Busbar assembly, motor, electric power steering system and vehicle

Abstract

The present invention provides a busbar assembly, a motor, an electric power steering system, and a vehicle. The busbar assembly includes a plurality of busbars arranged at intervals, each busbar including a main body section and a welding hook disposed on the main body section. The plurality of main body sections of the plurality of busbars constitute a main body portion, the main body portion including a first wall surface and a second wall surface opposite to each other, the first wall surface being closer to the central axis of the motor than the second wall surface. The plurality of welding hooks of the plurality of busbars include a first welding hook and a second welding hook, at least a portion of the first welding hook being disposed protruding from the first wall surface, and at least a portion of the second welding hook being disposed protruding from the second wall surface. The present invention avoids the concentration of the plurality of welding hooks in the same position by disposing the plurality of welding hooks as the first welding hook and the second welding hook with different orientations, rationally utilizing space, increasing the distance between two adjacent welding hooks among the plurality of welding hooks, reducing the difficulty of wire entanglement, wire cutting, and welding, and improving assembly efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a busbar assembly, a motor, an electric power steering system and a vehicle. Background Art

[0002] Currently, the busbar of a motor is composed of a plurality of bus bars, which are interconnected with the starting and ending ends of the windings in the motor stator to ensure normal operation of the motor.

[0003] In order to achieve effective connection between the busbar and the winding, a plurality of welding hooks are provided on the busbar, and the plurality of welding hooks are connected to the corresponding winding. However, due to the large number of welding hooks, when the arrangement of the plurality of welding hooks is unreasonable, the spacing between adjacent welding hooks will be small, which will directly affect the welding efficiency between the winding and the welding hooks and increase the difficulty of welding. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art or related art.

[0005] To this end, a first aspect of the present invention is to provide a current collecting assembly.

[0006] A second aspect of the present invention is to provide an electric motor.

[0007] A third aspect of the present invention is to provide an electric power steering system.

[0008] A fourth aspect of the present invention is to provide a vehicle.

[0009] In view of this, according to a first aspect of the present invention, a busbar assembly for use with a motor is provided. The busbar assembly includes a plurality of spaced-apart busbars, each busbar including a main body segment and a welding hook disposed on the main body segment. The main body segment of the plurality of busbars constitutes a main body portion, which includes a first wall surface and a second wall surface that are opposed to each other, the first wall surface being closer to the central axis of the motor than the second wall surface. The plurality of welding hooks of the plurality of busbars include a first welding hook and a second welding hook, at least a portion of the first welding hook being disposed protruding from the first wall surface, and at least a portion of the second welding hook being disposed protruding from the second wall surface.

[0010] The busbar assembly provided by the present invention includes a plurality of busbars arranged at intervals, and the busbars are insulated from each other. The busbar is a conductor, and the busbar is used to connect the ends of the windings that need to be connected together in the multiple windings of the motor stator, thereby realizing the electrical connection of the multiple winding ends and realizing the busbar function. Each busbar includes a main body section and a welding hook, and the welding hook is provided on the main body section. For a busbar, the number of welding hooks is at least one. The main body sections of the plurality of busbars are used to form a supporting skeleton of the busbar, and the welding hooks are used to connect with the windings. The main body sections of the plurality of busbars are bent and / or curved around the central axis of the motor to form a main body. The main body section includes a first wall surface facing the central axis, and a second wall surface facing away from the first wall surface. Specifically, when the main body section is an arc section, and when the main body section is annular, the first wall surface is an inner contour surface, and the second wall surface is an outer contour surface. The plurality of busbars include a plurality of welding hooks, and the plurality of welding hooks include two types of welding hooks with different orientations, namely, a first welding hook and a second welding hook. At least a portion of the first welding hook is arranged to protrude from the first wall surface, that is, at least a portion of the first welding hook is exposed beyond the first wall surface, that is, the first welding hook is an inner welding hook. At least a portion of the second welding hook is arranged to protrude from the second wall surface, that is, at least a portion of the second welding hook is exposed beyond the second wall surface, that is, the second welding hook is an outer welding hook. By arranging the plurality of welding hooks as the first welding hook and the second welding hook with different orientations, the present invention avoids the plurality of welding hooks from being concentrated in the same position, rationally utilizes space, increases the distance between two adjacent welding hooks in the plurality of welding hooks, reduces the difficulty of wire winding, wire cutting, and welding, and improves assembly efficiency.

[0011] In a possible design, further, the multiple bus bars include at least three phase bus bars and a neutral bus bar, wherein the at least three phase bus bars are distributed at intervals, the welding hook of each phase bus bar is a second welding hook, and the neutral bus bar is arranged on one side of the at least three phase bus bars, and the welding hook of the neutral bus bar is a first welding hook.

[0012] In this design, the multiple busbars include at least three phase busbars and a neutral busbar, and the at least three phase busbars include a U-phase busbar, a V-phase busbar, and a W-phase busbar. The welding hook of each phase busbar is a second welding hook, that is, the welding hook of the phase busbar is an outer welding hook. The neutral busbar is provided on one side of the at least three phase busbars, and the welding hook of the neutral busbar is a first welding hook, that is, the welding hook of the neutral busbar is an inner welding hook. By concentrating the first welding hook on the neutral busbar and the second welding hook on the at least three phase busbars, the preparation of different types of busbars and the connection of the windings are simplified, the distance between the windings and the welding hooks is shortened, thereby shortening the length of the windings and reducing the difficulty of welding the windings.

[0013] In a possible design, further, at least three phase bus bars are distributed at intervals in the radial direction.

