Busbars, motors and vehicles

Abstract

This invention provides a bus, a motor, and a vehicle. The bus includes: a frame, which is an insulating component; multiple busbars, each busbar including a main body embedded in the frame and extending circumferentially along the frame, and multiple connecting portions connected to the main body and protruding outward from the frame, the multiple connecting portions being used to connect to the terminals of the motor stator windings; and multiple terminals connected to the multiple busbars for connecting to a power source. The main bodies of all busbars are stacked and spaced apart along the axial direction of the frame, and the connecting portions of all busbars are spaced apart along the circumferential direction of the frame, with the end faces of the connecting portions away from the stator windings flush with the axial direction of the frame. This design facilitates control over the stripping position of each terminal, facilitates welding of the terminals and connecting portions on the production line, and facilitates trimming of excess wire ends after welding, thereby significantly improving production efficiency, shortening the production cycle, and improving product consistency.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and more specifically, to a bus, a motor including the bus, and a vehicle including the motor. Background Technology

[0002] Motor stators typically have multiple windings, each with two terminals: a start terminal and an end terminal. The start and end terminals of different windings need to be interconnected according to product requirements to ensure normal motor operation. This wiring method is relatively complex, which is not conducive to fast and efficient operation on the production line and reduces product production efficiency. Summary of the Invention

[0003] In order to solve at least one of the above-mentioned technical problems, one object of the present invention is to provide a bus.

[0004] Another object of the present invention is to provide a motor including the above-described busbar.

[0005] Another object of the present invention is to provide a vehicle including the above-described motor.

[0006] To achieve the above objectives, the first aspect of the present invention provides a busbar, comprising: a frame, the frame being an insulating component; a plurality of busbars, each busbar including a main body portion embedded in the frame and extending along the circumferential direction of the frame, and a plurality of connecting portions connected to the main body portion and protruding outward from the frame, the plurality of connecting portions being used to connect to the terminals of a motor stator winding; and a plurality of terminals connected to the plurality of busbars for connecting to a power source; wherein the main bodies of all the busbars are stacked and spaced apart from each other along the axial direction of the frame, the connecting portions of all the busbars are spaced apart along the circumferential direction of the frame, and the end faces of the connecting portions of all the busbars away from the stator winding are flush with the axial direction of the frame.

[0007] The busbar provided by the first aspect of the present invention can connect the terminals of multiple windings of a motor stator using the connecting parts of multiple busbars, and achieve electrical connection of corresponding terminals by utilizing the good conductivity of the busbars, without having to directly connect the corresponding terminals. This reduces wiring difficulty, facilitates efficient and rapid operation on the production line, and improves product production efficiency. Simultaneously, all connecting parts are spaced apart along the circumferential direction of the frame, corresponding to the terminals of the multiple windings spaced apart along the circumferential direction on the motor stator. Furthermore, the end faces of all connecting parts away from the stator windings are flush with the axial direction of the frame. This ensures that the terminals of the multiple windings of the motor stator maintain a consistent shape and size, facilitating control of the paint stripping position of each terminal, easy welding of terminals to connecting parts on the production line, and easy trimming of excess wire after welding. This significantly improves production efficiency, shortens the production cycle, and enhances product consistency.

[0008] Specifically, the busbar includes a frame, multiple busbars, and multiple terminals. The frame is an insulating component, which can be injection molded. It supports the multiple busbars and terminals and isolates adjacent busbars, providing electrical insulation. The multiple busbars are all conductors. Each busbar includes a main body and multiple connecting parts. The multiple connecting parts of each busbar are used to connect the terminals of multiple windings of the electronic stator that need to be connected together. The main body realizes the electrical connection of these terminals, realizing the busbar function. The multiple terminals are connected to the multiple busbars. Each terminal is electrically connected to the terminal of the corresponding busbar. The multiple terminals are connected to the power supply to form an electrical circuit, which supplies power to the multiple windings of the motor stator. In this process, the main body of multiple busbars is stacked along the axial direction of the frame, so the radial dimensions of the multiple main body can be kept consistent. Multiple busbars connected to terminals are simply stacked together to ensure that all connecting parts are spaced apart along the circumferential direction of the frame, and that the end faces of all connecting parts away from the stator winding are flush in the axial direction, and that the positions of multiple terminals are correct. Then, the frame can be processed by integral injection molding. The processing technology is relatively simple, and the structure of the frame is also relatively simple. Since all the connecting parts of the busbar are distributed at intervals along the circumferential direction of the frame and correspond to the positions of multiple terminals of the motor stator, it is not necessary to reserve a long length of the terminal to ensure that it can extend to the position of other terminals and connect with them. This shortens the length of the terminal and effectively prevents the terminals from getting tangled or confused during the wiring process, thereby reducing the difficulty of wiring. In addition, the end faces of all connecting parts away from the stator winding are kept flush in the axial direction of the frame (that is, the end faces of all connecting parts away from the stator winding are located on the same plane perpendicular to the central axis of the frame). Since the wire ends above the connecting parts are cut off when cutting the wire, the terminals of all windings can also be kept flush and reserved with the same length. After welding, the excess wire ends are cut off at the same position, achieving a high degree of consistency in the wiring operation. This is convenient for both manual and machine operation, and thus helps to significantly improve the production line efficiency.

[0009] In addition, the bus in the above-mentioned technical solution provided by the present invention may also have the following additional technical features:

[0010] In the above technical solution, the end faces of all the connecting parts of the busbars near the stator windings are kept flush with the axial direction of the frame, so that all the connecting parts are kept flush with the axial direction of the frame.

[0011] All busbar connections are flush with the stator winding end faces in the axial direction of the frame (i.e., all connections are located on the same plane perpendicular to the central axis of the frame). This flush alignment allows for the removal of the outer enamel coating from the wire during wiring, improving consistency and enabling all connections to have the same shape, thus enhancing product regularity and ease of manufacturing.

[0012] In the above technical solution, at least a portion of the busbar also includes an extension portion, which is located between the outer periphery of the main body and the connecting portion, for connecting the main body and the connecting portion, and the extension portion extends at least partially along the axial direction of the skeleton, so that all the connecting portions remain flush with the axial direction of the skeleton.

[0013] At least some busbars include extensions, with each end of the extension connecting to the main body and a connecting part, respectively. Since the extensions extend at least partially along the axial direction of the frame, multiple connecting parts can easily achieve axial alignment with the frame, facilitating the design of the connecting parts' shape and size as needed, thus optimizing the product structure. Specifically, only some busbars may include extensions, using these extensions to keep their connecting parts flush with the extensions of other busbars without extensions; alternatively, all busbars may include extensions, with different extensions extending axially by different dimensions, ensuring all connecting parts remain axially aligned. Of course, busbars may also not have extensions, achieving axial alignment of all connecting parts directly through the specific connection positions between the connecting parts and the main body, and through the rational design of the connecting parts' shape and size.

[0014] In the above technical solution, the extension is embedded in the skeleton.

[0015] With the extension embedded in the frame, only the connecting parts are exposed outside the frame. This makes the busbar's appearance structure more regular, and the frame can provide good support for the extension, preventing deformation or shaking. This improves the stability of each connecting part, which is beneficial for production line operations and further improves production efficiency.

[0016] In any of the above technical solutions, the connecting part is provided with a limiting groove adapted to the terminal, the limiting groove is for the terminal to pass through and is suitable for welding connection with the terminal.

[0017] The connection part is equipped with a limiting groove. During the wiring operation, the terminal is passed through the limiting groove before welding. The limiting groove can not only effectively limit the terminal and prevent it from shaking or tilting, but also increase the contact area between the terminal and the connection part, thereby reducing the welding difficulty and further improving production efficiency.

[0018] In the above technical solution, the connecting part includes a connecting piece and a bending piece. The connecting piece is connected to the main body and extends along the circumferential direction of the skeleton. The bending piece is connected to the connecting piece and bends and extends, and together with the connecting piece, they form a U-shaped limiting groove.

[0019] The connecting part includes a connecting piece and a bending piece. The connecting piece and the bending piece form a U-shaped limiting groove, so that the limiting groove has a structure with open ends in the axial direction and notches in the circumferential direction (that is, the projection of the limiting groove on the axial end face of the skeleton is U-shaped). This helps to increase the space of the limiting groove, making it easier for the wiring terminal to pass through quickly. It also helps to increase the space for welding operations and reduce the difficulty of welding operations.

[0020] In the above technical solution, the thickness direction of the connecting piece and the thickness direction of the bending piece are perpendicular to the axial direction of the skeleton.

[0021] The thickness directions of the connecting piece and the bending piece are both perpendicular to the axis of the skeleton. This increases the depth of the limiting groove, which helps to increase the contact area between the limiting groove and the wiring terminal. This not only helps to further reduce the welding difficulty, but also helps to improve the welding connection strength.

[0022] In the above technical solution, the U-shaped openings of all the limiting grooves face the same rotation direction.

[0023] All the U-shaped openings of the limiting slots face the same direction of rotation, such as clockwise or counterclockwise, which makes the structure of the busbar more regular. This facilitates the processing and shaping of each busbar and allows all terminals to pass through the limiting slots synchronously by rotating the busbar appropriately during production line operation, thus further improving production efficiency.

[0024] In the above technical solution, the dimension of the connecting piece along the circumferential direction of the skeleton is greater than the dimension of the bent piece and its opposite portion along the circumferential direction of the skeleton.

[0025] If the dimension of the connecting piece along the circumferential direction of the skeleton is greater than the dimension of the portion of the bent piece opposite to the connecting piece along the circumferential direction of the skeleton, then the connecting piece and the bent piece form a J-shaped structure. This facilitates the reasonable setting of the position of the limiting groove and provides a more favorable operating space for the welding operation of the wiring terminal.

[0026] In any of the above technical solutions, the connecting part includes an extension piece extending in the radial direction of the skeleton, the inner radial end of the extension piece being connected to the main body, and the outer radial end of the extension piece being connected to the part of the connecting part used to connect the terminal.

[0027] The connecting part also includes an extension piece, which extends along the radial direction of the skeleton, and its inner and outer ends are respectively connected to the main body and the part of the connecting part used to connect the terminal (as in the aforementioned technical solution). This increases the radial distance between the part of the connecting part used to connect the terminal and the main body, which is beneficial to reducing the radial dimension of the main body to reduce production costs, and also beneficial to increasing the distance between adjacent connecting parts. Therefore, it is beneficial to rationally design the shape and size of the connecting part and further optimize the product structure.

[0028] In the above technical solution, the busbar connected to the terminal is connected to the terminal through an extension piece of one of the connecting parts.

[0029] For a busbar with a terminal, the busbar is connected to the terminal through an extension of one of the connecting parts. This eliminates the need to design additional structures on the busbar to connect the terminal, thus simplifying the structure of the busbar and preventing an increase in the radial dimension of the busbar.

[0030] In the above technical solution, the extension piece is perpendicular to the axial direction of the skeleton, the terminal is in the shape of a sheet, and the dimension a0 of the extension piece connected to the terminal along the thickness direction of the terminal is greater than the dimension a of the other extension pieces of the same busbar along the thickness direction of the terminal.

