A busbar and a flat wire motor

Abstract

The present invention relates to the technical field of motors, and discloses a busbar and a flat wire motor. The busbar includes a busbar bracket, and a first-phase busbar, a second-phase busbar, a third-phase busbar and a neutral point connection busbar stacked in sequence within the busbar bracket. The first-phase busbar, the second-phase busbar, the third-phase busbar and the neutral point connection busbar each include a main body portion, and a first connection portion and a second connection portion located on both sides of the main body portion respectively. The first connection portion is connected to a first outgoing conductor corresponding to the innermost phase of the stator winding, and the second connection portion is connected to a second outgoing conductor corresponding to the outermost phase of the stator winding. The main body portions of the first-phase busbar, the second-phase busbar, the third-phase busbar and the neutral point connection busbar are all arranged between the first outgoing conductor and the second outgoing conductor. The structure of the present invention is compact and reliable, convenient to assemble, simple in process, small in size, high in integration, and easy to realize automated production.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and particularly to a busbar and a flat wire motor. Background Art

[0002] With the rapid growth of the new energy vehicle market and the rapid development of new energy vehicle technologies, the electric drive system is gradually moving towards high speed, miniaturization, and high efficiency. At the same time, the vehicle has put forward higher requirements for the cost and performance of the electric drive system. Therefore, the motor assembly is gradually developing towards miniaturization and integration.

[0003] Flat wire motors are increasingly favored due to their outstanding high slot fill factor and high power density, from four-layer pin windings to six-layer pin windings, and then to eight-layer pin windings. With the increase in the number of parallel branches and the number of layers, their lead wires are becoming more and more complex. In order to reduce the assembly difficulty, reduce the error frequency, improve the appearance quality of the motor stator assembly, and also to achieve automated production, flat wire motors mostly use busbars to shape and connect their lead wires. Currently, the existing busbars on the market either have a simple winding form, or are bulky and have complex processes, or connect the lead wires non-integrally to increase the assembly process to reduce the complexity of the busbar. Summary of the Invention

[0004] Based on the above problems, the purpose of the present invention is to provide a busbar and a flat wire motor with simple process, small volume, and high integration.

[0005] To achieve the above purpose, the following technical solutions are provided:

[0006] In a first aspect, the present invention provides a busbar, which includes a busbar bracket and a first-phase busbar, a second-phase busbar, a third-phase busbar, and a neutral point connection busbar stacked in sequence within the busbar bracket. The first-phase busbar is used to connect to the U-phase lead wire of the stator winding of the flat wire motor, the second-phase busbar is used to connect to the V-phase lead wire of the stator winding of the flat wire motor, and the third-phase busbar is used to connect to the W-phase lead wire of the stator winding of the flat wire motor. The first-phase busbar, the second-phase busbar, the third-phase busbar, and the neutral point connection busbar respectively include a main body portion and a first connection portion and a second connection portion located on both sides of the main body portion. The first connection portion is connected to the first lead conductor corresponding to the innermost phase of the stator winding, and the second connection portion is connected to the second lead conductor corresponding to the outermost phase of the stator winding. The main body portions of the first-phase busbar, the second-phase busbar, the third-phase busbar, and the neutral point connection busbar are all arranged between the first lead conductor and the second lead conductor.

[0007] As an alternative to the busbar provided by the present invention, it further includes a temperature sensor adhesively bonded to the busbar bracket. The busbar bracket is provided with a receiving groove, and the temperature sensor is located in the receiving groove.

[0008] As an alternative to the busbar provided by the present invention, the busbar bracket is provided with a first card slot, a second card slot, and a third card slot, and the leads of the temperature sensor sequentially pass through the first card slot, the second card slot, and the third card slot.

[0009] As an alternative to the busbar provided by the present invention, connection pieces are provided on the main body parts of the first-phase busbar, the second-phase busbar, and the third-phase busbar. The connection pieces of the first-phase busbar, the second-phase busbar, and the third-phase busbar are used to connect to the inverter-side busbar. The first card slot is located between the connection piece of the first-phase busbar and the connection piece of the second-phase busbar. The second card slot is located between the connection piece of the second-phase busbar and the connection piece of the third-phase busbar. The third card slot is located on the side of the connection piece of the third-phase busbar away from the connection piece of the second-phase busbar.