[0014] In this design, at least three phase bus bars are spaced apart in the radial direction, and the neutral bus bar is located inside the at least three phase bus bars, reducing the axial space requirement of the bus assembly. For example, in the radial direction, the neutral bus bar and the at least three phase bus bars are different arc segments of concentric circles, that is, from the inside out, they include the neutral bus bar, the first bus bar, the second bus bar, and the third bus bar. Alternatively, each of the at least three phase bus bars includes arc segments of at least three different radii, thereby achieving an interlaced arrangement of the at least three phase bus bars, and within the same radius, a portion of each of the at least three phase bus bars is located at that radius.

[0015] In a possible design, further, at least three phase bus bars are stacked and spaced apart in the axial direction.

[0016] In this design, at least three phase bus bars are stacked and arranged at intervals along the axial direction, and the neutral bus bar is provided on one axial side of the at least three phase bus bars, thereby reducing the radial space requirement of the bus assembly.

[0017] In a possible design, further, the opening of the first welding hook faces the central axis of the motor.

[0018] In this design, the opening of the first welding hook is arranged toward the central axis of the motor, so that the terminal of the stator winding can pass through the opening and enter the first welding hook. Specifically, there are multiple first welding hooks, and the multiple first welding hooks are arranged at intervals.

[0019] In a possible design, further, there are multiple second welding hooks, and the free ends of the multiple second welding hooks are bent toward the same side.

[0020] In this design, multiple second welding hooks are spaced apart around the outer ring of the main body. Each of the second welding hooks includes a first end connected to the main body and a second end (free end) facing away from the first end. The second ends of the second welding hooks are bent / curved to form a wire-accommodating area, into which the stator winding terminals extend and connect. Furthermore, the second ends of the second welding hooks are bent toward the same side, meaning that only one wire-accommodating area is formed between two adjacent second welding hooks. This means that only one wire-accommodating area is formed between the two second welding hooks to accommodate a single winding terminal. This ensures that the winding terminals are evenly distributed, providing ample space for welding the winding terminals and preventing interference between the multiple terminal welding configurations. If the free ends of two adjacent second welding hooks are bent toward each other, two wire-accommodating areas are formed between the two second welding hooks, requiring concentrated welding of the two winding terminals between the two second welding hooks, making welding more difficult.

[0021] Specifically, the free ends of the plurality of second welding hooks can be bent in a counterclockwise or clockwise direction.

[0022] In a possible design, further, the number of the first welding hooks is the same as the number of the second welding hooks, and a first welding hook is provided on the inner side of two adjacent second welding hooks among the plurality of second welding hooks.

[0023] In this design, the number of first welding hooks on the neutral busbar is equal to the sum of the number of second welding hooks on the multiple phase busbars. For example, the winding's terminal end is connected to the second welding hooks of all phase busbars, and the winding's starting end is connected to the first welding hook of the neutral busbar. A first welding hook is located inside two adjacent second welding hooks within the multiple second welding hooks. In other words, within the main body, the multiple welding hooks are arranged in an intermittent pattern, with any first welding hook located circumferentially between two second welding hooks. When connecting the winding terminals, the nearest welding hook can be selected for welding, reducing the difficulty of welding the winding.

[0024] In a possible design, the busbar assembly further includes an insulating member, and a plurality of busbars are connected to the insulating member at intervals.

[0025] In this design, the busbar assembly also includes an insulating member, which supports the multiple busbars and isolates adjacent busbars from each other, providing electrical insulation. Furthermore, the insulating member can be an insulating frame, onto which the multiple busbars are mounted. The insulating member can also be an injection-molded part, integrally molded with the multiple busbars.

[0026] In a possible design, the busbar assembly further includes a positioning portion, which is provided on the insulating member and is used to cooperate with the stator frame of the motor.

[0027] In this design, the busbar also includes a positioning portion, which is provided on the insulating member and can be integrally formed with the insulating member through injection molding. The positioning portion is designed to mate with the stator frame of the motor, thereby achieving a secure connection between the busbar assembly and the stator frame. Furthermore, the positioning portion can be a clip that snaps onto the stator frame. Alternatively, the positioning portion can be a riveted member that is riveted to the stator frame.

[0028] In a possible design, the busbar assembly further includes a mounting notch, which is provided on the insulating member, and at least a portion of the first welding hook is located in the mounting notch.

[0029] In this design, the bus assembly also includes an installation notch, which is provided on the inner wall of the insulating part. When the terminal of the winding extends into the first welding hook, the inner space of the insulating part is relatively compact, and the installation notch can play an effective avoidance role, providing space for the welding of the winding and improving welding efficiency.

[0030] Furthermore, there are multiple mounting notches and multiple first welding hooks, and the multiple mounting notches and the multiple first welding hooks are arranged in a one-to-one correspondence.

[0031] In one possible design, at least three phase busbars further have the same structure, and the main body section of each phase busbar includes a first main body section, a second main body section, and a third main body section that are connected. The at least three phase busbars include three phase copper bars, wherein the first main body section of any one of the three phase copper bars is located outside the other two of the three phase copper bars, the second main body section of any one of the phase copper bars is located between the other two phase copper bars, and a portion of the third main body section of any one of the phase copper bars is located inside the other two phase copper bars.

[0032] In this design, at least three phase busbars share the same structure, meaning they all share a single mold. The entire busbar assembly requires only two molds: one for the phase busbars and one for the neutral busbar. This reduces the number of molds needed to produce the busbars, lowering the difficulty of busbar processing, improving production efficiency, and lowering busbar production costs, effectively enhancing product competitiveness. Furthermore, the busbars are made of copper, which has good electrical conductivity and is relatively inexpensive. Furthermore, copper is easy to stamp and form, and possesses sufficient hardness.