[0031] The extension tab is perpendicular to the axis of the frame, which helps to reduce the axial dimension of the busbar. The dimension a0 of the extension tab connected to the terminal along the thickness direction of the terminal is greater than the dimension a of other extension tabs on the same busbar along the thickness direction of the terminal. This helps to increase the contact area between the extension tab and the terminal, thereby improving the connection strength and stability of the terminal and reducing the probability of terminal deformation.

[0032] In the above technical solution, the terminal is bent into an L-shape, including an extension section parallel to the axis of the skeleton and a connecting section parallel to the extension piece, and the connecting section is welded to the extension piece.

[0033] The terminal bending feature includes an extension section and a connecting section. The extension section extends along the axis of the frame to connect to the power supply, and the connecting section is parallel to the extension piece and welded to it. This increases the contact area between the terminal and the extension piece, thereby improving the connection strength and stability of the terminal and reducing the probability of terminal deformation.

[0034] In the above technical solution, the dimension b0 of the portion of the extension piece connected to the terminal for connecting the terminal along the circumferential direction of the frame is greater than the dimension b of other portions on the same busbar for connecting the terminal along the circumferential direction of the frame.

[0035] The circumferential dimension of the portion of the extension piece connected to the terminal, corresponding to the portion for connecting the terminal, is appropriately increased relative to the circumferential dimension of other portions of the busbar for connecting the terminal along the frame. This increases the circumferential distance between the terminal and the portion of the connection part for connecting the terminal, thereby providing clearance space and facilitating the soldering operation of the terminal.

[0036] In any of the above technical solutions, all the busbars are divided into neutral busbars and multiple phase busbars. Multiple terminals correspond one-to-one with and are connected to multiple phase busbars. The main bodies of multiple phase busbars are arranged adjacent to each other in sequence. The main body of the neutral busbar is located facing the winding.

[0037] All busbars are divided into neutral busbars and phase busbars. The circuits formed by the terminals connected to the phase busbars (such as the ends of some windings) and the circuits formed by the terminals connected to the neutral busbars (such as the beginnings of all windings) can be connected in parallel to form multi-phase circuits. Since phase busbars have relatively fewer terminals connected to them, while neutral busbars have relatively more, the number of connection points for phase busbars is also less than that for neutral busbars. Therefore, by arranging the main bodies of multiple phase busbars adjacent to each other, only the axial position of the connection points of the phase busbars needs to be changed to align with the axial position of the neutral busbar, without changing the axial position of the connection points of the central busbar. This reduces processing difficulty and improves production efficiency. If the main body of the neutral busbar is positioned facing the windings, the connection points of the phase busbars can be offset closer to the windings, which helps shorten the distance between the terminals and the connection points, thereby shortening the terminal length and reducing the difficulty of soldering the terminals.

[0038] Of course, the arrangement of the busbars can be changed arbitrarily.

[0039] In the above technical solution, the connecting part of the neutral busbar is directly connected to its main body, and the connecting part of each phase busbar is connected to its main body through an extension. The extension extends along the axial direction of the skeleton towards the neutral busbar, so that the connecting part of the phase busbar and the connecting part of the neutral busbar are flush with each other in the axial direction of the skeleton.

[0040] The neutral busbar's connecting portion is directly connected to its main body, while the connecting portion of each phase busbar is connected to its main body via an extension. That is, the neutral busbar has no extension, while multiple phase busbars include extensions that extend towards the neutral busbar. The axial lengths of the extensions of the multiple phase busbars are unequal, ensuring that the connecting portion of each phase busbar is flush with the connecting portion of the neutral busbar in the axial direction of the frame. This effectively simplifies the structure of the neutral busbar and further shortens the distance between the terminal and the connecting portion, thus facilitating a further reduction in terminal length and welding difficulty.

[0041] In any of the above technical solutions, the two ends of the connecting parts of all the busbars do not protrude from the plane containing the two axial end faces of the frame.

[0042] All connecting parts do not protrude beyond the plane containing the axial end faces of the frame at both ends. Compared to connecting parts protruding beyond the axial end faces of the frame, the axial height of the busbar can be reduced, resulting in less space occupied in the axial direction of the busbar. This is beneficial for reducing the axial length of the motor and optimizing the motor structure.

[0043] In any of the above technical solutions, the thickness t of all the main body parts is equal; and / or the spacing t2 between adjacent main body parts is equal.

[0044] If all busbars have the same thickness in their main body, all busbars can be made from the same material, which helps reduce the types of raw materials, facilitates processing and molding, and saves costs. Optionally, the thickness of the busbars can be in the range of 0.7mm-1.0mm (e.g., 0.7mm, 0.8mm, 0.9mm, 1.0mm, etc.).

[0045] The equal spacing between adjacent main sections ensures a regular internal structure of the busbar and guarantees electrical insulation between each busbar. Optionally, the spacing between adjacent main sections is 0.5mm-3mm (e.g., 0.5mm, 1mm, 2mm, 3mm, etc.).

[0046] In any of the above technical solutions, the skeleton includes an annular bracket and a plurality of strip brackets integrally connected to the annular bracket. The main body of all the busbars is embedded in the annular bracket. The plurality of strip brackets correspond one-to-one with the plurality of terminals, and a portion of each terminal is embedded in the corresponding strip bracket.

[0047] The frame includes a ring-shaped support and strip-shaped supports. The ring-shaped support supports multiple busbars and ensures insulation between them. The strip-shaped supports support multiple terminals and ensure electrical insulation between the terminals and other structures. Since the ring-shaped support and the strip-shaped supports are integrally connected—specifically, formed as a single unit during injection molding—the connection is more reliable. Compared to existing technologies that separately mold insulating components and then attach them to the terminals, this design provides excellent support and positioning for the terminals, effectively preventing them from shaking or deforming. This ensures good positional and perpendicularity of the terminals, resulting in a robust structure. Furthermore, when the controller PIN is inserted into the terminal, the portion of the terminal exposed above the strip-shaped support is less prone to deformation and failure.

[0048] In the above technical solution, the dimension c of the strip-shaped support along the axial direction of the skeleton is greater than or equal to half of the dimension c0 of the terminal along the axial direction of the skeleton.

[0049] If the dimension c of the strip support along the axis of the skeleton is greater than or equal to half of the dimension c0 of the terminal along the axis of the skeleton, then the area of ​​the strip skeleton covering the terminal exceeds half of the terminal. Therefore, it can significantly improve the supporting and limiting effect on the terminal, effectively ensuring the stability and reliability of the terminal.

[0050] In the above technical solution, the terminal is connected to one of the connecting parts of the corresponding busbar. In the projection of the plane perpendicular to the central axis of the frame, the strip-shaped bracket is asymmetrically arranged about the terminal in the thickness direction of the terminal, and the size d1 of the part near the corresponding connecting part for connecting the terminal is smaller than the size d2 of the part away from the corresponding connecting part for connecting the terminal.

[0051] When a terminal is connected to one of the connecting parts of a corresponding busbar, the terminal and the part of the connecting part used for connecting the wiring terminal are relatively close. However, the circumferential wrapping of the strip support around the terminal may interfere with the soldering operation of the wiring terminal. Therefore, the strip support is arranged asymmetrically, with the part closer to the connecting wiring terminal being relatively thinner and the part farther away from the connecting wiring terminal being relatively thicker. This ensures reliable support for the terminal while avoiding the part of the connecting part used for connecting the wiring terminal, leaving space for the soldering operation of the wiring terminal and helping to reduce the difficulty of the soldering operation.

[0052] In the above technical solution, the dimension d of one of the strip supports along the thickness direction of the terminal is different from the dimension d of the other strip supports along the thickness direction of the terminal.

[0053] One of the strip supports has a different dimension along the thickness direction of the terminal than the other strip supports, making the three strip supports not completely identical in appearance. This can prevent assembly errors, facilitate quick identification of each busbar, and thus locate the relative position between the busbar and the stator winding, which is beneficial to further improve production efficiency.

[0054] In any of the above technical solutions, the main body has a ring structure; or, the main body has an arc-shaped structure.

[0055] The main body of the busbar has a complete ring structure, which helps to improve the strength of the busbar, thereby improving the stability and reliability of the busbar.

[0056] The main body of the busbar has an arc-shaped structure, not a complete ring. This allows for a reduction in the circumferential length of the main body while maintaining the same number of connecting parts. This helps save raw materials and facilitates processing and shaping, such as by bending.

[0057] In any of the above technical solutions, the projection of the terminal on the axial end face of the skeleton is elongated, and the length direction of its projection extends along the radial direction of the skeleton; or, the projection of the terminal on the axial end face of the skeleton is elongated, and the length direction of its projection extends along the circumferential direction of the skeleton.

[0058] The projection of the terminal onto the axial end face of the busbar is elongated. Since the terminal is generally a thin, elongated sheet extending along the axis of the busbar, the projection of the terminal onto the axial end face of the busbar is essentially the same as the shape of the terminal's cross-section. The length of this projection extends radially along the busbar, making efficient use of the busbar's radial space and meeting customer requirements for radial terminal arrangement. Alternatively, the length of this projection can also extend circumferentially along the busbar, making efficient use of the busbar's circumferential space and meeting customer requirements for circumferential terminal arrangement, while also reducing the busbar's radial dimensions.

[0059] In any of the above technical solutions, the plurality of terminals are uniformly arranged along the circumferential direction of the busbar; and / or, the plurality of connecting portions are uniformly distributed along the circumferential direction of the main body.

[0060] Multiple terminals are evenly distributed along the circumference of the busbar, resulting in a relatively regular structure. This arrangement helps increase the distance between terminals, ensuring electrical insulation between them and meeting customer requirements for uniform circumferential distribution. Of course, multiple terminals can also be concentrated in one area or distributed in other ways.

[0061] Multiple connecting parts are evenly distributed along the circumferential direction of the main body, making the structure of the busbar more regular, which is easy to process and shape. It also ensures that all connecting parts of the busbar are evenly distributed along the circumferential direction after assembly. Since the terminals of the motor stator winding are also generally evenly distributed along the circumferential direction, a one-to-one correspondence is maintained.

[0062] In any of the above technical solutions, the number of busbars is four, the number of terminals is three, the number of connection parts of the three busbars is equal, and the number of connection parts of the other busbar is the sum of the number of connection parts of the other three busbars.

[0063] There are four busbars and three terminals, which can be connected in a proper manner to form a three-phase motor. Three of the busbars are phase busbars, which are connected to an equal number of terminals to form the U-phase busbar, V-phase busbar, and W-phase busbar, respectively. The other busbar is a neutral busbar, which is connected to the other terminal of all windings.

[0064] In any of the above technical solutions, the surface of the frame facing away from the terminal is provided with a hook for engaging the motor stator.

[0065] Hooks are provided on the surface of the frame away from the terminals to facilitate engagement with the stator and prevent the busbar from shaking, tilting, or shifting during welding, which helps to further improve production efficiency.