[0010] As an alternative to the busbar provided by the present invention, oblong holes are provided on the connection pieces of the first-phase busbar, the second-phase busbar, and the third-phase busbar, and the inverter-side busbar is threadedly connected to the oblong holes through riveting studs.

[0011] As an alternative to the busbar provided by the present invention, the busbar bracket is integrally formed by an injection molding process.

[0012] As an alternative to the busbar provided by the present invention, a plurality of positioning holes are provided in the circumferential direction of the busbar bracket.

[0013] As an alternative to the busbar provided by the present invention, the bottom surface of the busbar bracket is a plane.

[0014] As an alternative to the busbar provided by the present invention, the main body parts of the first-phase busbar, the second-phase busbar, and the third-phase busbar are arranged at equal intervals along the axial direction of the busbar bracket.

[0015] In a second aspect, the present invention further provides a flat wire motor, including a housing, a stator, and a rotor. The stator includes a stator core and a stator winding assembled into the slots of the stator core. The stator further includes the busbar as described above, and the stator winding is connected to a connection copper bar through the busbar.

[0016] The beneficial effects of the present invention are:

[0017] The busbar and the flat wire motor provided by the present invention. The busbar includes a busbar bracket and a first-phase busbar, a second-phase busbar, a third-phase busbar, and a neutral point connection busbar that are sequentially stacked within the busbar bracket. The first-phase busbar is connected to the U-phase lead-out wire of the stator winding of the flat wire motor, the second-phase busbar is connected to the V-phase lead-out wire of the stator winding of the flat wire motor, and the third-phase busbar is connected to the W-phase lead-out wire of the stator winding of the flat wire motor. The first-phase busbar, the second-phase busbar, the third-phase busbar, and the neutral point connection busbar each include a main body portion and a first connection portion and a second connection portion located on both sides of the main body portion respectively. The first connection portion is connected to the first lead-out conductor corresponding to the innermost phase of the stator winding, and the second connection portion is connected to the second lead-out conductor corresponding to the outermost phase of the stator winding. The main body portions of the first-phase busbar, the second-phase busbar, the third-phase busbar, and the neutral point connection busbar are all arranged between the first lead-out conductor and the second lead-out conductor. The busbar and the flat wire motor provided by the present invention, with a complex winding form of an eight-layer winding, require 24 lead-out wires to be uniformly welded and fixed on the busbar, while leading out connection terminals that can be directly connected to the inverter assembly, and integrating temperature sensors, effectively improving production efficiency, having a compact and reliable structure, being convenient for assembly, having a simple process, a small volume, a high degree of integration, and being easy to realize automated production. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following will briefly introduce the drawings required for description in the embodiments of the present invention. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on the content of the embodiments of the present invention and these drawings.

[0019] Figure 1 is a schematic structural diagram of the busbar and the stator of the flat wire motor provided by the specific embodiment of the present invention;

[0020] Figure 2 is a schematic structural diagram of the busbar provided by the specific embodiment of the present invention from one perspective;

[0021] Figure 3 is a schematic structural diagram of the busbar provided by the specific embodiment of the present invention from another perspective;

[0022] Figure 4 is an exploded schematic diagram of the busbar provided by the specific embodiment of the present invention.

[0023] In the figure:

[0024] 1 - busbar bracket; 2 - first-phase busbar; 3 - second-phase busbar; 4 - third-phase busbar; 5 - neutral point connection busbar; 6 - temperature sensor;

[0025] 11 - accommodation groove; 12 - first card slot; 13 - second card slot; 14 - third card slot; 15 - positioning hole; 16 - bottom plate; 17 - housing; 18 - reinforcing rib; 19 - avoidance hole; 110 - first reinforcing plate; 111 - second reinforcing plate;

[0026] 21 - main body part; 22 - first wiring part; 23 - second wiring part; 24 - connecting piece; 25 - oblong hole; 26 - through hole;

[0027] 61 - lead wire;

[0028] 100 - stator core; 200 - stator winding. Detailed implementation manner

[0029] To make the technical problems solved by the present invention, the technical solutions adopted and the achieved technical effects clearer, the technical solutions of the embodiments of the present invention will be further described in detail below with reference to the drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative efforts belong to the scope of protection of the present invention.