[0033] Furthermore, the main body section of each phase busbar includes a first main body section, a second main body section, and a third main body section that are connected. At least three phase busbars include three phase copper bars, which are arranged in a 120° circumferential array. The specific arrangement of the three phase copper bars satisfies the following conditions: a portion of the first main body section of any phase copper bar is located outside the other two phase copper bars, a portion of the second main body section of any phase copper bar is located between the other two phase copper bars, and a portion of the third main body section of any phase copper bar is located inside the other two phase copper bars. It should be noted that "inside" refers to the direction toward the central axis. "Outside" refers to the direction away from the central axis. For a phase copper bar, the distance between the first main body section and the central axis can be equal or unequal. Similarly, the distance between the second and third main body sections and the central axis is not limited. However, the minimum distance between the first main section and the central axis is greater than the maximum distance between the second main section and the central axis, and the minimum distance between the second main section and the central axis is greater than the maximum distance between the third main section and the central axis, thereby preventing the three phase copper bars from interfering with each other during assembly.

[0034] In a possible design, further, the first main segment is a first arc segment, the second main segment is a second arc segment, and the third main segment is a third arc segment. The radius R1 of the circle where the first arc segment is located, the radius R2 of the circle where the second arc segment is located, and the radius R3 of the circle where the third arc segment is located satisfy R1>R2>R3.

[0035] In this design, the first main section, the second main section, and the third main section are all arc sections, which can facilitate the interlacing of multiple bus bars. The radius of the first main section is greater than the radius of the second arc section, and the radius of the second main section is greater than the radius of the third main section. Since the three phase bus bars have the same structure, the first main sections of the three phase bus bars can form an incomplete outer ring, the second main sections of the three phase bus bars can form an incomplete middle ring, and the third main sections of the three phase bus bars can form an incomplete inner ring. By making each phase bus bar include at least three arc sections with different radii, interference problems during the assembly of multiple phase bus bars can be effectively prevented.

[0036] In a possible design, further, the central angle corresponding to the first arc segment is smaller than 180°.

[0037] In this design, the central angle corresponding to the first arc segment is less than 180°, that is, the circumferential angle of the first arc segment is less than 180°, thereby facilitating mold forming.

[0038] In one possible design, further, the second arc segment and the third arc segment include a second arc segment and a third arc segment located on the axial end face of the phase bus bar, and the second arc segment and the third arc segment include endpoints that are far away from each other, and the angles formed by the two endpoints and the perpendicular to the central axis of the motor are less than 180°.

[0039] In this design, the second arc segment and the third arc segment include a second arc segment and a third arc segment located on the axial end face of the phase bus bar, the second arc segment includes an endpoint A away from the third arc segment, the third arc segment includes an endpoint B away from the second arc segment, and the lines connecting endpoints A and B and the perpendicular to the center axis can form an angle α, and the angle α is less than 180°. When the second arc segment and the third arc segment are an integrated structure, during the preparation process, the circumferential angle α of the second arc segment and the third arc segment is less than 180°, which can facilitate mold forming.

[0040] In a possible design, further, the first main body segment is welded to the outer circumferential surface of the second main body segment.

[0041] In this design, the first main section is welded to the outer circumference of the second main section, simplifying the fabrication of the first, second, and third main sections. A portion of the first main section is attached to the outer circumference of the second main section. Alternatively, the third main section can be welded to the inner circumference of the second main section, with the third, second, and first main sections arranged from the inside out.

[0042] In a possible design, further, the second main body segment and the third main body segment are an integrated structure.

[0043] In this design, the second main section and the third main section are an integrated structure. In order to connect the main sections with different radii, a bending section is provided between the second main section and the third main section. The second main section and the third main section are connected by the bending section. When there are multiple bus bars in the busbar, the second main section and the third main section with different radial sizes can facilitate the interlaced arrangement of multiple bus bars with the same structure.

[0044] In one possible design, the second welding hook further includes a connecting portion and an extending portion. The connecting portion extends axially and is located on the axial end surface of the main body segment. The connecting portion is used to mount the terminal assembly of the motor. One end of the extending portion is connected to the connecting portion, and the other end of the extending portion extends radially away from the central axis of the motor and then bends.

[0045] In this design, the second welding hook includes a connecting portion and an extending portion. The connecting portion extends axially and is located on the axial end face of the main section. The connecting portion is used to install the terminal assembly of the motor. One connecting portion can install one terminal assembly. By separately providing corresponding connecting portions for the terminal assembly, accurate installation of the terminal assembly can be ensured. Specifically, a second welding hook includes one connecting portion, and the number of connecting portions is multiple. The number of wiring terminals in the terminal assembly of the motor is less than the number of connecting portions, and the connecting portion at the appropriate position can be selected for connection according to the interface requirements of the motor. In other words, not all connecting portions will correspond to the installation of wiring terminals. Connecting portions at appropriate positions will be used. Providing multiple connecting portions can meet the various interface requirements of the motor.

[0046] In one possible design, a portion of the insulating member extends away from the first wall to form an assembly portion, wherein the assembly portion is located between the two second welding hooks. The busbar assembly further includes an assembly interface, which is provided on the assembly portion and is used to mount a terminal assembly of the motor.

[0047] In this design, a portion of the insulating part extends away from the first wall surface, that is, the portion of the insulating part extends outward to form an assembly portion. An assembly portion is arranged between the two second welding hooks, and the assembly portion has an assembly interface. The assembly interface is used to install the terminal assembly of the motor, thereby ensuring the reliable connection performance of the terminal assembly.

[0048] In a possible design, the phase bus bar further includes a release groove, which is provided at the connection between the connecting portion, the extending portion and the main body segment.

[0049] In this design, the phase bus bar also includes a release groove, which is provided at the connection between the connecting portion, the extension portion and the main section. The release groove can release the stress during the forming process of the second welding hook. In addition, when the terminal of the winding is welded to the second welding hook, the second welding hook will be subjected to external force. The release groove can provide partial deformation margin to prevent fatigue fracture at the connection between the connecting portion, the extension portion and the main section.

[0050] In a possible design, further, the main section of the neutral bus bar includes a plurality of fourth main sections distributed at intervals, any two of the plurality of fourth main sections have the same structure, and a plurality of first welding hooks are distributed at intervals on each fourth main section.