[0066] The second aspect of the present invention provides an electric motor, comprising: an electric motor body including a stator, the stator having windings having two terminals; and a busbar as described in any one of the first aspects of the present invention, wherein the connecting portion of the busbar is connected to the terminals.

[0067] The motor provided by the second aspect of the present invention, since it includes the busbar described in any one of the first aspects of the technical solution, has all the beneficial effects of any of the above technical solutions, which will not be repeated here.

[0068] In the above technical solution, the number of windings is 12, and the 12 windings are connected in a star connection manner.

[0069] Because the 12 windings have 24 terminals and are connected in a star configuration, the 12 wire ends at the starting points of the 12 windings need to be connected together, and the ending points of windings 1, 4, 7, and 10, windings 2, 5, 8, and 11, and windings 3, 6, 9, and 12 need to be connected together separately, making the wiring method very complex. The solution proposed in this application effectively reduces the wiring difficulty, resulting in a simple and reliable connection. Of course, the number of windings is not limited to 12; it can also be 9, 15, etc.; the connection method of the windings is not limited to the above method; it can also be a delta connection or other methods.

[0070] The third aspect of the present invention provides a vehicle, comprising: a vehicle body; and an electric motor as described in any one of the second aspects, installed in the vehicle body.

[0071] The vehicle provided by the third aspect of the present invention, having included the motor described in the second aspect, possesses all the beneficial effects of any of the aforementioned technical solutions, which will not be repeated here.

[0072] Additional aspects and advantages of the invention will become apparent in the following description or may be learned by practice of the invention. Attached Figure Description

[0073] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0074] Figure 1 This is a schematic diagram of the structure of the U-phase busbar according to some embodiments of the present invention;

[0075] Figure 2 yes Figure 1 A top view of the U-phase busbar structure shown;

[0076] Figure 3 yes Figure 2 A schematic cross-sectional view of the U-phase busbar shown.

[0077] Figure 4 This is a schematic diagram of the structure of the V-phase busbar according to some embodiments of the present invention;

[0078] Figure 5 yes Figure 4 A top view of the V-phase busbar structure shown;

[0079] Figure 6 yes Figure 5 A schematic cross-sectional view of the V-phase busbar shown.

[0080] Figure 7 This is a schematic diagram of the structure of the W-phase busbar according to some embodiments of the present invention;

[0081] Figure 8 yes Figure 7 The diagram shows a top view of the W-phase busbar structure.

[0082] Figure 9 yes Figure 8 A schematic cross-sectional view of the W-phase busbar shown.

[0083] Figure 10 This is a top view schematic diagram of the phase busbar and terminal connection according to some embodiments of the present invention;

[0084] Figure 11 yes Figure 10 Schematic diagram of the cross-sectional structure along the AA direction;

[0085] Figure 12 yes Figure 10 A front view schematic diagram of the structure shown;

[0086] Figure 13 This is a three-dimensional structural schematic diagram of the neutral busbar described in some embodiments of the present invention;

[0087] Figure 14 yes Figure 13 A top view of the neutral busbar structure shown.

[0088] Figure 15 yes Figure 14 Schematic diagram of the cross-sectional structure along the BB direction;

[0089] Figure 16 This is an assembly diagram of the neutral busbar, the W-phase busbar, and a corresponding terminal as described in some embodiments of the present invention;

[0090] Figure 17 yes Figure 16 This is an assembly diagram of the neutral busbar, W-phase busbar, V-phase busbar, and the corresponding two terminals as described in some embodiments of the present invention;

[0091] Figure 18 This is an assembly diagram of the neutral busbar, W-phase busbar, V-phase busbar, U-phase busbar, and the corresponding three terminals as described in some embodiments of the present invention;

[0092] Figure 19 This is a schematic diagram of the main view structure of the bus described in some embodiments of the present invention;

[0093] Figure 20 This is a top view schematic diagram of the busbar structure described in some embodiments of the present invention;

[0094] Figure 21 yes Figure 20 Schematic diagram of the cross-sectional structure along the CC direction;

[0095] Figure 22 yes Figure 20 A combined diagram of the cross-sectional view of the central CC direction and a partial cross-sectional view of another part of the busbar;

[0096] Figure 23 yes Figure 20 Schematic diagram of the cross-sectional structure along the DD direction;

[0097] Figure 24 This is a partial top view of the motor structure described in some embodiments of the present invention;

[0098] Figure 25 yes Figure 24 Schematic diagram of the cross-sectional structure along the EE direction;

[0099] Figure 26 This is a schematic diagram showing the distribution of the motor stator windings and terminals according to some embodiments of the present invention;

[0100] Figure 27 yes Figure 26 The diagram shows the winding wiring of the motor.

[0101] Figure 28 yes Figure 26 The circuit connection diagram of the motor shown is illustrated.

[0102] in, Figures 1 to 26 The correspondence between the reference numerals and component names in the attached drawings is as follows:

[0103] 1. Frame, 11. Ring-shaped bracket, 12. Strip-shaped bracket, 13. Hook, 2. Busbar, 21. Main body, 211. First end, 212. Second end, 22. Connecting part, 221. Extension piece, 222. Connecting piece, 223. Bending piece, 23. Extension part, 24. Neutral busbar, 251. U-phase busbar, 252. V-phase busbar, 253. W-phase busbar, 26. Limiting groove, 3. Terminal, 31. Extension section, 32. Connecting section, 4. Motor body, 41. Terminal, 42. Stator. Detailed Implementation

[0104] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0105] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0106] The following reference Figures 1 to 28 This invention describes a bus and a motor according to some embodiments of the present invention.

[0107] First, we will introduce an embodiment of the first aspect, specifically a bus.

[0108] Example 1

[0109] A busbar includes: a frame 1, multiple busbars 2, and multiple terminals 3, such as... Figure 20 As shown.

[0110] Specifically, frame 1 is an insulating component.

[0111] Each busbar 2 includes a main body 21 and multiple connecting parts 22, such as Figures 1 to 9 as well as Figure 13 and Figure 14 As shown. The main body 21 is embedded within the skeleton 1 (as shown). Figure 19 and Figure 20 As shown), and extends along the circumferential direction of skeleton 1, as... Figure 1 , Figure 2 , Figure 4 , Figure 5 , Figure 7 , Figure 8 , Figure 13 and Figure 14 As shown; multiple connecting parts 22 are connected to the main body 21 and protrude outward from the frame 1, as... Figure 20 As shown, terminal 41 is used to connect the windings of motor stator 42.

[0112] Multiple terminals 3 are connected to multiple busbars 2, such as Figures 16 to 18 As shown, it is used to connect the power supply.

[0113] Among them, the main body 21 of all busbars 2 are stacked and arranged along the axial direction of the skeleton 1 (e.g. Figures 16 to 18 As shown), and they are spaced apart from each other (as shown). Figures 21 to 23 As shown), the connection portions 22 of all busbars 2 are spaced apart along the circumferential direction of the frame 1, and the end faces of all busbars 2 that are away from the stator winding are flush with the axial direction of the frame 1, as shown. Figure 18 and Figure 19 As shown.

[0114] The bus provided in this embodiment can connect the terminals 41 of multiple windings of the motor stator 42 using the connecting parts 22 of multiple busbars 2, and achieve electrical connection of the corresponding terminals 41 by utilizing the good conductivity of the busbars 2, without having to directly connect the corresponding terminals 41. This reduces the difficulty of wiring, facilitates efficient and rapid operation on the production line, and helps improve product production efficiency.

[0115] Meanwhile, all the connecting parts 22 are spaced apart along the circumferential direction of the frame 1, corresponding to the terminals 41 of the multiple windings spaced apart along the circumferential direction on the motor stator 42. Furthermore, the end faces of all the connecting parts 22 away from the stator windings are flush with the axial direction of the frame 1. This ensures that the terminals 41 of the multiple windings of the motor stator 42 maintain a consistent shape and size. This facilitates control over the stripping position of each terminal 41, facilitates welding of the terminals 41 to the connecting parts 22 on the production line, and makes it easier to trim excess wire ends after welding. This significantly improves production efficiency, shortens the production cycle, and enhances product consistency.

[0116] Specifically, the busbar includes a frame 1, multiple busbars 2, and multiple terminals 3. The frame 1 is an insulating component, which can be injection molded. It supports the multiple busbars 2 and the multiple terminals 3, and isolates adjacent busbars 2, providing electrical insulation. The multiple busbars 2 are all conductors, and each busbar 2 includes a main body 21 and multiple connecting parts 22. The multiple connecting parts 22 of each busbar 2 are used to connect the terminals 41 of the multiple windings of the electronic stator 42 that need to be connected together, and the electrical connection of these terminals 41 is realized through the main body 21, realizing the busbar function.

[0117] Multiple terminals 3 are connected to multiple busbars 2. Terminals 3 can be integrally formed with their corresponding busbars, or they can be formed separately and then mounted on their respective busbars. Each terminal 3 is electrically connected to the terminal 41 of its corresponding busbar 2. Multiple terminals 3 are connected to a power source to form an electrical circuit, supplying power to multiple windings of the motor stator 42. The main bodies 21 of the multiple busbars 2 are stacked along the axial direction of the frame 1, ensuring that the radial dimensions of the main bodies 21 remain consistent. Thus, multiple busbars 2 connected to terminals 3 can be simply stacked together, such as... Figure 16 and Figure 17 As shown, all connecting parts 22 are spaced apart along the circumferential direction of the frame 1, and the end faces of all connecting parts 22 away from the stator winding are flush in the axial direction, and the positions of the multiple terminals 3 are correct, such as... Figure 18 As shown, the skeleton 1 can then be processed by one-piece injection molding. The processing technology is relatively simple, and the structure of the skeleton 1 is also relatively simple.

[0118] Since all the connecting parts 22 of the busbar are distributed at intervals along the circumferential direction of the frame 1, such as Figure 20 As shown, the positions of the multiple terminals 41 of the motor stator 42 correspond to those of the terminals 41. Figure 24As shown, there is no need to reserve a long length for terminal 41 to ensure it can extend to other terminals 41 for connection. This shortens the length of terminal 41 and effectively prevents terminals 41 from tangling or getting confused during wiring, thus reducing wiring difficulty. Furthermore, the end faces of all connecting parts 22 away from the stator winding are flush with the axial direction of the frame 1 (i.e., the end faces of all connecting parts 22 away from the stator winding are located on the same plane perpendicular to the central axis of the frame 1), as shown. Figure 19 As shown, this ensures that all winding terminals 41 remain flush, with the same length reserved for welding. After welding, excess wire ends are trimmed at the same location, achieving a high degree of consistency in wiring operations. This facilitates both manual and machine operation, thus significantly improving production line efficiency.

[0119] Optionally, the busbar 2 can be made of copper, which has good electrical conductivity and is relatively inexpensive. Alternatively, the busbar 2 can be made of H65 brass, which is easy to stamp and has sufficient hardness.

[0120] Furthermore, the end faces of all busbar 2 connection portions 22 near the stator winding are kept flush with the axial direction of the frame 1, so that all connection portions 22 are kept flush with the axial direction of the frame 1.

