invention has a simple structure. The first copper bar is respectively connected to the three-phase lead-out wires of the stator winding and the second copper bar, the second copper bar is connected to the DC bus of the controller, the three-phase parallel copper bar is connected to the neutral point lead-out wire of the stator winding, the three-phase parallel copper bar reduces the current density per unit cross-section, and the temperature sensor is fixed on the sensor fixing rod of the three-phase parallel copper bar. While monitoring the temperatures of the first copper bar, the second copper bar, the three-phase parallel copper bar and the stator winding, it can also improve the problem of large current circulating and heating through the flat wire motor, thereby avoiding burning and damage to the motor.

[0049] The present invention further provides a flat wire motor, comprising a stator, wherein the ends of the stator adopt a flat wire motor end connection device as described in any one of the above items.

[0050] Compared with the prior art, the present invention provides a flat wire motor end connection device and a flat wire motor, which have a simple structure. A first copper bar is respectively connected to the three-phase lead-out wires of the stator winding and the second copper bar, the second copper bar is connected to the DC bus of the controller, and the three-phase parallel copper bar is connected to the neutral point lead-out wire of the stator winding. The three-phase parallel copper bar reduces the current density per unit cross-section, and the temperature sensor is fixed on the sensor fixing rod of the three-phase parallel copper bar. While monitoring the temperatures of the first copper bar, the second copper bar, the three-phase parallel copper bar and the stator winding, the problem of large current circulating and heating through the flat wire motor can be improved, thereby avoiding burning and damage to the motor.

[0051] Although the terms such as first copper bar, winding connection pin, lead wire connection surface, busbar, second copper bar, three-phase parallel copper bar, first sensor fixing rod and second sensor fixing rod are used more frequently in this article, the possibility of using other terms is not excluded. These terms are used only to more conveniently describe and explain the essence of the present invention; interpreting them as any additional limitation is contrary to the spirit of the present invention.

[0052] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flat wire motor end connection device, characterized in that: It comprises a first copper bar (10), a second copper bar (20) and a three-phase parallel copper bar (30), wherein the first copper bar (10) is respectively connected to the three-phase lead wires of the stator winding (40) and the second copper bar (20), and the second copper bar (20) is used to be connected to a controller DC bus; The first copper bar (10) comprises a winding connection foot (11), a lead wire connection surface (12) and a busbar (13) connected in a mountain shape, wherein the lead wire connection surface (12) protrudes relatively from the winding connection foot (11) and the busbar (13); the winding connection foot (11) is connected to the three-phase lead wires of the stator winding (40), the lead wire connection surface (12) is used to connect to the second copper bar (20), and the busbar (13) is used for the current of the stator winding (40) to pass through; The second copper busbar (20) comprises a first copper busbar connector (22) and a lead-out wire connector (23) connected via a flexible connector (21), the first copper busbar connector (22) being connected to the lead-out wire connection surface (12), and the lead-out wire connector (23) being provided with a connection terminal for connecting to a controller DC busbar; The three-phase parallel copper bar (30) is connected to the neutral point lead-out line of the stator winding (40). The three-phase parallel copper bar (30) comprises a horizontal three-phase parallel copper bar (31) and a vertical three-phase parallel copper bar (32). The horizontal three-phase parallel copper bar (31) is arranged horizontally compared to the end of the stator winding (40); the vertical three-phase parallel copper bar (32) is arranged vertically compared to the end of the stator winding (40). The three-phase parallel copper bar (30) is used to reduce the current density per unit cross section. A sensor fixing rod for fixing a temperature sensor (50) is provided on the three-phase parallel copper bar (30). The temperature sensor (50) is used to monitor the temperature of the first copper bar (10), the second copper bar (20), the three-phase parallel copper bar (30) and the stator winding (40).

2. A flat wire motor end connection device according to claim 1, characterized in that: The flexible connecting piece (21) is made of laminated soft copper material, and the flexible connecting piece (21) is arc-shaped.

3. The flat wire motor end connection device according to claim 1, characterized in that: The first copper busbar (10), the first copper busbar connector (22) and the three-phase parallel copper busbar (30) are all coated with insulating powder.

4. The flat wire motor end connection device according to claim 1, characterized in that: The horizontal three-phase parallel copper bar (31) comprises a horizontal winding connection foot (311), a horizontal busbar (312) and a first sensor fixing rod (313) connected to each other; the horizontal winding connection foot (311) is connected to a neutral point lead-out line of a stator winding (40); and the horizontal busbar (312) is used for the current of the stator winding (40) to pass through.

5. A flat wire motor end connection device according to claim 4, characterized in that: The vertical three-phase parallel copper busbar (32) comprises a vertical winding connection foot (321), a vertical busbar (322) and a second sensor fixing rod (323) connected to each other; the vertical winding connection foot (321) is connected to a neutral point lead-out line of a stator winding (40); and the vertical busbar (322) is used for the current of the stator winding to pass through.

6. A flat wire motor end connection device according to claim 5, characterized in that: The sensor fixing rod comprises the first sensor fixing rod (313) and the second sensor fixing rod (323), and the temperature sensor (50) is arranged on the first sensor fixing rod (313) and / or the second sensor fixing rod (323) via a fixing sleeve (51).

7. A flat wire motor, characterized in that: It comprises a stator, and the end of the stator adopts a flat wire motor end connection device as described in any one of claims 1-6.

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