[0051] In this design, the main section of the neutral busbar includes multiple spaced-apart fourth sections. Any two of these sections have identical structures, allowing for easy molding and low-cost production using a single mold. The sections are arranged in a 180° circumferential array. Multiple first welding hooks are spaced-apart on each section. Specifically, each section has six first welding hooks. The neutral busbar includes 12 first welding hooks.

[0052] In a possible design, further, the fourth main body segment is a fourth arc segment, and the central angle corresponding to the fourth arc segment is less than 180°.

[0053] In this design, the fourth main segment is a fourth arc segment, and the central angle of the fourth arc segment is less than 180°, which facilitates demolding of the fourth arc segment. The radius R4 of the circle containing the fourth arc segment is smaller than the radius R3 of the circle containing the third main segment, avoiding assembly interference between the neutral busbar and the phase busbar.

[0054] According to a second aspect of the present invention, a motor is provided, comprising a housing and a busbar assembly provided by any of the above designs, the busbar assembly being disposed within the housing. The motor also includes a stator frame disposed axially to one side of the busbar assembly, the stator frame having windings connected to weld hooks of the busbar assembly.

[0055] The motor provided by the present invention includes the busbar assembly provided by any of the above designs, and therefore has all the beneficial effects of the busbar assembly, which will not be described in detail here.

[0056] Furthermore, the motor also includes a casing, the bus assembly is arranged in the casing, and the motor also includes a stator frame, the stator frame is connected to one axial side of the bus assembly, and the winding arranged on the stator frame can be connected to the welding hook of the bus assembly.

[0057] In a possible design, further, the stator frame includes a frame body and a matching portion, wherein the matching portion is provided on a side of the frame body close to the bus assembly, and the matching portion is connected to a positioning portion of the bus assembly.

[0058] In this design, the stator frame includes a frame body and a mating portion. The mating portion is located on a side of the frame body close to the bus assembly. The mating portion is connected to the positioning portion of the bus assembly, thereby achieving accurate connection between the frame body and the bus assembly.

[0059] In one possible design, the motor further includes a control assembly disposed on the other side of the busbar assembly along the axial direction, the control assembly having a controller. A terminal assembly includes a terminal frame and wiring terminals disposed on the terminal frame, the wiring terminals being connected between the connection portion of the busbar assembly and the controller, and the terminal frame being mounted at the assembly interface of the busbar assembly.

[0060] In this design, a portion of the terminal skeleton extends into the assembly interface of the bus assembly, thereby realizing the connection of the insulating part. One end of the terminal is connected to the controller, and the other end of the terminal is connected to the connecting part, so that the winding is connected to the controller through the bus assembly and the terminal.

[0061] It should be noted that the connection terminals are connected to the connection portion by resistance welding. Of course, other welding methods such as ultrasonic welding or other fixed connection methods can also be used. Optionally, the number of the connection terminals is three.

[0062] According to a third aspect of the present invention, an electric power steering system is provided, comprising a motor provided by any of the above designs.

[0063] The electric power steering system provided by the present invention includes the motor provided by any of the above designs, and therefore has all the beneficial effects of the motor, which will not be described in detail here.

[0064] According to a fourth aspect of the present invention, a vehicle is provided, comprising the electric power steering system provided by any one of the above designs.

[0065] The vehicle provided by the present invention includes the electric power steering system provided by any of the above designs, and therefore has all the beneficial effects of the electric power steering system, which will not be described in detail here. It is worth noting that the vehicle can be a traditional fuel vehicle or a new energy vehicle. Among them, new energy vehicles include pure electric vehicles, extended-range electric vehicles, hybrid vehicles, fuel cell electric vehicles, hydrogen engine vehicles, etc.

[0066] Additional aspects and advantages of the invention will become apparent from the description which follows, or may be learned by practice of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments with reference to the accompanying drawings, in which:

[0068] Figure 1 It shows one of the structural schematic diagrams of the confluence assembly according to one embodiment of the present invention;

[0069] Figure 2 A second structural schematic diagram of a confluence assembly according to an embodiment of the present invention is shown;

[0070] Figure 3 It shows one of the structural schematic diagrams of a phase bus bar of a bus assembly according to one embodiment of the present invention;

[0071] Figure 4 A second structural schematic diagram of a phase bus bar of a bus assembly according to an embodiment of the present invention is shown;

[0072] Figure 5 A schematic structural diagram of a neutral bus bar of a bus assembly according to an embodiment of the present invention is shown;

[0073] Figure 6 The third structural diagram of the confluence assembly according to one embodiment of the present invention is shown;

[0074] Figure 7 A partial structural schematic diagram of a motor according to an embodiment of the present invention is shown;

[0075] Figure 8 A partial structural schematic diagram of a motor according to an embodiment of the present invention is shown;

[0076] Figure 9 shows one of the structural schematic diagrams of a motor according to one embodiment of the present invention;

[0077] Figure 10 A second structural diagram of a motor according to an embodiment of the present invention is shown;

[0078] Figure 11 FIG. 4 shows a circuit schematic diagram of a motor according to an embodiment of the present invention.

[0079] in, Figures 1 to 10 The corresponding relationship between the reference numerals and component names is as follows:

[0080] 100 busbar components,

[0081] 110 busbars,

[0082] 111-phase busbar, 1111 first main section, 1112 second main section, 1113 third main section, 111a first-phase copper bar, 111b second-phase copper bar, 111c third-phase copper bar,

[0083] 112 neutral bus bar,

[0084] 120 main body, 121 first wall, 122 second wall,

[0085] 131 first welding hook,

[0086] 132 second welding hook, 1321 connecting portion, 1322 extending portion, 1323 releasing slot,

[0087] 140 insulating member, 141 assembly portion, 142 assembly interface, 143 installation notch,

[0088] 150 positioning unit,

[0089] 200 motors,

[0090] 210 stator frame, 211 stator core,

[0091] 220 terminal,

[0092] 230 terminal assembly, 231 terminal block, 232 terminal frame. DETAILED DESCRIPTION

[0093] In order to more clearly understand the above-mentioned objects, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that, in the absence of conflict, the embodiments of the present application and the features therein can be combined with each other.