[0121] All the connecting portions 22 of the busbars 2, near the end faces of the stator windings, are flush with the axial direction of the frame 1 (i.e., all the connecting portions 22, near the end faces of the stator windings, are located on the same plane perpendicular to the central axis of the frame 1). This flush alignment of all connecting portions 22 with the frame 1 allows for the removal of the outer enamel coating from the wire during wiring, enabling welding at the same location and further improving the consistency of the wiring operation. Simultaneously, it allows all connecting portions 22 to adopt the same shape, improving product regularity and consistency, and facilitating processing and forming.

[0122] Furthermore, at least part of the busbar 2 also includes an extension 23, such as Figure 1 , Figure 4 and Figure 7 As shown. The extension 23 is located between the outer periphery of the main body 21 and the connecting portion 22, serving to connect the main body 21 and the connecting portion 22; and the extension 23 extends at least partially along the axial direction of the skeleton 1 (e.g., Figure 12 As shown), all connecting parts 22 are kept flush in the axial direction of the skeleton 1.

[0123] At least part of the busbar 2 includes an extension 23, with the two ends of the extension 23 connected to the main body 21 and the connecting part 22, respectively. Since the extension 23 extends at least partially along the axial direction of the frame 1, the extension 23 can easily make multiple connecting parts 22 flush in the axial direction of the frame 1; and it is convenient to reasonably design the shape and size of the connecting parts 22 as needed, which is beneficial to optimizing the structure of the product.

[0124] Optionally, only a portion of the busbar 2 may include an extension 23, using the extension 23 to keep its connecting portion 22 flush with the extensions 23 of other busbars 2 without extensions 23. For example... Figure 16 , Figure 17 and Figure 18 In the middle, the U-phase busbar 251, the V-phase busbar 252 and the W-phase busbar 253 are provided with extensions 23 of different axial lengths, while the neutral busbar 24 does not have an extension 23. The three phase busbars 2 are connected by extensions 23 of different axial lengths so that their connecting parts 22 are kept axially flush with the connecting parts 22 of the neutral busbar 24.

[0125] Alternatively, all busbars 2 may include extensions 23, with the extensions 23 of different busbars 2 extending axially by different dimensions, so that all connecting parts 22 remain flush in the axial direction.

[0126] Of course, the busbar 2 may also be without the extension 23, and all the connecting parts 22 can be made flush with the skeleton 1 along the axis by the specific connection position of the connecting part 22 and the main body 21, and by reasonably designing the shape and size of the connecting part 22.

[0127] Optionally, the extension 23 is embedded in the skeleton 1, such as... Figure 22 and Figure 23 As shown.

[0128] If the extension 23 is embedded in the frame 1, then only the connecting part 22 is exposed outside the frame 1, such as... Figure 20 As shown. In this way, the busbar has a relatively regular appearance and structure, and the frame 1 can provide good support for the extension 23, effectively preventing the extension 23 from deforming or shaking, thereby improving the stability of the positions of each connection 22, which is beneficial to production line operation and further improves production efficiency.

[0129] Furthermore, the connecting part 22 is provided with a limiting groove 26 that is adapted to the wiring terminal 41, such as Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown, the limiting groove 26 allows the terminal 41 to pass through (e.g., Figure 24 (as shown) and is suitable for welding to terminal 41.

[0130] The connecting part 22 is provided with a limiting groove 26. During the wiring operation, the terminal 41 is passed through the limiting groove 26 before welding. In this way, the limiting groove 26 can not only effectively limit the terminal 41 to prevent it from shaking or tilting, but also increase the contact area between the terminal 41 and the connecting part 22, thereby reducing the welding difficulty and further improving production efficiency.

[0131] Specifically, the connecting part 22 includes a connecting piece 222 and a bending piece 223, such as Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown. The connecting piece 222 is connected to the main body 21 and extends along the circumferential direction of the frame 1, as shown. Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown; the bent piece 223 is connected to the connecting piece 222 and bends and extends, and together with the connecting piece 222, forms a U-shaped limiting groove 26, as shown. Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown.

[0132] The connecting part 22 includes a connecting piece 222 and a bending piece 223. The connecting piece 222 and the bending piece 223 form a U-shaped limiting groove 26, so that the limiting groove 26 has a structure that is open at both ends in the axial direction and has a notch in the circumferential direction (that is, the projection of the limiting groove 26 on the axial end face of the frame 1 is U-shaped). This helps to increase the space of the limiting groove 26, making it easier for the wiring terminal 41 to pass through quickly, and also helps to increase the space for welding operations and reduce the difficulty of welding operations.

[0133] The thickness directions of the connecting piece 222 and the bending piece 223 are perpendicular to the axial direction of the skeleton 1, such as... Figure 1 , Figure 4 , Figure 7 , Figure 13 As shown.

[0134] The thickness direction of the connecting piece 222 and the thickness direction of the bending piece 223 are both perpendicular to the axis of the skeleton 1. This increases the depth of the limiting groove 26, which is beneficial to increasing the contact area between the limiting groove 26 and the terminal 41. This not only helps to further reduce the welding difficulty, but also helps to improve the welding connection strength.

[0135] Furthermore, the U-shaped openings of all the limiting grooves 26 face the same direction of rotation, such as... Figure 18 and Figure 20 As shown.

[0136] All the U-shaped openings of the limiting grooves 26 face the same direction of rotation (e.g., all clockwise or all counterclockwise), making the structure of the busbar more regular. This facilitates the processing and shaping of each busbar 2 and allows all terminals 41 to pass through each limiting groove 26 synchronously by appropriately rotating the busbar during production line operation, thus further improving production efficiency.

[0137] Wherein, the dimension of the connecting piece 222 along the circumferential direction of the skeleton 1 is larger than the dimension of the bending piece 223 and its opposite portion along the circumferential direction of the skeleton 1, such as... Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown.

[0138] The dimension of the connecting piece 222 along the circumferential direction of the skeleton 1 is greater than the dimension of the part of the bent piece 223 opposite to the connecting piece 222 along the circumferential direction of the skeleton 1. Thus, the connecting piece 222 and the bent piece 223 form a J-shaped structure, which facilitates the reasonable setting of the position of the limiting groove 26 and provides a more favorable operating space for the welding operation of the terminal 41.

[0139] Furthermore, the connecting portion 22 also includes an extension piece 221 extending in the radial direction of the skeleton 1, such as... Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown. The radial inner end of the extension piece 221 is connected to the main body 21, and the radial outer end of the extension piece 221 is connected to the part of the connecting part 22 used to connect the terminal 41.

[0140] The connecting portion 22 also includes an extension piece 221, which extends radially along the skeleton 1. Its inner and outer radial ends are respectively connected to the main body 21 and the portion of the connecting portion 22 used to connect the terminal 41 (specifically, the connecting piece 222). This increases the radial distance between the connecting piece 222 and the main body 21, which is beneficial for reducing the radial dimension of the main body 21 to lower production costs, and also for increasing the distance between adjacent connecting portions 22. Therefore, it facilitates the rational design of the shape and size of the connecting portion 22, further optimizing the product structure.

[0141] Furthermore, multiple terminals 3 are evenly arranged along the circumferential direction of the busbar, such as... Figure 20 and Figure 24 As shown.

[0142] Multiple terminals 3 are evenly distributed along the circumferential direction of the busbar, resulting in a relatively regular structure. This arrangement helps increase the distance between terminals 3, ensuring electrical insulation between them and meeting the customer's requirement for even circumferential distribution of terminals 3. Of course, multiple terminals 3 can also be concentrated in one area or distributed in other ways.

[0143] Furthermore, multiple connecting portions 22 are evenly distributed along the circumferential direction of the main body portion 21, such as... Figure 18 , Figure 20 and Figure 24 As shown.

[0144] Multiple connecting parts 22 are evenly distributed along the circumferential direction of the main body 21, making the structure of the busbar 2 more regular, which is convenient for processing and forming. It also enables all connecting parts 22 of the busbar to be evenly distributed along the circumferential direction after assembly. Since the terminals 41 of the motor stator 42 winding are also generally evenly distributed along the circumferential direction, a one-to-one correspondence is maintained.

[0145] Furthermore, the connecting portions 22 of all busbars 2 do not protrude beyond the plane containing the axial end faces of the frame 1 at both ends along the axial direction, such as... Figure 19 As shown.

[0146] All connecting parts 22 do not protrude from the plane containing the axial end faces of the frame 1 at both ends along the axial direction. Compared with connecting parts 22 protruding from the axial end faces of the frame 1, the axial height of the busbar frame 1 can be reduced, so that the space occupied by the busbar in the axial direction is less, which is beneficial to reduce the axial length of the motor and optimize the structure of the motor.

[0147] Example 2

[0148] The difference from Embodiment 1 is that, based on Embodiment 1, the busbar 2 connected to the terminal 3 is further connected to the terminal 3 via an extension piece 221 of one of the connecting portions 22, such as... Figures 16 to 18 As shown.

[0149] For a busbar 2 connected to a terminal 3, the busbar 2 is connected to the terminal 3 through an extension piece 221 of one of the connecting parts 22. Therefore, there is no need to design any additional structure on the busbar 2 to connect the terminal 3, which simplifies the structure of the busbar 2 and does not cause the radial dimension of the busbar to increase.

[0150] Of course, terminal 3 can also be formed by bending and extending busbar 2 directly. Alternatively, terminal 3 can be directly connected to main body 21, spaced apart from connecting part 22.

[0151] Among them, the extension piece 221 is perpendicular to the axis of the skeleton 1, such as... Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown. Terminal 3 is plate-shaped, and the dimension a0 of the extension piece 221 connected to terminal 3 along the thickness direction of terminal 3 is larger than the dimension a of the other extension pieces 221 of the same busbar 2 along the thickness direction of terminal 3, such as... Figure 2 , Figure 5 , Figure 8 and Figure 10 As shown.

[0152] The extension piece 221 is perpendicular to the axis of the frame 1, which helps to reduce the axial dimension of the busbar 2. The dimension a0 of the extension piece 221 connected to the terminal 3 along the thickness direction of the terminal 3 is greater than the dimension a of other extension pieces 221 on the same busbar 2 along the thickness direction of the terminal 3. This helps to increase the contact area between the extension piece 221 and the terminal 3, thereby improving the connection strength and stability of the terminal 3 and reducing the probability of deformation of the terminal 3.

[0153] Furthermore, terminal 3 is bent into an L-shape, such as... Figure 11 As shown. Specifically, terminal 3 includes an extension section 31 parallel to the axis of frame 1 and a connecting section 32 parallel to the extension piece 221. The connecting section 32 is welded to the extension piece 221, as shown. Figure 10 , Figure 11 and Figure 18 As shown.

[0154] Terminal 3 is bent and includes an extension section 31 and a connecting section 32. The extension section 31 extends along the axis of the frame 1 and is used to connect to the power supply. The connecting section 32 is parallel to the extension piece 221 and is welded to the extension piece 221. This increases the contact area between terminal 3 and extension piece 221, thereby improving the connection strength and stability of terminal 3 and reducing the probability of terminal 3 deformation.