[0030] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. Among them, the terms "first position" and "second position" are two different positions.

[0031] In the description of the present invention, it should be noted that unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it can be a fixed connection or a detachable connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0032] Such as Figures 1 to 4As shown in the figure, this embodiment provides a busbar, which includes a busbar bracket 1 and a first-phase busbar 2, a second-phase busbar 3, a third-phase busbar 4, and a neutral point connection busbar 5 stacked in the busbar bracket 1 in sequence. The first-phase busbar 2 is used to connect to the U-phase lead of the stator winding 200 of the flat wire motor, the second-phase busbar 3 is used to connect to the V-phase lead of the stator winding 200 of the flat wire motor, and the third-phase busbar 4 is used to connect to the W-phase lead of the stator winding 200 of the flat wire motor.

[0033] The first-phase busbar 2, the second-phase busbar 3, the third-phase busbar 4, and the neutral point connection busbar 5 respectively include a main body portion 21 and a first connection portion 22 and a second connection portion 23 located on both sides of the main body portion 21. The first connection portion 22 is connected to the first outgoing conductor corresponding to the innermost phase of the stator winding 200, and the second connection portion 23 is connected to the second outgoing conductor corresponding to the outermost phase of the stator winding 200.

[0034] The main body portions 21 of the first-phase busbar 2, the second-phase busbar 3, the third-phase busbar 4, and the neutral point connection busbar 5 are all arranged between the first outgoing conductor and the second outgoing conductor. Specifically, there are 12 first connection portions 22 on the inner circle of the busbar, which are welded to the 12 first outgoing conductors corresponding to the innermost phase of the stator winding 200 one by one. There are 12 second connection portions 23 on the outer circle of the busbar, which are welded to the 12 second outgoing conductors corresponding to the outermost phase of the stator winding 200 one by one.

[0035] To facilitate the measurement of the temperature parameters of the stator, optionally, the busbar further includes a temperature sensor 6 adhered to the busbar bracket 1. A receiving groove 11 is provided on the busbar bracket 1, and the temperature sensor 6 is located in the receiving groove 11.

[0036] To facilitate installation, optionally, the busbar bracket 1 is provided with a first card slot 12, a second card slot 13, and a third card slot 14. The lead 61 of the temperature sensor 6 sequentially passes through the first card slot 12, the second card slot 13, and the third card slot 14. The first card slot 12 and the second card slot 13 are opened in the horizontal direction, and the third card slot 14 is opened in the vertical direction, thereby clamping and limiting the lead 61 of the temperature sensor 6 in different directions, avoiding the inaccurate position of the installation point of the temperature sensor 6 on the production line.

[0037] Optionally, connection tabs 24 are provided on the main bodies 21 of the first-phase busbar 2, the second-phase busbar 3, and the third-phase busbar 4. The connection tabs 24 of the first-phase busbar 2, the second-phase busbar 3, and the third-phase busbar 4 are used to connect to the inverter-side busbar. The first card slot 12 is located between the connection tab 24 of the first-phase busbar 2 and the connection tab 24 of the second-phase busbar 3. The second card slot 13 is located between the connection tab 24 of the second-phase busbar 3 and the connection tab 24 of the third-phase busbar 4. The third card slot 14 is located on the side of the connection tab 24 of the third-phase busbar 4 away from the connection tab 24 of the second-phase busbar 3. The connection tabs 24 of the first-phase busbar 2, the second-phase busbar 3, and the third-phase busbar 4 are arranged in sequence, making full use of the limited installation space.

