A three-phase copper busbar structure for a hybrid motor

Abstract

The present invention relates to a three-phase copper busbar structure for a hybrid electric motor, comprising a copper busbar assembly, wherein the copper busbar assembly is composed of three soft copper busbars welded and arranged with three hard copper busbars, a connecting hole being provided at the extended end of the soft copper busbar, a blocking block being provided on the extended end of the hard copper busbar, a threaded insert being riveted and provided at the front end of the extended end of the hard copper busbar, an inwardly recessed blind hole being provided on the threaded insert, an insulating shell being injection-molded on the portion of the copper busbar assembly welded between the blocking blocks, an assembly groove being provided on the insulating shell for mounting the hard copper busbar, an assembly hole being provided on the assembly groove, the threaded insert on the hard copper busbar being embedded in the assembly hole, the gap between the assembly groove and the hard copper busbar being filled with epoxy resin, a plurality of nesting holes being provided on the insulating shell, and nesting being provided in the nesting holes. The present invention has a compact structure, is easy to assemble, satisfies the requirements for protecting the motor copper busbar and providing good insulation effects, and is conducive to mass production and automated production of motors.

Description

Technical Field

[0001] The present invention relates to the technical field of hybrid motors, and in particular to a three-phase copper busbar structure of a hybrid motor. Background Art

[0002] As a key electrical component in the powertrain of new energy vehicles, the motor's three-phase copper busbar connects the stator's three-phase wires to external high-voltage lines, transmitting output current and voltage while preventing electromagnetic interference. During motor operation, the transmission of motor power directly impacts the overall vehicle's power. This requires that the connection between the motor and the three-phase copper busbar meet requirements such as mechanical reliability, temperature rise stability, and airtightness.

[0003] At present, the traditional three-phase copper busbar of the motor is a split part. Due to the vibration of the motor, it is easy to cause the parts of the three-phase copper busbar to become loose, generate noise, and affect the normal operation of the three-phase copper busbar. Summary of the Invention

[0004] The purpose of the present invention is to address the corresponding deficiencies of the prior art and to provide a hybrid motor three-phase copper busbar structure that is more stable and safe and does not require special assembly with the motor.

[0005] The objective of the present invention is achieved by adopting the following scheme: a three-phase copper busbar structure of a hybrid electric motor, comprising: a copper busbar assembly, wherein the copper busbar assembly is composed of three soft copper buses welded and arranged respectively with three hard copper buses, a connecting hole is provided at the extended end of the soft copper busbar, a blocking block is provided on the extended end of the hard copper busbar, a threaded insert is riveted at the front end of the extended end of the hard copper busbar, an inwardly recessed blind hole is provided on the threaded insert, an insulating shell is injection-molded on the part of the copper busbar assembly welded between the blocking blocks, a copper busbar groove is provided on the insulating shell, the soft copper busbar and the hard copper busbar are welded and fixed at the notch of the copper busbar groove, an assembly groove for installing the hard copper busbar is provided on the insulating shell, an assembly hole is provided on the assembly groove, the threaded insert on the hard copper busbar is embedded in the assembly hole, the gap between the assembly groove and the hard copper busbar is filled with epoxy resin, a plurality of nesting holes are provided on the insulating shell, and nesting is provided in the nesting holes.

[0006] Furthermore, the soft copper busbar and the hard copper busbar are fixed by silver-copper brazing. The soft copper busbar is formed by stamping multiple copper sheets. The connection holes on the soft copper busbar are circular holes, waist-shaped holes, U-shaped holes or square holes.

[0007] Furthermore, the soft copper busbar can be bent by 0-90° relative to the thickness direction of the copper busbar and by 0-5° relative to the width direction of the copper busbar.

[0008] Furthermore, the bending angle of the hard copper busbar is 0-180°.

[0009] Furthermore, a sealing ring installation groove is provided on one end of the insulating shell assembly groove, and a sealing ring is provided in the sealing ring installation groove.

[0010] Furthermore, the insulating shell is provided with a heat dissipation groove and an oil guide groove.