[0155] Furthermore, the dimension b0 of the portion of the extension piece 221 connected to the terminal 3 corresponding to the portion for connecting the terminal 41 in the circumferential direction along the frame 1 is greater than the dimension b of other portions on the same busbar 2 for connecting the terminal 41 in the circumferential direction along the frame 1, such as... Figure 10 As shown.

[0156] The dimension b0 of the portion of the extension piece 221 connected to the terminal 3 that is used to connect the terminal 41 along the circumferential direction of the frame 1 is appropriately increased relative to the dimension b of the other portions of the busbar 2 used to connect the terminal 41 along the circumferential direction of the frame 1. This can increase the circumferential distance between the terminal 3 and the portion of the connecting part 22 used to connect the terminal 41, thereby providing clearance space and facilitating the soldering operation of the terminal 41.

[0157] Specifically, by appropriately extending the length of the connecting piece 222, the distance between the U-shaped limiting groove 26 and the extension piece 221 can be increased, thereby avoiding the U-shaped limiting groove 26.

[0158] Optionally, all busbars 2 are divided into neutral busbars 24 and multiple phase busbars 2, such as Figures 16 to 18 As shown. Multiple terminals 3 correspond one-to-one with and are connected to multiple phase busbars 2. The main bodies 21 of the multiple phase busbars 2 are arranged adjacent to each other in sequence, as shown. Figure 18 and Figure 22 As shown, the main body 21 of the neutral busbar 24 is positioned facing the winding, as... Figure 25 As shown.

[0159] All busbars 2 are divided into neutral busbar 24 and phase busbar 2. The circuit formed by the terminals 41 connected to the phase busbar 2 (e.g., the end of some windings) and the circuit formed by the terminals 41 connected to the neutral busbar 24 (e.g., the beginning of all windings) can achieve multiple parallel connections to form a multi-phase circuit. Since the terminals 41 connected to the phase busbar 2 are relatively few, such as Figure 1 , Figure 4 , Figure 7 There are only four connection parts 22 in the middle; the neutral busbar 24 has relatively more connection terminals 41, such as Figure 13 There are 12 connecting parts 22, so the number of connecting parts 22 of the phase busbar 2 is less than the number of connecting parts 22 of the neutral busbar 24. Therefore, the main body parts 21 of the multiple phase busbars 2 are arranged adjacent to each other in sequence, such as Figures 16 to 18 As shown, it is only necessary to change the axial position of the connecting part 22 of the phase busbar 2 so that the connecting part 22 is flush with the axial position of the neutral busbar 24, without changing the axial position of the connecting part 22 of the center busbar 2, which helps to reduce the processing difficulty and improve production efficiency.

[0160] Furthermore, by positioning the main body 21 of the neutral busbar 24 towards the winding, the connecting portion 22 of the phase busbar 2 can be shifted closer to the winding, which helps to shorten the distance between the terminal 41 and the connecting portion 22. Figure 25 As shown, this shortens the length of terminal 41 and reduces the difficulty of soldering terminal 41.

[0161] Of course, the arrangement of busbar 2 can be changed arbitrarily.

[0162] The connecting portion 22 of the neutral busbar 24 is directly connected to its main body 21 (e.g., Figure 13 As shown), the connecting portion 22 of each phase busbar is connected to its main body 21 via an extension portion 23 (as shown). Figure 1 , Figure 4 and Figure 7As shown), the extension 23 extends along the axial direction of the skeleton towards the neutral busbar 24 (as shown). Figure 1 , Figure 4 and Figure 7 As shown), the connection portion 22 of the phase busbar and the connection portion 22 of the neutral busbar 24 are kept flush in the axial direction of the frame 1, as shown. Figure 19 As shown.

[0163] The connecting portion 22 of the neutral busbar 24 is directly connected to its main body 21. The connecting portion 22 of each phase busbar is connected to its main body 21 via an extension portion 23. That is, the neutral busbar 24 does not have an extension portion 23; only multiple phase busbars include extension portions 23. These extension portions 23 extend towards the neutral busbar 24, and the axial lengths of the extension portions 23 of the multiple phase busbars are unequal, ensuring that the connecting portion 22 of each phase busbar is flush with the connecting portion 22 of the neutral busbar 24 in the axial direction of the frame 1. This effectively simplifies the structure of the neutral busbar 24 and further shortens the distance between the terminal 41 and the connecting portion 22, thus facilitating a further reduction in the length of the terminal 41 and reducing the welding difficulty of the terminal 41.

[0164] Specifically, the extension 221 of the neutral busbar 24 is straight, such as... Figure 13 As shown, it is directly connected to the outer periphery of the main body 21 of the neutral busbar 24. The extension plate 221 of the phase busbar is also straight, as shown. Figure 1 , Figure 4 and Figure 7 As shown, an extension portion 23 is provided between the extension piece 221 and the main body portion 21 of the phase busbar. The extension portion 23 extends axially toward the neutral busbar 24, so that the extension piece 221 of the phase busbar and the extension piece 221 of the neutral busbar 24 remain flush. In this way, the connecting portion 22 of the phase busbar and the connecting portion 22 of the neutral busbar 24 also remain flush.

[0165] Example 3

[0166] The difference from any of the above embodiments is that, based on any of the above embodiments, the skeleton 1 further includes an annular support 11 and a plurality of strip supports 12. Specifically, the plurality of strip supports 12 are integrally connected to the annular support 11, such as... Figure 23 As shown. The main body 21 of all busbars 2 is embedded within the annular support 11, as... Figures 21 to 23 As shown. Multiple strip-shaped supports 12 correspond one-to-one with multiple terminals 3, as follows... Figure 20 As shown, a portion of each terminal 3 is embedded within the corresponding strip-shaped bracket 12, as... Figure 23 and Figure 25 As shown.

[0167] The frame 1 includes an annular support 11 and strip supports 12. The annular support 11 supports multiple busbars 2 and ensures insulation between the busbars 2. The strip supports 12 support multiple terminals 3 and ensure electrical insulation between the terminals 3 and other structures. Because the annular support 11 and the strip supports 12 are integrally connected, specifically through integral molding during injection molding to form a single structure, the connection is relatively reliable. Figure 23 and Figure 25 As shown, compared with the existing technology of separately forming insulating parts and then sleeved on the terminal 3, the strip bracket 12 of this solution can provide good support and limit the terminal 3, effectively prevent the terminal 3 from shaking and deforming, ensure the position and perpendicularity of the terminal 3, and make the structure reliable. This makes it less likely for the part of the terminal 3 exposed on the strip bracket 12 to deform and fail when the controller PIN is inserted into the terminal 3.

[0168] Optionally, the dimension c of the strip support 12 along the axis of the skeleton 1 is greater than or equal to half of the dimension c0 of the terminal 3 along the axis of the skeleton 1.

[0169] If the dimension c of the strip support 12 along the axis of the skeleton 1 is greater than or equal to half of the dimension c0 of the terminal 3 along the axis of the skeleton 1, then the area of ​​the strip skeleton 1 covering the terminal 3 exceeds half of the terminal 3, thus significantly improving the supporting and limiting effect on the terminal 3, and effectively ensuring the stability and reliability of the terminal 3.

[0170] Furthermore, terminal 3 is connected to one of the connecting portions 22 of the corresponding busbar 2. In the projection onto a plane perpendicular to the central axis of the frame 1, the strip-shaped support 12 is arranged asymmetrically about terminal 3 in the thickness direction, as shown below. Figure 20 As shown, the dimension d1 of the part near the corresponding connecting part 22 used to connect the terminal 41 is smaller than the dimension d2 of the part far from the corresponding connecting part 22 used to connect the terminal 41.

[0171] Terminal 3 is connected to one of the connecting parts 22 of the corresponding busbar 2. Since terminal 3 and the part of the connecting part 22 used to connect the terminal 41 are relatively close, and the strip bracket 12 circumferentially surrounds terminal 3, it may interfere with the soldering operation of the terminal 41. Therefore, the strip bracket 12 is arranged asymmetrically. Figure 20 As shown, the portion closer to the connecting terminal 41 is relatively thinner, while the portion farther from the connecting terminal 41 is relatively thicker, such as... Figure 20 As shown, this ensures reliable support for terminal 3 while avoiding the part of the connecting part 22 used to connect the terminal 41, leaving space for the welding operation of terminal 41, which helps to reduce the difficulty of the welding operation.

[0172] Furthermore, the dimension d of one of the strip supports 12 along the thickness direction of the terminal 3 is different from the dimension d of the other strip supports 12 along the thickness direction of the terminal 3, such as... Figure 20 As shown.

[0173] One of the strip supports 12 has a different dimension along the thickness direction of the terminal 3 than the other strip supports 12, making the three strip supports 12 not completely identical in appearance. Figure 20 As shown. This serves to prevent assembly errors, facilitates quick identification of each busbar 2, and allows for the positioning of the relative positions between the busbars and the stator 42 windings, thereby further improving production efficiency.

[0174] Of course, the dimensions of the multiple strip supports 12 along the thickness direction of the terminal 3 can also be different, which can also play a role in preventing assembly errors.

[0175] Optionally, the main body 21 has an arc-shaped structure, such as... Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown.

[0176] The main body 21 of the busbar 2 has an arc-shaped structure and is not a complete ring. In this way, while ensuring the same number of connecting parts 22, the circumferential length of the main body 21 can be reduced, which helps to save raw materials and facilitates processing and forming, such as by bending.

[0177] Furthermore, the multiple connecting portions 22 of each busbar 2 are sequentially designated as the xth connecting portion 22 starting from the notch of its main body 21 along the same rotation direction, and the multiple phase busbars are sequentially designated as the yth phase busbar along the axial direction of the frame, with the first phase busbar arranged adjacent to the neutral busbar 24.

[0178] The included angle α between the axis connecting the first connecting portion 22 of the neutral busbar 24 and the adjacent first phase busbar, and the included angle β between the axis connecting the first connecting portion 22 of the first phase busbar and the adjacent first connecting portion 22 of the second phase busbar, satisfy the following:

[0179] α = 360° / (2×m×n) + 360°×K / (m×n), β = 360°×P / (m×n) and β≠360°×Q / n, m is the number of phase busbars, n is the number of stator windings per phase, K∈[0, (m×n-1)], P∈(0, (m×n-1)], Q∈[1, m].

[0180] Each busbar 2 has multiple connecting parts 22 that are sequentially denoted as the xth connecting part 22, starting from the notch of its main body 21 and rotating in the same direction. For example, counting clockwise from the notch of the main body 21, they are the first connecting part 22, the second connecting part 22, the third connecting part 22, and so on. Multiple phase busbars are sequentially denoted as the yth phase busbar along the axial direction of the frame 1. The first phase busbar is arranged in phase with the neutral busbar 24. That is, starting from the phase busbar that is closest to the neutral busbar 24 in the axial direction, they are the first phase busbar, the second phase busbar, and so on.