[0038] Optionally, oblong holes 25 are provided on the connection tabs 24 of the first-phase busbar 2, the second-phase busbar 3, and the third-phase busbar 4. The inverter-side busbar is threadedly connected to the oblong holes 25 through press riveting studs. On the one hand, it reduces the difficulty of installation operation. On the other hand, the press riveting studs are closed-type, avoiding the shedding of iron filings during tightening and improving the cleanliness.

[0039] Optionally, the busbar support 1 is integrally formed by an injection molding process. Specifically, after the first-phase busbar 2, the second-phase busbar 3, the third-phase busbar 4, and the neutral point connection busbar 5 are stacked and positioned, the busbar support 1 is injection molded.

[0040] Optionally, a plurality of positioning holes 15 are provided on the circumference of the busbar support 1. There are 12 positioning holes 15 on the outer circumference of the busbar support 1 for circumferential positioning of the busbars.

[0041] For convenient axial positioning with the tooling fixture, optionally, the bottom surface of the busbar support 1 is a plane. During the assembly process of the busbar and the stator winding 200, the bottom surface of the busbar support 1 can be used for planar positioning, which is easy to realize automated production.

[0042] Optionally, the main bodies 21 of the first-phase busbar 2, the second-phase busbar 3, and the third-phase busbar 4 are arranged at equal intervals along the axial direction of the busbar support 1, making full use of the effective space in the axial and radial directions.

[0043] In this embodiment, the busbar bracket 1 includes a bottom plate 16 and a housing 17 disposed on the bottom plate 16. A plurality of reinforcing ribs 18 are circumferentially arranged on the housing 17 for reinforcement. An avoidance hole 19 is also provided on the housing 17 for avoiding the first connection portions 22 and the second connection portions 23 of the first-phase busbar 2, the second-phase busbar 3, the third-phase busbar 4, and the neutral point connection busbar 5. Two first connection portions 22 and two second connection portions 23 are respectively provided for the first-phase busbar 2, the second-phase busbar 3, and the third-phase busbar 4. Six first connection portions 22 and six second connection portions 23 are respectively provided for the neutral point connection busbar 5, and they are arranged adjacent to each other in pairs. In the circumferential direction, the first connection portions 22 and the second connection portions 23 of the first-phase busbar 2, the second-phase busbar 3, the third-phase busbar 4, and the neutral point connection busbar 5 are arranged in sequence. A plurality of through holes 26 are respectively provided on the main body portions 21 of the first-phase busbar 2, the second-phase busbar 3, the third-phase busbar 4, and the neutral point connection busbar 5. A circumferential first reinforcing plate 110 and a radial second reinforcing plate 111 are provided on the bottom plate 16.

[0044] The busbar provided in this embodiment is equipped with a complex winding form of eight-layer windings. It is necessary to uniformly weld and fix 24 lead-out wires on the busbar, and at the same time lead out connection terminals that can be directly connected to the inverter assembly, and integrate the temperature sensor 6, effectively improving production efficiency, with a compact and reliable structure, convenient assembly, simple process, small volume, high integration, and easy to realize automated production.

[0045] This embodiment also provides a flat wire motor, which includes a housing, a stator, and a rotor. The stator includes a stator core 100 and a stator winding 200 assembled into the slot of the stator core 100. The stator also includes the busbar as described above. The stator winding 200 is connected to a connection copper bar through the busbar, with a compact and reliable structure, convenient assembly, simple process, small volume, high integration, and easy to realize automated production. Because the flat wire occupies less space, the outer diameter and volume of the motor can be reduced, resulting in a smaller volume, less material used, and lower cost for the flat wire motor. Compared with the round wire motor, the flat wire motor can take a relatively smaller slot opening size, which can effectively reduce the cogging torque, thereby reducing the motor noise.