[0094] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the scope of protection of the present invention is not limited to the specific embodiments disclosed below.

[0095] Refer to the following Figures 1 to 11 The bus assembly 100 , the motor 200 , the electric power steering system and the vehicle according to some embodiments of the present invention are described.

[0096] According to a first aspect of the present invention, a busbar assembly 100 is provided for use in a motor 200, such as Figure 1 、 Figure 2 and Figure 6As shown, the busbar assembly 100 includes a plurality of busbars 110 arranged at intervals. Each busbar 110 includes a main body section and a welding hook provided on the main body section. The multiple main body sections of the multiple busbars 110 constitute a main body portion 120. The main body portion 120 includes a first wall surface 121 and a second wall surface 122 that are opposite to each other. The first wall surface 121 is closer to the central axis of the motor 200 than the second wall surface 122. The multiple welding hooks of the multiple busbars 110 include a first welding hook 131 and a second welding hook 132. At least a portion of the first welding hook 131 protrudes from the first wall surface 121, and at least a portion of the second welding hook 132 protrudes from the second wall surface 122.

[0097] The busbar assembly 100 provided by the present invention includes a plurality of busbars 110 arranged at intervals, and the busbars 110 are insulated from each other. The busbar 110 is a conductor, and the busbar 110 is used to connect the winding ends that need to be connected together in the multiple windings of the stator of the motor 200, thereby realizing the electrical connection of the multiple winding ends and realizing the busbar function. Each busbar 110 includes a main body section and a welding hook, and the welding hook is provided on the main body section. For a busbar 110, the number of welding hooks is at least one. The main body sections of the plurality of busbars 110 are used to form a supporting skeleton for the busbar, and the welding hooks are used to connect with the windings. The main body sections of the plurality of busbars 110 are bent and / or curved around the central axis of the motor 200 to form a main body portion 120. The main body portion 120 includes a first wall 121 facing the central axis, and a second wall 122 opposite to the first wall 121. Specifically, when the main body section is an arc segment, and the main body portion 120 is annular, the first wall surface 121 is an inner contour surface, and the second wall surface 122 is an outer contour surface. The plurality of busbars 110 include a plurality of welding hooks, which include two types of welding hooks facing in different directions: a first welding hook 131 and a second welding hook 132. At least a portion of the first welding hook 131 protrudes from the first wall surface 121, that is, at least a portion of the first welding hook 131 is exposed beyond the first wall surface 121, that is, the first welding hook 131 is an inner welding hook. At least a portion of the second welding hook 132 protrudes from the second wall surface 122, that is, at least a portion of the second welding hook 132 is exposed beyond the second wall surface 122, that is, the second welding hook 132 is an outer welding hook. The present invention avoids the multiple welding hooks from being concentrated at the same position by setting the multiple welding hooks as the first welding hook 131 and the second welding hook 132 in different directions, rationally utilizes space, increases the distance between two adjacent welding hooks among the multiple welding hooks, reduces the difficulty of wire winding, wire cutting and welding, and improves assembly efficiency.

[0098] In one possible design, Figure 1 、 Figure 2 and Figure 6As shown, further, the multiple bus bars 110 include at least three phase bus bars 111 and a neutral bus bar 112, wherein the at least three phase bus bars 111 are distributed at intervals, and the welding hook of each phase bus bar 111 is a second welding hook 132, and the neutral bus bar 112 is arranged on one side of the at least three phase bus bars 111, and the welding hook of the neutral bus bar 112 is a first welding hook 131.

[0099] In this design, the multiple busbars 110 include at least three phase busbars 111 and a neutral busbar 112. The at least three phase busbars 111 include a U-phase busbar 111, a V-phase busbar 111, and a W-phase busbar 111. Each phase busbar 111 has a second welding hook 132 as its welding hook, meaning that the welding hooks of each phase busbar 111 are outer welding hooks. The neutral busbar 112 is located on one side of the at least three phase busbars 111. The welding hooks of the neutral busbar 112 are first welding hooks 131 as its welding hooks, meaning that the welding hooks of the neutral busbar 112 are inner welding hooks. By concentrating the first welding hooks 131 on the neutral busbar 112 and the second welding hooks 132 on the at least three phase busbars 111, the preparation of different types of busbars 110 and the connection of windings are simplified, the distance between the windings and the welding hooks is shortened, and thus the length of the windings is shortened, making the welding of the windings less difficult.

[0100] It should be noted that the circuit composed of the windings (such as the ending ends of the windings) connected to the second welding hooks 132 of at least three phase bus bars 111 and the circuit composed of the windings (such as the starting ends of the windings) connected to the first welding hooks 131 of the neutral bus bar 112 can be connected in parallel to form a multi-phase circuit.

[0101] Furthermore, for each phase bus bar 111, there are multiple second welding hooks 132. Specifically, there are four second welding hooks 132 on each phase bus bar 111. When there are three phase bus bars 111, the three phase bus bars 111 include twelve second welding hooks 132, which are spaced apart and arranged on the outer circle of the main body 120. Correspondingly, there are twelve first welding hooks 131 on the neutral bus bar 112, which are spaced apart and arranged on the inner circle of the main body 120.

[0102] In another design, the first welding hook 131 and the second welding hook 132 can be arbitrarily arranged on the phase bus bar 111 and the neutral bus bar 112, that is, for a bus bar 110, it can include a first welding hook 131 extending toward the central axis, or it can include a second welding hook 132 extending away from the central axis, which is more flexible.