[0181] Specifically, during stacking, the neutral busbar 24 is used as a reference, and the phase busbars are stacked one by one. When stacking the first phase busbar, an axial angle α is generated between its first connecting part 22 and the first connecting part 22 of the neutral busbar 24. Then, the second phase busbar is stacked, and an axial angle β is generated between its first connecting part 22 and the first connecting part 22 of the first phase busbar. At this point, the multiple connecting parts 22 of the first phase busbar and the multiple connecting parts 22 of the second phase busbar occupy several circumferential gaps between adjacent connecting parts 22 of the neutral busbar 24. For schemes with a third or even more phase busbars, the neutral busbar 24 still has a small number of connecting parts 22 with relatively large circumferential gaps. This means that some of the circumferential connecting parts 22 are relatively concentrated, while others are relatively dispersed. Therefore, the remaining phase busbars only need to distribute their connecting parts 22 within these circumferential gaps, ensuring that all connecting parts 22 are evenly distributed along the circumferential direction of the frame 1 after assembly. Since the number of terminals 41 connected to the phase busbars is relatively small, such as... Figure 1 , Figure 4 , Figure 7 There are only four connection parts 22 in the middle, while the neutral busbar 24 has relatively more connection terminals 41, such as Figure 13 There are 12 connecting parts 22 in the phase bus bar, so the number of connecting parts 22 of the phase bus bar is less than that of the neutral bus bar 24. Therefore, the rotation of the phase bus bar is easier to control precisely, reducing the probability of visual confusion and improving assembly efficiency.

[0182] Where α = 360° / (2×m×n) + 360°×K / (m×n), β = 360°×P / (m×n) and β ≠ 360°×Q / n. m×n is the number of stator slots adapted to the busbar, i.e., the total number of coil windings. 360° / (2×m×n) is half the angle between the axes of the two adjacent connecting parts 22 of the neutral busbar 24. 360°×K / (m×n) and 360°×P / (m×n) are integer multiples of the angle between the axes of the two adjacent connecting parts 22 of the neutral busbar 2. 360° / n is half the angle between the axes of the two adjacent connecting parts 22 of the phase busbar. 360°×Q / n is an integer multiple of the angle between the axes of the two adjacent connecting parts 22 of the phase busbar.

[0183] Thus, when the axial connection angle between the first connecting portion 22 of the neutral busbar 24 and the first connecting portion 22 of the first phase busbar is α, it indicates that the first connecting portion 22 of the first phase busbar is located between any two adjacent connecting portions 22 of the neutral busbar 24. Then, the first connecting portion 22 of the second phase busbar rotates β relative to the first connecting portion 22 of the first phase busbar. This ensures that each connecting portion 22 of the second phase busbar is located between two adjacent connecting portions 22 of the neutral busbar 24, and avoids overlap with some connecting portions 22 of the first phase busbar in the circumferential direction. This ensures that the connecting portions 22 of the neutral busbar 24, the connecting portions 22 of the first phase busbar, and the connecting portions 22 of the second phase busbar are staggered in the circumferential direction.

[0184] It is worth noting that the included angle between the axial lines connecting the two connecting parts 22 refers to the angle between the perpendicular line connecting the center of one connecting part 22 to the central axis of the frame, and the perpendicular line connecting the center of the other connecting part 22 to the central axis of the frame. The center of the connecting part 22 refers to the center of the portion of the connecting part 22 corresponding to the terminal of the stator winding; that is, in the projection onto the plane perpendicular to the central axis of the busbar, the center of the connecting part 22 coincides with the terminal of the stator winding. For schemes where all connecting parts 22 have identical shapes and dimensions, the included angle between the axial lines connecting the two connecting parts 22 refers to the angle between the perpendicular lines connecting the same portion of the two connecting parts 22 to the central axis of the frame.

[0185] Optionally, m is 3.

[0186] If m is 3, then there are four busbars 2 and three terminals, which can be connected to form a three-phase motor. Three of the busbars 2 are phase busbars, connected to an equal number of terminals to form U-phase busbar 251, V-phase busbar 252, and W-phase busbar 253, respectively. The remaining busbar 2 is a neutral busbar 24, connected to the other terminal of all windings. The first phase busbar adjacent to the neutral busbar 24 is defined as W-phase busbar 253, followed by V-phase busbar 252 and U-phase busbar 251. After stacking the neutral busbar 24, W-phase busbar 253, and V-phase busbar 252, the neutral busbar 24 has exactly n gaps, corresponding to the n connecting parts 22 of the U-phase busbar 251. Therefore, the n connecting parts 22 of the U-phase busbar 251 are placed in the corresponding gap positions.

[0187] Furthermore, the included angle γ between the axis connecting the first connecting part 22 of the second phase bus bar and the first connecting part 22 of the third phase bus bar satisfies: γ=360°×P / (m×n) and γ≠360°×Q / n.

[0188] The axial angle between the first connecting part 22 of the second phase busbar and the first connecting part 22 of the third phase busbar is γ. Since γ = 360° × P / (m × n) and γ ≠ 360° × Q / n, γ = β. Therefore, the process of stacking the third phase busbar is the same as that of stacking the second phase busbar, which is beneficial to further improve production efficiency. For example, β = γ = 30°, or β = γ = 120°.

[0189] Optionally, K is 0.

[0190] If K = 0, then α = 360° / (2×m×n). The first connection part 22 of the first phase busbar is located between the first two connection parts 22 of the neutral busbar 24. This makes the value of α smaller, which is beneficial to further reduce the assembly difficulty of the busbar 2 and further improve production efficiency.

[0191] Of course, K can also be 1, 2 or other integers.

[0192] Alternatively, P and n satisfy: P = n.

[0193] If P = n, then β = 360° / m and β ≠ 360° × Q / n. This simplifies the calculation method of β, which is conducive to further reducing the assembly difficulty of busbar 2 and further improving production efficiency.

[0194] Of course, P may not be equal to n.

[0195] Optionally, n is 4.

[0196] n is 4, meaning there are 4 stator windings per phase. Of course, n is not limited to 4; it can also be 1, 2, 3, 5, or other values.

[0197] Let the two ends of the main body 21 be designated as the first end 211 and the second end 212, respectively. For example, if all the main body parts 21 extend in a clockwise direction to form an arc shape, then the first end 211 and the second end 212 of any main body part 21 can be designated as the first end 211 and the second end 212, respectively. Figure 1 , Figure 4 , Figure 7 , Figure 10 and Figure 13 As shown, the connecting part 22 adjacent to the first end 211 is the first connecting part 22, and the connecting part 22 adjacent to the second end 212 is the nth connecting part 22. Therefore, during the stacking of busbars 2, the first connecting part 22 of the main body 21 of the previous busbar 2 can be used as a reference to rotate the subsequently stacked busbars 2, and the required axial connection angle can be quickly obtained.

[0198] Thus, after stacking, the angle between the axis connecting the first connecting part 22 of the first phase busbar and the first connecting part 22 of the neutral busbar 24 is 180° / (m×n), and the angle between the axis connecting the first connecting parts 22 of any two adjacent phase busbars is 360° / m. This arrangement is simple and highly operable.

[0199] For example, when m = 3, n = P = 4, and K = 0, α = 180° / (m × n) = 15°, β = γ = 360° / m = 120°. First, stack the W-phase busbar 253 on the neutral busbar 24, such that the angle between the axis connecting the first end 211 of the W-phase busbar 253 and the first end 211 of the neutral busbar 24 is 15°. Figure 16 As shown. Then, the V-phase busbar 252 is stacked on top of the W-phase busbar 253, such that the angle between the axis connecting the first end 211 of the V-phase busbar 252 and the first end 211 of the W-phase busbar 253 is 120°, as shown. Figure 17 As shown. Finally, the U-phase busbar 251 is stacked on top of the V-phase busbar 252, such that the angle between the axis connecting the first end 211 of the U-phase busbar 251 and the first end 211 of the V-phase busbar 252 is 120°, as shown. Figure 18 As shown.

[0200] Among them, multiple connecting parts 22 are evenly distributed along the circumferential direction of the main body 21, and the first connecting part 22 and the last connecting part 22 are located at both ends of the main body 21, such as Figure 1 , Figure 4 , Figure 7 and Figure 13 As shown.

[0201] Multiple connecting parts 22 are evenly distributed along the circumferential direction of the main body 21, making the structure of the busbar 2 more regular and easier to process and shape; and ensuring that all connecting parts 22 of the busbar are evenly distributed along the circumferential direction after assembly. Since the terminals 41 of the motor stator winding are also generally evenly distributed along the circumferential direction, a one-to-one correspondence is maintained.

[0202] Meanwhile, the first connecting part 22 and the last connecting part 22 are located at both ends of the main body 21, that is, the main body 21 is missing a part between the two connecting parts 22. This not only ensures the reliability of the connection between the main body 21 and the multiple connecting parts 22, but also shortens the length of the main body 21 as much as possible, which is conducive to further saving raw materials.

[0203] For example, when there are four connecting parts 22, the curvature of the main body 21 is 270°. Figure 1 , Figure 4 and Figure 7 As shown; when the number of connecting parts 22 is 6, the curvature of the main body 21 is 300°; when the number of connecting parts 22 is 12, the curvature of the main body 21 is 330°, as... Figure 13 As shown.

[0204] Furthermore, this design also makes the two connecting parts 22 located at both ends of the main body 21 (i.e., the first connecting part 22 and the last connecting part 22) clearly distinguishable from the connecting parts 22 in other parts. When stacking multiple busbars 2, they can serve as reference objects to further improve stacking efficiency, thereby further improving assembly efficiency.

[0205] Let the two ends of the main body 21 be designated as the first end 211 and the second end 212, respectively. For example, if all the main body parts 21 extend in a clockwise direction to form an arc shape, then the first end 211 and the second end 212 of any main body part 21 can be designated as the first end 211 and the second end 212, respectively. Figure 1 , Figure 4 , Figure 7 , Figure 10 and Figure 13 As shown, the connecting part 22 connected to the first end 211 is the first connecting part 22, and the connecting part 22 connected to the second end 212 is the nth connecting part 22. Therefore, during the stacking of busbars 2, the first end 211 of the main body 21 of the previous busbar 2 can be used as a reference to rotate the subsequently stacked busbars 2, and the required axial connection angle can be quickly obtained.

[0206] Of course, the two ends of the main body 21 can also be extended appropriately.

[0207] Furthermore, the number of connection parts 22 for each phase bus bar is n, and each terminal is connected to the xth connection part 22 of the corresponding phase bus bar, where x∈[2,n-1].

[0208] Multiple terminals 3 correspond one-to-one with multiple phase busbars. Each phase busbar has n connecting portions 22, which connect to the n coils of each phase stator. Each terminal is connected to the x-th connecting portion 22 of its corresponding phase busbar. Since x is greater than or equal to 2 and less than or equal to n-1, the connecting portions 22 of the terminals are not located on either side of the notch in the main body 21. Compared to the two ends of the main body 21, other parts of the main body 21 have relatively higher strength and a relatively lower probability of deformation. Therefore, connecting the terminals to the connecting portions 22 of the main body 21 away from the notch helps to further improve the positional accuracy and perpendicularity of the terminals, further reducing the probability of terminal deformation.

[0209] Optionally, x is 2.