[0011] The above technical solution is adopted: comprising: a copper busbar assembly, which is composed of three soft copper buses welded and arranged with three hard copper buses respectively, a connecting hole is provided on the extended end of the soft copper busbar, a blocking block is provided on the extended end of the hard copper busbar, a threaded insert is riveted on the front end of the extended end of the hard copper busbar, an inwardly recessed blind hole is provided on the threaded insert, an insulating shell is injection molded on the part of the copper busbar assembly welded between the blocking blocks, an assembly groove for installing the hard copper busbar is provided on the insulating shell, an assembly hole is provided on the assembly groove, the threaded insert on the hard copper busbar is embedded in the assembly hole, the gap between the assembly groove and the hard copper busbar is filled with epoxy resin, a plurality of nesting holes are provided on the insulating shell, and nesting is provided in the nesting holes. The entire copper busbar assembly is injection molded into the insulating shell through a mold, so that the entire copper busbar assembly and the insulating shell form a complete whole, which improves reliability and solves the NVH problem of the split three-phase copper busbar. The setting of the blocking block and the potting epoxy resin forms a double sealing effect, sealing the entire three-phase copper busbar structure to prevent the internal cooling oil temperature generated during the long-term operation of the motor and the continuous transmission of large current from causing the three-phase copper busbar to be in a thermal equilibrium state. Due to the different thermal expansion coefficients of metal and plastic, gaps will be generated between the metal and plastic, resulting in airtightness or oil leakage.

[0012] The soft copper busbar and the hard copper busbar are fixed by silver-copper brazing. The soft copper busbar is stamped from multiple copper sheets. The connection holes on the soft copper busbar are circular holes, waist-shaped holes, U-shaped holes or square holes. Silver-copper brazing can reduce the vibration and impact of the copper busbar assembly caused by the motor during operation. The different shapes of the connection holes can meet the connection needs of different types of power transmission wires and copper busbar assemblies.

[0013] The soft copper busbar can be bent 0-90° relative to the thickness and 0-5° relative to the width. The rigid copper busbar can be bent at angles of 0-180°. Different bending angles allow for assembly at different heights and angles.

[0014] A sealing ring installation groove is provided on one end of the insulating shell assembly groove, and a sealing ring is provided in the sealing ring installation groove. The sealing ring further seals the insulating shell, thereby improving the air tightness of the insulating shell.

[0015] The insulating shell is provided with a heat dissipation groove and an oil guide groove. The heat dissipation groove can quickly reduce the temperature of the copper busbar assembly, and the oil guide groove is used for the flow of oil in the motor box.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] The busbar structure of the present invention is compact and easy to assemble. It adopts a new design, new process and new structure to meet the protection and insulation protection of the motor copper busbar assembly. It has a low cost and is conducive to the batch and automated production of motors. It can also meet the high temperature generated and continuous transmission of large current during the long-term operation of the motor, and can withstand high and low temperature impacts for a long time. The different thermal deformation coefficients of metal and plastic will not affect the air tightness of the assembly or oil leakage, thereby ensuring product reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the three-phase copper busbar structure of the present invention;

[0019] Figure 2 This is a schematic structural diagram of the copper busbar assembly of the present invention;

[0020] Figure 3 It is a structural schematic diagram of the insulating housing of the present invention;

[0021] Figure 4 It is a structural schematic diagram of the insulating housing of the present invention from another direction. DETAILED DESCRIPTION