[0046] Note that the above is only the preferred embodiment of the present invention and the applied technical principles. Those skilled in the art will understand that the present invention is not limited to the specific embodiments here. Various obvious changes, re-adjustments, and substitutions can be made by those skilled in the art without departing from the protection scope of the present invention. Therefore, although the present invention has been described in more detail through the above embodiments, the present invention is not limited to the above embodiments. Without departing from the concept of the present invention, more other equivalent embodiments can be included, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A bus bar, characterized in that, It includes a busbar bracket (1), as well as a first-phase busbar (2), a second-phase busbar (3), a third-phase busbar (4) and a neutral point connection busbar (5) stacked in sequence within the busbar bracket (1). The first-phase busbar (2) is used to connect to the U-phase lead-out wire of the stator winding (200) of the flat wire motor. The second-phase busbar (3) is used to connect to the V-phase lead-out wire of the stator winding (200) of the flat wire motor. The third-phase busbar (4) is used to connect to the W-phase lead-out wire of the stator winding (200) of the flat wire motor. The first-phase busbar (2), the second-phase busbar (3), the third-phase busbar (4) and the neutral point connection busbar (5) respectively include a main body portion (21), as well as a first connection portion (22) and a second connection portion (23) located on both sides of the main body portion (21). The first connection portion (22) is connected to the first outgoing conductor corresponding to the innermost phase of the stator winding (200), and the second connection portion (23) is connected to the second outgoing conductor corresponding to the outermost phase of the stator winding (200). The main body portions (21) of the first-phase busbar (2), the second-phase busbar (3), the third-phase busbar (4) and the neutral point connection busbar (5) are all arranged between the first outgoing conductor and the second outgoing conductor; It further includes a temperature sensor (6) adhered to the busbar bracket (1). A receiving groove (11) is provided on the busbar bracket (1), and the temperature sensor (6) is located within the receiving groove (11); The busbar bracket (1) is provided with a first card slot (12), a second card slot (13) and a third card slot (14). The lead (61) of the temperature sensor (6) sequentially passes through the first card slot (12), the second card slot (13) and the third card slot (14); The first card slot (12) and the second card slot (13) are opened in the horizontal direction, and the third card slot (14) is opened in the vertical direction; Connection pieces (24) are provided on the main body portions (21) of the first-phase busbar (2), the second-phase busbar (3) and the third-phase busbar (4). The connection pieces (24) of the first-phase busbar (2), the second-phase busbar (3) and the third-phase busbar (4) are used to connect to the inverter-side busbar. The first card slot (12) is located between the connection piece (24) of the first-phase busbar (2) and the connection piece (24) of the second-phase busbar (3). The second card slot (13) is located between the connection piece (24) of the second-phase busbar (3) and the connection piece (24) of the third-phase busbar (4). The third card slot (14) is located on the side of the connection piece (24) of the third-phase busbar (4) away from the connection piece (24) of the second-phase busbar (3); The busbar support (1) includes a bottom plate (16) and a housing (17) disposed on the bottom plate (16). A plurality of reinforcing ribs (18) are circumferentially provided on the housing (17) for reinforcement. An avoidance hole (19) is also provided on the housing (17) for avoiding the first connection portions (22) and the second connection portions (23) of the first-phase busbar (2), the second-phase busbar (3), the third-phase busbar (4), and the neutral point connection busbar (5).

2. The bus bar according to claim 1, characterized in that, Elongated holes (25) are provided on the connection pieces (24) of the first-phase busbar (2), the second-phase busbar (3), and the third-phase busbar (4). The inverter-side busbar is threadedly connected to the elongated holes (25) through press rivet studs.

3. The bus bar according to claim 1, characterized in that, The busbar support (1) is integrally formed by an injection molding process.

4. The bus bar according to claim 1, wherein A plurality of positioning holes (15) are circumferentially provided on the busbar support (1).

5. The bus bar according to claim 1, characterized in that, The bottom surface of the busbar support (1) is a flat surface.

6. The bus bar according to any one of claims 1-5, characterized in that, The main body portions (21) of the first-phase busbar (2), the second-phase busbar (3), and the third-phase busbar (4) are arranged at equal intervals along the axial direction of the busbar support (1).

7. A flat wire motor, comprising a housing, a stator and a rotor, the stator comprising a stator core (100) and a stator winding (200) assembled into the slot of the stator core (100), characterized in that, The stator further includes a busbar as described in any one of claims 1-6, and the stator winding (200) is connected to a connection copper bar through the busbar.

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