[0103] In one possible design, further, as Figure 1 and Figure 2 As shown, at least three phase bus bars 111 are spaced apart in the radial direction.

[0104] In this design, at least three phase busbars 111 are spaced apart radially, and a neutral busbar 112 is disposed inboard of the at least three phase busbars 111, reducing the axial space required by the busbar assembly 100. Specifically, when the phase busbars 111 and the neutral busbar 112 are radially arranged, the axial height of the busbar 110 is greater than the radial thickness of the busbar 110. For example, in the radial direction, the neutral busbar 112 and the at least three phase busbars 111 are different arc segments of concentric circles, namely, from the inside out, the neutral busbar 112, the first busbar 110, the second busbar 110, and the third busbar 110. Alternatively, each of the at least three phase bus bars 111 includes arc segments of at least three different radii, thereby achieving an interlaced arrangement of the at least three phase bus bars 111. Within the same radius, a portion of each of the at least three phase bus bars 111 is located at the radius.

[0105] In a possible design, further, at least three phase bus bars 111 are stacked and spaced apart in the axial direction.

[0106] In this design, at least three phase busbars 111 are stacked and spaced axially, with a neutral busbar 112 positioned axially to one side of the at least three phase busbars 111. This reduces the radial space required by busbar assembly 100. When the phase and neutral busbars 111, 112 are arranged axially, the axial thickness of busbar 110 is less than its radial width, resulting in a sheet-like structure. Furthermore, the main body of each busbar 110 is an arc segment of the same radius. When multiple arc segments are stacked axially, they form a cylinder, further optimizing space utilization.

[0107] In one possible design, further, as Figure 1 、 Figure 2 、 Figure 5 and Figure 6 As shown, the opening of the first welding hook 131 faces the central axis of the motor 200 .

[0108] In this design, the opening of the first welding hook 131 is arranged toward the central axis of the motor 200, so that the stator winding terminal 220 can pass through the opening and enter the first welding hook 131. Specifically, there are multiple first welding hooks 131, and the multiple first welding hooks 131 are arranged at intervals.

[0109] In one possible design, further, as Figure 1 、 Figure 2 、 Figure 3 and Figure 4 As shown, there are multiple second welding hooks 132 , and the free ends of the multiple second welding hooks 132 are bent toward the same side.

[0110] In this design, multiple second welding hooks 132 are spaced apart and arranged around the outer ring of the main body 120. Each of the second welding hooks 132 includes a first end connected to the main body 120 and a second end (free end) facing away from the first end. The second ends of the second welding hooks 132 are bent / curved to form a wire-accommodating region, into which the stator winding terminals 220 extend and connect. Furthermore, the second ends of the second welding hooks 132 are bent toward the same side, meaning that only one wire-accommodating region is formed between two adjacent second welding hooks 132. In other words, the region between two second welding hooks 132 accommodates only one winding terminal 220. This ensures that the winding terminals 220 are evenly distributed, providing ample space for welding the winding terminals 220, and preventing interference between the welded components of the multiple terminals 220. If the free ends of two adjacent second welding hooks 132 are bent toward each other, the two second welding hooks 132 form two wire-accommodating areas. The two winding terminals 220 need to be welded together between the two second welding hooks 132 , which makes welding more difficult.

[0111] Specifically, the free ends of the plurality of second welding hooks 132 may be bent in a counterclockwise or clockwise direction.

[0112] In one possible design, further, as Figure 1 、 Figure 2 and Figure 6 As shown, the number of the first welding hooks 131 is the same as the number of the second welding hooks 132 , and one first welding hook 131 is provided inside two adjacent second welding hooks 132 among the plurality of second welding hooks 132 .

[0113] In this design, the number of first welding hooks 131 on the neutral busbar 112 is equal to the sum of the number of second welding hooks 132 on the multiple phase busbars 111. For example, the end of the winding is connected to the second welding hooks 132 of all phase busbars 111, and the beginning of the winding is connected to the first welding hook 131 of the neutral busbar 112. A first welding hook 131 is provided inside two adjacent second welding hooks 132 among the multiple second welding hooks 132. In other words, for the main body 120, the multiple welding hooks arranged inside and outside are arranged in an alternating pattern. In the circumferential direction, any first welding hook 131 is located between two second welding hooks 132. When the winding terminal 220 is being connected, the desired welding hook can be selected nearby for welding, reducing the difficulty of winding welding.

[0114] In one possible design, further, as Figure 6 As shown, the busbar assembly 100 further includes an insulating member 140 , and the plurality of busbars 110 are connected to the insulating member 140 at intervals.

[0115] In this design, busbar assembly 100 also includes an insulator 140. This insulator 140 supports the multiple busbars 110 and isolates adjacent busbars 110 from each other, providing electrical insulation. Furthermore, insulator 140 can be an insulating frame, onto which the multiple busbars 110 are mounted. Insulator 140 can also be an injection-molded component, integrally molded with the multiple busbars 110.

[0116] In one possible design, further, as Figure 6 and Figure 9 As shown, the busbar assembly 100 further includes a positioning portion 150 . The positioning portion 150 is provided on the insulating member 140 . The positioning portion 150 is used to cooperate with the stator frame 210 of the motor 200 .

[0117] In this design, busbar 110 also includes a positioning portion 150, which is provided on insulator 140. Positioning portion 150 can be integrally formed with insulator 140 through injection molding. Positioning portion 150 is designed to mate with stator frame 210 of motor 200, thereby achieving a secure connection between busbar assembly 100 and stator frame 210. Furthermore, positioning portion 150 can be a clip that snaps onto stator frame 210. Alternatively, positioning portion 150 can be a riveted component that is riveted to stator frame 210.