[0022] like Figures 1 to 4 As shown, a three-phase copper busbar structure of a hybrid motor includes: a copper busbar assembly 1, wherein the copper busbar assembly 1 is composed of three soft copper buses 11 welded and arranged with three hard copper buses 12, a connecting hole 111 is provided at the extended end of the soft copper busbar 11, a blocking block 13 is provided on the extended end of the hard copper busbar 12, a rivet hole is provided at the front end of the extended end of the hard copper busbar 12, a threaded insert 2 is riveted into the rivet hole by a riveting machine, an inwardly recessed blind hole with an internal thread is provided on the threaded insert 2 to avoid clogging of the thread by the molten material of the insulating shell 4, and the blind hole is manufactured according to the effective thread length of the fixing bolt. An insulating housing 4 is injection molded on the portion between the blocking blocks 13 at the welding point 3 of the copper busbar assembly 1. A copper busbar groove 14 is provided on the insulating housing 4. The soft copper busbar 11 and the hard copper busbar 12 are welded and fixed at the notch of the copper busbar groove 14. An assembly groove 41 for mounting the hard copper busbar 12 is provided on the insulating housing 4. The assembly groove 41 is provided with an assembly hole 42. The threaded insert 2 on the hard copper busbar 12 is embedded in the assembly hole 42. The gap between the assembly groove 41 and the hard copper busbar 12 is filled with epoxy resin 43. A plurality of nesting holes 44 are provided on the insulating housing 4. In this embodiment, there are five nesting holes 44, and nesting holes 45 are provided in the nesting holes 44. A sealing ring 6 mounting groove 5 is provided on one end of the assembly groove 41 of the insulating housing 4, and a sealing ring 6 is provided in the sealing ring 6 mounting groove 5. The insulating housing 4 is provided with a heat dissipation groove 7 and an oil guide groove.

[0023] The soft copper busbar 11 and the hard copper busbar 12 of this embodiment are fixed by silver-copper brazing. A 0.3mm to 0.5mm weld is retained at the welding point 3 between the soft copper busbar 11 and the hard copper busbar 12 for filling with silver-copper brazing material. The soft copper busbar 11 is made of multiple copper sheets or foils that are hardened at both ends using polymer diffusion welding, and the copper busbar is retained in the middle. The connection hole 111 on the soft copper busbar 11 is a circular hole, a waist-shaped hole, a U-shaped hole, or a square hole. The connection hole 111 of this embodiment is a circular hole. The soft copper busbar 11 can be bent 0 to 90 degrees relative to the thickness of the copper busbar and 0 to 5 degrees relative to the width of the copper busbar. The bending angle of the hard copper busbar 12 is 0 to 180 degrees.

[0024] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications made to the present invention by those skilled in the art without departing from the spirit of the present invention shall fall within the scope of protection of the present invention.

Claims

1. A three-phase copper busbar structure for a hybrid motor, characterized in that: include: A copper busbar assembly, wherein the copper busbar assembly is composed of three soft copper buses welded and arranged respectively with three hard copper buses, a connecting hole is provided on the extended end of the soft copper busbar, a blocking block is provided on the extended end of the hard copper busbar, a threaded insert is riveted on the front end of the extended end of the hard copper busbar, an inwardly recessed blind hole is provided on the threaded insert, an insulating shell is injection molded of the hard copper busbar portion between the welding point of the soft copper busbar and the hard copper busbar of the copper busbar assembly and the blocking block, a copper busbar groove is provided on the insulating shell, the soft copper busbar and the hard copper busbar are welded and fixed at the notch of the copper busbar groove, an assembly groove for installing the hard copper busbar is provided on the insulating shell, an assembly hole is provided on the assembly groove, the threaded insert on the hard copper busbar is embedded in the assembly hole, the gap between the assembly groove and the hard copper busbar is filled with epoxy resin, a plurality of nesting holes are provided on the insulating shell, and nesting is provided in the nesting holes.

2. The hybrid motor three-phase copper busbar structure according to claim 1, characterized in that: The soft copper busbar and the hard copper busbar are fixed by silver-copper brazing. The soft copper busbar is formed by stamping multiple copper sheets. The connection holes on the soft copper busbar are circular holes, waist-shaped holes, U-shaped holes or square holes.

3. The hybrid motor three-phase copper busbar structure according to claim 1, characterized in that: The soft copper busbar can be bent by 0-90 degrees relative to the thickness direction of the copper busbar and by 0-5 degrees relative to the width direction of the copper busbar.

4. The hybrid motor three-phase copper busbar structure according to claim 1, characterized in that: The bending angle of the hard copper busbar is 0-180°.

5. The hybrid motor three-phase copper busbar structure according to claim 1, characterized in that: A sealing ring installation groove is provided on one end of the insulating shell assembly groove, and a sealing ring is provided in the sealing ring installation groove.

6. The hybrid motor three-phase copper busbar structure according to claim 1, characterized in that: The insulating shell is provided with a heat dissipation groove and an oil guide groove.

Images