[0210] When x is 2, the terminal is connected to the second connecting part 22 of the corresponding phase busbar. In this way, the first connecting part 22 of the phase busbar serves as a reference for locating the position of the phase busbar, and the second connecting part 22 is used to connect the terminal, which facilitates location and helps to further improve production efficiency. Of course, x is not limited to 2 and can be other values.

[0211] Example 4

[0212] The difference from any of the above embodiments is that the main body 21 has a ring structure.

[0213] The main body 21 of the busbar 2 has a complete ring structure, which helps to improve the strength of the busbar 2, thereby improving the stability and reliability of the busbar.

[0214] Optionally, the projection of terminal 3 onto the axial end face of frame 1 is elongated, and the length of its projection extends along the radial direction of frame 1, such as... Figure 18 , Figure 20 and Figure 24 As shown.

[0215] The projection of terminal 3 onto the axial end face of frame 1 is elongated. Since terminal 3 is generally a thin, elongated sheet extending along the axial direction of frame 1, the projection of terminal 3 onto the axial end face of frame 1 is essentially the same as the shape of the cross-section of terminal 3. The length direction of this projection extends along the radial direction of frame 1, such as... Figure 20 and Figure 24 As shown, the radial space of the busbar is used in a reasonable way, which can meet the customer's requirement for the radial arrangement of terminal 3.

[0216] Example 5

[0217] The difference from any of the above embodiments is that the projection of the terminal 3 on the axial end face of the frame 1 is elongated, and the length direction of its projection extends along the circumferential direction of the frame 1.

[0218] The projection of terminal 3 on the axial end face of frame 1 is elongated. Since terminal 3 is generally a thin, elongated sheet extending along the axial direction of frame 1, the projection of terminal 3 on the axial end face of frame 1 is basically the same as the shape of the cross-section of terminal 3. The length direction of this projection can also extend along the circumferential direction of frame 1, making reasonable use of the circumferential space of the busbar, which can meet the customer's requirement for the circumferential arrangement of terminal 3, and is conducive to reducing the radial dimension of the busbar.

[0219] In any of the above embodiments, optionally, all the main body portions 21 have the same thickness t, such as... Figure 21 and Figure 22 As shown.

[0220] If all the main body parts 21 have the same thickness, then all the busbars 2 can be made of the same material, which helps to reduce the types of raw materials, facilitates processing and molding, and also helps to save costs.

[0221] Optionally, the thickness t of the busbar 2 is in the range of 0.7mm-1.0mm (e.g., 0.7mm, 0.8mm, 0.9mm, 1.0mm, etc.).

[0222] Optionally, the spacing t2 between adjacent main body parts 21 is equal, such as... Figure 21 and Figure 22 As shown.

[0223] The equal spacing between adjacent main body sections 21 ensures a regular internal structure of the busbar and guarantees electrical insulation between each busbar 2.

[0224] Optionally, the spacing t2 between adjacent main body parts 21 is 0.5mm-3mm (e.g., 0.5mm, 1mm, 2mm, 3mm, etc.).

[0225] Optionally, the distance t1 between the axial end faces of the main body 21 of the multiple busbars 2 and the axial end faces of the frame 1 is smaller than the distance t2 between adjacent main body 21s, such as... Figure 21 and Figure 22 As shown. That is to say, the distance between the neutral busbar 24 and the axial end face of the frame 1 and the distance between the U-phase busbar 251 and the axial end face of the frame 1 are equal, denoted as t1. Then t1 < t2. This is beneficial to reduce the longitudinal height of the frame 1, which in turn is beneficial to further reduce the longitudinal dimension of the busbar and further reduce the axial length of the motor.

[0226] Of course, the spacing between the neutral busbar 24 and the axial end face of the frame 1, as well as the spacing between the U-phase busbar 251 and the axial end face of the frame 1, can also be adjusted as needed. Furthermore, all the main body parts 21 have the same width.

[0227] All the main body parts 21 have the same width, that is, all the main body parts 21 have the same size along the radial direction of the frame 1. In this way, after all the main body parts 21 of the busbar 2 are stacked along the axial direction of the frame 1, the inner edges of all the main body parts 21 are located on the same circle, and the outer edges of all the main body parts 21 are also located on the same circle, making the structure of the busbar more regular, which is convenient for the processing and shaping of each busbar 2 and also convenient for the processing and shaping of the frame 1.

[0228] Furthermore, the main body 21 of all phase busbars is the same, such as Figure 1 , Figure 4 and Figure 7 As shown.

[0229] All phase busbars have the same main body 21, that is, their shape and size are completely consistent, which helps to reduce the processing difficulty of phase busbars and improve production efficiency.

[0230] Furthermore, in the projection onto a plane perpendicular to the axis of the skeleton 1, the main bodies 21 of all the busbars 2 overlap to form a ring, as shown below. Figure 20 As shown.

[0231] In the projection onto the plane perpendicular to the axis of the frame 1, the main body portions 21 of all the busbars 2 overlap to form a ring. That is, the projections of the main body portions 21 of all the busbars 2 onto the plane perpendicular to the axis of the frame 1 are all located within the same ring. Since each main body portion 21 has a notch, its projection is not a complete ring. However, the superposition of the projections of multiple main body portions 21 forms a complete ring. This is beneficial for improving the strength of the busbar and also facilitates the rotation and misalignment of the busbars 2 with each other, ensuring that all the connecting portions 22 are evenly distributed along the circumferential direction of the frame 1.

[0232] Optionally, the number of busbars 2 is four, and the number of terminals 3 is three, such as... Figure 18 As shown, the number of connection parts 22 in the three busbars 2 is equal, and the number of connection parts 22 in the other busbar 2 is the sum of the number of connection parts 22 in the other three busbars 2.

[0233] There are four busbars 2 and three terminals 3, which, through proper connection, can form a three-phase motor. Three of the busbars 2 are phase busbars 2, each connected to an equal number of terminals 41, forming U-phase busbars 251 (e.g., ...). Figures 1 to 3 (as shown), V-phase busbar 252 (as shown) Figures 4 to 6(as shown) and W phase busbar 253 (as shown) Figures 7 to 10 (As shown). Another bus bar 2 is a neutral bus bar 24 (as shown). Figures 13 to 15 (As shown), it is connected to the other terminal 41 of all windings.

[0234] Of course, the number of busbars 2 is not limited to four; it can also be three, five, etc.

[0235] Furthermore, the surface of the frame 1 facing away from the terminal 3 is provided with a hook 13, such as... Figure 19 As shown, it is used to snap onto the motor stator 42, as follows. Figure 25 As shown.

[0236] A hook 13 is provided on the surface of the frame 1 away from the terminal 3 to facilitate engagement with the stator 42, preventing the busbar from shaking, tilting, or shifting during the welding process, which is conducive to further improving production efficiency.

[0237] The number of hooks 13 can be multiple, and the multiple hooks 13 are evenly distributed along the circumferential direction of the skeleton 1. The hooks 13 and the skeleton 1 can be integrally formed by injection molding.

[0238] Furthermore, the stator 42 is generally also provided with an injection-molded insulating frame, on which a slot adapted to the latch 13 can be provided, and the latch 13 is directly inserted into the slot, such as... Figure 25 As shown, this achieves a snap-fit ​​connection with the stator 42.

[0239] like Figure 24 and Figure 25 As shown, the motor provided in the second aspect of the present invention includes: a motor body 4 and a bus as described in any of the embodiments of the first aspect.

[0240] Specifically, the motor body 4 includes a stator 42, and the stator 42 is provided with windings, such as... Figure 26 As shown, the winding has two terminals 41; the busbar connection 22 is connected to the terminals 41, as shown. Figure 25 As shown.

[0241] The motor provided in the second aspect of the present invention, having included the busbar of any of the embodiments in the first aspect, has all the beneficial effects of any of the above embodiments, which will not be repeated here.

[0242] Optionally, terminal 41 is connected to the busbar by resistance welding. Of course, other welding methods such as ultrasonic welding or other fixed connection methods can also be used.

[0243] Optionally, the number of windings is 12, such as Figure 26 and Figure 27 As shown, the 12 windings are connected in a star configuration, as follows: Figure 28 As shown.

[0244] Because the 12 windings have 24 terminals and are connected in a star configuration, the 12 wire ends at the starting points of the 12 windings need to be connected together, and the ending points of windings C1, C4, C7, and C10, windings C2, C5, C8, and C11, and windings C3, C6, C9, and C12 need to be connected together separately, making the wiring method very complex. The solution proposed in this application effectively reduces the wiring difficulty, resulting in a simple and reliable wiring method.

[0245] Of course, the number of windings is not limited to 12; it can also be 8, 16, etc. The connection method of the windings is not limited to the above methods; it can also be a delta connection or other methods.

[0246] The vehicle provided in the third aspect of the present invention includes: a vehicle body and an electric motor as described in any one of the technical solutions of the second aspect, which is installed in the vehicle body.

[0247] The vehicle provided by the third aspect of the present invention, having included the motor described in the second aspect, possesses all the beneficial effects of any of the aforementioned technical solutions, which will not be repeated here.

[0248] The following explanation uses the 8P12S permanent magnet motor as an example.

[0249] For an 8P12S permanent magnet motor, there are 12 teeth. Each tooth has a winding formed by wire wound around it. Each winding has one start end and one end end, resulting in 24 wire ends, evenly distributed circumferentially, one every 15°. Figure 26 As shown. The motors are connected in a star configuration with four parallel circuits, as follows. Figure 28 As shown. This wiring method requires connecting the 12 wire ends of the 12 windings together, as follows. Figure 27 and Figure 28 As shown, the terminals of windings C1, C4, C7, and C10, windings C2, C5, C8, and C11, and windings C3, C6, C9, and C12 are connected together, resulting in a complex wiring configuration. Therefore, a simple and reliable structure is needed.

[0250] The present invention aims to design a bus structure that can meet the wiring requirements of the 8P12S type motor, and has the characteristics of small axial and radial space occupation, simple wiring, and reliable structure.

[0251] The busbar includes an insulating frame 1, a center point copper busbar (neutral busbar 24), a U-phase copper busbar (U-phase busbar 251), a V-phase copper busbar (V-phase busbar 252), a W-phase copper busbar (W-phase busbar 253), and three terminals 3. The insulating frame 1 is integrally injection molded to support the copper busbars and terminals 3 and to insulate the copper busbars. The insulating frame 1 is snap-fitted to the motor stator 42 frame 1. The center point copper busbar and the U, V, and W-phase copper busbars are copper busbars of equal thickness, manufactured through stamping, bending, and other processes. The main body is a notched ring, from which U-shaped terminals 3 (connecting parts 22 with U-shaped limiting grooves 26) extend for welding to copper enameled wire (terminals 41). The three terminals 3 are distributed 120° circumferentially and are resistance-welded to the U, V, and W-phase copper busbars to input current to the motor windings.