[0118] In one possible design, further, as Figure 6 As shown, the busbar assembly 100 further includes a mounting notch 143 . The mounting notch 143 is provided on the insulating member 140 , and at least a portion of the first welding hook 131 is located in the mounting notch 143 .

[0119] In this design, the bus assembly 100 also includes an installation notch 143, which is provided on the inner wall of the insulating member 140. When the terminal 220 of the winding extends into the first welding hook 131, the inner space of the insulating member 140 is relatively compact, and the installation notch 143 can play an effective avoidance role, providing space for the welding of the winding and improving welding efficiency.

[0120] Furthermore, there are multiple mounting notches 143 and multiple first welding hooks 131 , and the multiple mounting notches 143 and the multiple first welding hooks 131 are arranged in a one-to-one correspondence.

[0121] In one possible design, further, as Figure 1 and Figure 2As shown, at least three phase busbars 111 have the same structure. The main body section of each phase busbar 111 includes a first main body section 1111, a second main body section 1112, and a third main body section 1113. The at least three phase busbars 111 include three phase copper bars. The first main body section 1111 of any phase copper bar is located outside the other two phase copper bars, the second main body section 1112 of any phase copper bar is located between the other two phase copper bars, and a portion of the third main body section 1113 of any phase copper bar is located inside the other two phase copper bars.

[0122] In this design, at least three phase busbars 111 have the same structure, meaning they share a common mold. This means that the busbar assembly 100 as a whole only requires two molds: one for producing the phase busbars 111 and one for producing the neutral busbar 112. This reduces the number of molds required to produce the busbars 110, lowering the difficulty of processing the busbars 110, improving production efficiency, and lowering the production cost of the busbars, effectively enhancing the product's competitiveness. Furthermore, the busbars 110 are made of copper, which has good electrical conductivity and is relatively inexpensive. Furthermore, copper is easy to stamp and form, and possesses sufficient hardness.

[0123] Specifically, each phase bus bar 111 includes four second welding hooks 132 arranged at even intervals, and each second welding hook 132 includes a connecting portion 1321 for arranging the connection terminal 231 .

[0124] Furthermore, the main body section of each phase bus bar 111 includes a first main body section 1111, a second main body section 1112, and a third main body section 1113 that are connected. At least three phase bus bars 111 include three phase copper bars, which are arranged in a 120° circumferential array. The specific arrangement of the three phase copper bars satisfies that a portion of the first main body section 1111 of any phase copper bar is located outside the other two phase copper bars, a portion of the second main body section 1112 of any phase copper bar is located between the other two phase copper bars, and a portion of the third main body section 1113 of any phase copper bar is located inside the other two phase copper bars. It should be noted that "inside" refers to the direction toward the central axis. "Outside" refers to the direction away from the central axis. For a phase copper bar, the distance between the first main body section 1111 and the central axis can be equidistant or unequal. Similarly, the distance between the second main body section 1112 and the third main body section 1113 and the central axis is not limited. However, the minimum distance between the first main section 1111 and the central axis is greater than the maximum distance between the second main section 1112 and the central axis, and the minimum distance between the second main section 1112 and the central axis is greater than the maximum distance between the third main section 1113 and the central axis, thereby preventing the three phase copper bars from interfering with each other during the assembly process.

[0125] For example, three phase copper bars include a first-phase copper bar 111a, a second-phase copper bar 111b, and a third-phase copper bar 111c, which are interlaced. Specifically, a portion of the first main section 1111 of the first-phase copper bar 111a is located outside the second-phase copper bar 111b and the third-phase copper bar 111c, a portion of the second main section 1112 of the first-phase copper bar 111a is located between the second-phase copper bar 111b and the third-phase copper bar 111c, and a portion of the third main section 1113 of the first-phase copper bar 111a is located inside the second-phase copper bar 111b and the third-phase copper bar 111c.

[0126] In one possible design, further, as Figure 3 and Figure 4 As shown, the first main segment 1111 is the first arc segment, the second main segment 1112 is the second arc segment, and the third main segment 1113 is the third arc segment. The radius R1 of the circle where the first arc segment is located, the radius R2 of the circle where the second arc segment is located, and the radius R3 of the circle where the third arc segment is located satisfy R1>R2>R3.

[0127] In this design, the first main section 1111, the second main section 1112, and the third main section 1113 are all arc sections, which can facilitate the interlacing of multiple bus bars 110. The radius of the first main section 1111 is greater than the radius of the second arc section, and the radius of the second main section 1112 is greater than the radius of the third main section 1113. Since the three phase bus bars 111 have the same structure, the first main sections 1111 of the three phase bus bars 111 can form an incomplete outer ring, the second main sections 1112 of the three phase bus bars 111 can form an incomplete middle ring, and the third main sections 1113 of the three phase bus bars 111 can form an incomplete inner ring. By making each phase bus bar 111 include at least three arc sections with different radii, interference problems during the assembly of multiple phase bus bars 111 are effectively prevented.

[0128] In a possible design, further, the central angle corresponding to the first arc segment is smaller than 180°.

[0129] In this design, the central angle corresponding to the first arc segment is less than 180°, that is, the circumferential angle of the first arc segment is less than 180°, thereby facilitating mold forming.

[0130] In a possible design, further, the second arc segment and the third arc segment include a second arc segment and a third arc segment located on the axial end face of the phase bus bar 111, and the second arc segment and the third arc segment include endpoints that are far away from each other, and the two endpoints form an angle less than 180° with the perpendicular to the central axis of the motor 200.

[0131] In this design, the second arc segment and the third arc segment include a second arc segment and a third arc segment located on the axial end face of the phase bus bar 111, the second arc segment includes an endpoint A away from the third arc segment, and the third arc segment includes an endpoint B away from the second arc segment. The lines connecting endpoints A and B and the perpendicular to the center axis can form an angle α, and the angle α is less than 180°. When the second arc segment and the third arc segment are an integrated structure, during the preparation process, the circumferential angle α of the second arc segment and the third arc segment is less than 180°, which can facilitate mold forming.