[0252] Specifically, this motor is an 8P12S motor with 12 teeth. Copper wire is wound around each tooth, forming 12 windings C1-C12. Each winding has one start end and one end end, as shown below. Figure 26 As shown. Based on the motor circuit design ( Figure 27 As shown, the starting wire ends, which are evenly distributed along the circumference at 30°, need to be connected together to conduct electricity, which is defined as the center point connection. The ending wire ends, which are evenly distributed along the circumference at 30°, are divided into three parts: the ending ends of windings C1, C4, C7, and C10 are connected, which is defined as the U-phase connection; the ending ends of windings C2, C5, C8, and C11 are connected, which is defined as the V-phase connection; and the ending ends of windings C3, C6, C9, and C12 are connected, which is defined as the W-phase connection.

[0253] To meet the above connection requirements, a center point connection copper busbar was designed. Figure 13 and Figure 14 (as shown) and U, V, W phase copper busbars (as shown) Figure 10 (As shown). The center copper busbar and the U, V, and W phase copper busbars are formed by stamping and bending copper busbars of equal thickness. The thickness t of the copper busbar is between 0.7 and 1.0 mm, and the material is H65 brass, which is easy to stamp and has sufficient hardness. The ends of the copper busbars are designed with U-shaped grooves to facilitate the insertion of enameled wires into the U-shaped grooves, followed by resistance welding.

[0254] The three terminals 3 of this motor are arranged radially in the width direction, and are spaced 120° apart from each other. The three terminals 3 are distributed and resistance-welded to the three-phase copper busbars. To meet the requirements of resistance welding, the ends of the terminals 3 are bent (e.g., ...). Figure 11 As shown), the welding area of ​​the three-phase copper busbar was widened (as shown). Figure 10 (As shown).

[0255] Stack the four copper busbars one by one, with the center copper busbar at the bottom, followed by W, V, and U in sequence, as shown. Figures 16 to 18As shown. The spacing between layers is 0.5mm-3mm (e.g., 0.5mm, 1mm, 2mm, 3mm, but not limited to this range; other values ​​are also possible). The first U-shaped groove of the W-layer copper busbar differs from any groove of the center point copper busbar by 15°, as shown. Figure 16 As shown, terminal 3, which connects to copper busbars V and U, is 120° away from terminal 3 of phase W, as... Figure 17 and Figure 18 As shown. After stacking, perform overall injection molding. The shape after injection molding is as follows. Figure 20 As shown, the injection-molded body completely encloses the three terminals 3. The terminals 3 have good positional and perpendicularity, and a robust structure, making it less prone to deformation and failure when the controller pins are inserted into the terminals 3.

[0256] Because the center copper busbar and the U, V, and W phase copper busbars are at different heights, the U-shaped groove of the copper busbar is bent downwards to a height of h. Figure 3 , Figure 6 and Figure 9 As shown, except for the inconsistent height h, the three-phase copper is identical in all other parts. After bending, all U-shaped grooves are at the same height position, as shown. Figure 19 As shown. The advantages of this design are: less space is occupied in the height direction, which is conducive to reducing the axial length of the motor; the length of the enameled wire ends is equal, making it easy to control the stripping position, easy to resist weld on the production line, and easy to cut off the excess wire ends after welding.

[0257] The busbar wiring scheme is as follows:

[0258] The center point copper busbar connects the starting ends of the C1 to C12 windings;

[0259] The U-phase copper busbar connects the end wires of windings C1, C4, C7, and C10.

[0260] The V-phase copper busbar connects the end wires of windings C2, C5, C8, and C11.

[0261] The W-phase copper busbar connects the end wires of windings C3, C6, C9, and C12.

[0262] The second connecting part 22 of the U, V, and W phase copper busbars is welded to the terminal 3 in a clockwise direction, such as... Figure 10 As shown.

[0263] The height difference between layers is 1mm, and the first U-shaped groove of the W-phase copper busbar is 15° different from any U-shaped groove of the center point copper busbar.

[0264] The height difference between the V-phase copper busbar and the W-phase copper busbar is 1mm, and the three terminals are 120° apart in the circumferential direction.

[0265] The height difference between the U-phase copper busbar and the V-phase copper busbar is 1mm, and the three terminals are 120° apart in the circumferential direction.

[0266] Six hooks are made at one end of the frame, such as... Figure 19 As shown, it is hung at the slot of the stator 42 frame 1, as... Figure 25 As shown.

[0267] In summary, the above-mentioned wiring function can be achieved by welding the enameled wire to this bus structure. Therefore, this bus achieves the following technical effects: 1) It satisfies the requirements of a four-layer parallel star connection; 2) The integrated injection-molded ring frame (i.e., ring bracket) and strip frame (i.e., strip bracket) provide a robust structure with good terminal positioning and perpendicularity, facilitating ECU installation and minimizing terminal deformation during installation; 3) The copper busbar U-shaped grooves are roughly evenly distributed circumferentially at the same height, which is beneficial for resistance welding of the enameled wire and facilitates stripping and cutting of the enameled wire on the production line; 4) The busbar has a small axial height, which is beneficial for optimizing the axial length of the motor; 5) The U-shaped groove design of the busbar facilitates the integration of the enameled wire into the U-shaped groove; 6) It makes reasonable use of radial space, meeting the requirements of products that require radial terminal distribution.

[0268] In this invention, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise explicitly defined. The terms "install," "connect," "link," and "fix" should be interpreted broadly. For example, "connect" can be a fixed connection, a detachable connection, or an integral connection; "link" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0269] In the description of this invention, it should be understood that the terms "upper," "lower," "left," "right," "front," "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or unit referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0270] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0271] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A busbar, characterized in that, include: The skeleton is an insulating component; Multiple busbars, each of the busbars including a main body portion embedded in the frame and extending in the circumferential direction of the frame, and multiple connecting portions connected to the main body portion and protruding outward from the frame, the multiple connecting portions being used to connect the terminals of the motor stator winding; Multiple terminals, connected to multiple of the aforementioned busbars, are used to connect to a power source; The main body portions of all the busbars are stacked and spaced apart along the axial direction of the frame, the connecting portions of all the busbars are spaced apart along the circumferential direction of the frame, and the end faces of the connecting portions of all the busbars away from the stator winding are flush with the axial direction of the frame. All of the main body portions have the same thickness t; and / or The spacing t2 between adjacent main body parts is equal; The main body is arc-shaped and has a notch. A plurality of connecting parts are evenly distributed along the circumferential direction of the main body, wherein two connecting parts are located at the two ends of the main body, respectively. All of the aforementioned busbars are divided into neutral busbars and multiple phase busbars; The multiple connecting parts of each busbar are sequentially denoted as the xth connecting part, starting from the notch in the main body and rotating in the same direction; The number of connection parts in each phase busbar is n, and each terminal is connected to the x-th connection part of the corresponding phase busbar, where x∈[2,n-1]; The phase busbar has four connecting parts, and the arc of the main body of the phase busbar is 270°. The neutral busbar has 12 connecting parts, and the arc of the main body of the neutral busbar is 330°.

2. The busbar according to claim 1, characterized in that, All the connecting portions of the busbars are flush with the end faces of the stator windings in the axial direction of the frame, so that all the connecting portions are flush with the axial direction of the frame.

3. The busbar according to claim 2, characterized in that, At least a portion of the busbar also includes an extension located between the outer periphery of the main body and the connecting portion for connecting the main body and the connecting portion, and the extension extends at least partially along the axial direction of the skeleton so that all the connecting portions remain flush with the axial direction of the skeleton.

4. The busbar according to claim 3, characterized in that, The extension is embedded in the skeleton.

5. The busbar according to any one of claims 1 to 4, characterized in that, The connecting part is provided with a limiting groove that is adapted to the terminal block. The limiting groove allows the terminal block to pass through and is suitable for welding to the terminal block.

6. The busbar according to claim 5, characterized in that, The connecting part includes a connecting piece and a bending piece. The connecting piece is connected to the main body and extends along the circumferential direction of the skeleton. The bending piece is connected to the connecting piece and extends by bending, and together with the connecting piece, they form a U-shaped limiting groove.

7. The busbar according to claim 6, characterized in that, The thickness direction of the connecting piece and the thickness direction of the bending piece are perpendicular to the axial direction of the skeleton.

8. The busbar according to claim 6, characterized in that, All of the aforementioned limiting grooves have U-shaped openings facing the same direction of rotation.

9. The busbar according to claim 6, characterized in that, The dimension of the connecting piece along the circumferential direction of the skeleton is greater than the dimension of the bent piece and its opposite portion along the circumferential direction of the skeleton.

10. The busbar according to any one of claims 1 to 4, characterized in that, The connecting portion includes an extension piece extending radially along the skeleton, the inner radial end of the extension piece being connected to the main body portion, and the outer radial end of the extension piece being connected to the portion of the connecting portion used to connect the terminal.

11. The busbar according to claim 10, characterized in that, The busbar connected to the terminal is connected to the terminal via an extension piece of one of the connecting portions.

12. The busbar according to claim 11, characterized in that, The extension piece is perpendicular to the axis of the frame, the terminal is sheet-shaped, and the dimension of the extension piece connected to the terminal along the thickness direction of the terminal is larger than the dimension of other extension pieces of the same busbar along the thickness direction of the terminal.

13. The busbar according to claim 12, characterized in that, The terminal is bent into an L-shape and includes an extension section parallel to the axis of the skeleton and a connecting section parallel to the extension piece. The connecting section is welded to the extension piece.

14. The busbar according to claim 11, characterized in that, The portion of the extension piece connected to the terminal that is used to connect the terminal is larger in the circumferential direction of the frame than the other portions of the same busbar used to connect the terminal in the circumferential direction of the frame.

15. The busbar according to any one of claims 1 to 4, characterized in that, Each of the terminals corresponds to and is connected to a plurality of phase busbars. The main bodies of the plurality of phase busbars are arranged adjacent to each other in sequence. The main body of the neutral busbar is located facing the winding.

16. The busbar according to claim 15, characterized in that, The connecting portion of the neutral busbar is directly connected to its main body, and the connecting portion of each phase busbar is connected to its main body through an extension portion. The extension portion extends along the axial direction of the skeleton towards the neutral busbar, so that the connecting portion of the phase busbar and the connecting portion of the neutral busbar remain flush with each other in the axial direction of the skeleton.

17. The busbar according to any one of claims 1 to 4, characterized in that, The connecting portions of all the busbars do not protrude beyond the plane containing the axial end faces of the frame at both ends along the axial direction of the frame.

18. The busbar according to any one of claims 1 to 4, characterized in that, The projection of the terminal onto the axial end face of the frame is elongated, and the length of the projection extends along the radial direction of the frame; or The projection of the terminal on the axial end face of the skeleton is elongated, and the length direction of its projection extends along the circumferential direction of the skeleton.

19. The busbar according to any one of claims 1 to 4, characterized in that, The surface of the frame facing away from the terminal is provided with a hook for engaging the motor stator.

20. An electric motor, characterized in that, include: The motor body includes a stator, the stator having a winding with two terminals; and The busbar as described in any one of claims 1 to 19, wherein the connection portion of the busbar is connected to the terminal.

21. The motor according to claim 20, characterized in that, The number of windings is 12, and the 12 windings are connected in a star configuration.

22. A vehicle, characterized in that, include: Vehicle body; and The motor as described in claim 20 or 21 is installed in the vehicle body.

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