[0132] In one possible design, further, as Figure 3 and Figure 4 As shown, the first main body segment 1111 is welded to the outer circumferential surface of the second main body segment 1112 .

[0133] In this design, first main section 1111 is welded to the outer circumference of second main section 1112, simplifying the fabrication of first, second, and third main sections 1111, 1112, and 1113. A portion of first main section 1111 is attached to the outer circumference of second main section 1112. Alternatively, third main section 1113 can be welded to the inner circumference of second main section 1112, with third main section 1113, second main section 1112, and first main section 1111 arranged from the inside out.

[0134] In a possible design, further, the second main body segment 1112 and the third main body segment 1113 are an integrated structure.

[0135] In this design, the second main body section 1112 and the third main body section 1113 are an integrated structure. In order to connect the main body sections with different radii, a bending section is provided between the second main body section 1112 and the third main body section 1113. The second main body section 1112 and the third main body section 1113 are connected by the bending section. When there are multiple bus bars 110 in the busbar, the second main body section 1112 and the third main body section 1113 of different radial sizes can facilitate the interlaced arrangement of multiple bus bars 110 of the same structure.

[0136] In one possible design, Figure 4 As shown, the second welding hook 132 further includes a connecting portion 1321 and an extending portion 1322. The connecting portion 1321 extends axially and is located on the axial end surface of the main body section. The connecting portion 1321 is used to mount the terminal assembly 230 of the motor 200. One end of the extending portion 1322 is connected to the connecting portion 1321, and the other end of the extending portion 1322 extends radially away from the central axis of the motor 200 and then bends.

[0137] In this design, the second welding hook 132 includes a connecting portion 1321 and an extending portion 1322. The connecting portion 1321 extends axially and is located on the axial end surface of the main body section. The connecting portion 1321 is used to mount the terminal assembly 230 of the motor 200. One connecting portion 1321 can mount one terminal assembly 230. By providing a corresponding connecting portion 1321 for each terminal assembly 230, accurate mounting of the terminal assembly 230 can be ensured. Specifically, if one second welding hook 132 includes one connecting portion 1321, there are multiple connecting portions 1321. However, the number of terminal blocks 231 in the terminal assembly 230 of the motor 200 is less than the number of connecting portions 1321. Therefore, the connecting portion 1321 at the appropriate location can be selected for connection based on the interface requirements of the motor 200. In other words, not all connecting portions 1321 will correspond to the corresponding terminal blocks 231; connecting portions 1321 at appropriate locations will be used. Providing multiple connecting portions 1321 can meet the various interface requirements of the motor 200.

[0138] In one possible design, further Figure 6 、 Figure 9 and Figure 10 As shown, a portion of the insulating member 140 extends away from the first wall 121 to form an assembly portion 141, and one assembly portion 141 is located between the two second welding hooks 132. The busbar assembly 100 also includes an assembly interface 142, which is provided on the assembly portion 141 and is used to install the terminal assembly 230 of the motor 200.

[0139] In this design, a portion of the insulating member 140 extends away from the first wall 121, that is, the portion of the insulating member 140 extends outward to form an assembly portion 141. An assembly portion 141 is arranged between the two second welding hooks 132. The assembly portion 141 has an assembly interface 142. The assembly interface 142 is used to install the terminal assembly 230 of the motor 200, thereby ensuring the reliable connection performance of the terminal assembly 230.

[0140] In one possible design, further, as Figure 4 As shown, the phase bus bar 111 further includes a release groove 1323 , which is provided at the connection between the connecting portion 1321 , the extending portion 1322 and the main body segment.

[0141] In this design, the phase bus bar 111 also includes a release groove 1323, which is provided at the connection between the connecting portion 1321, the extension portion 1322 and the main section. The release groove 1323 can release the stress during the forming process of the second welding hook 132. In addition, when the terminal 220 of the winding is welded to the second welding hook 132, the second welding hook 132 will be subjected to external force. The release groove 1323 can provide partial deformation margin to prevent fatigue fracture at the connection between the connecting portion 1321, the extension portion 1322 and the main section.

[0142] In one possible design, further, as Figure 5 As shown, the main section of the neutral bus bar 112 includes a plurality of fourth main sections distributed at intervals, any two of the plurality of fourth main sections have the same structure, and a plurality of first welding hooks 131 are distributed at intervals on each fourth main section.

[0143] In this design, the main body of the neutral busbar 112 comprises multiple spaced-apart fourth segments. Any two of these segments have identical structures, allowing for easy molding and low-cost production using a single mold. The segments are arranged in a 180° circumferential array. Multiple first welding hooks 131 are spaced-apart on each fourth segment. Specifically, each fourth segment has six first welding hooks 131. The neutral busbar 112 includes twelve first welding hooks 131.

[0144] It should be noted that, for the bus assembly 100 as a whole, the three phase bus bars 111 have the same structure. Considering the mold forming, each phase bus bar 111 requires two hardware molds, so only three sets of hardware molds are needed as a whole.

[0145] In a possible design, further, the fourth main body segment is a fourth arc segment, and the central angle corresponding to the fourth arc segment is less than 180°.

[0146] In this design, the fourth main segment is a fourth arc segment, with a central angle less than 180°, facilitating demolding. The radius R4 of the circle encompassing the fourth arc segment is smaller than the radius R3 of the circle encompassing the third main segment 1113, preventing assembly interference between the neutral busbar 112 and the phase busbar 111. Specifically, the central angle of the fourth arc segment is approximately 150°.

[0147] In a specific embodiment, a busbar assembly 100 includes a plurality of spaced-apart busbars 110. Each busbar 110 includes a main body section and welding hooks disposed on the main body section. The main body sections of the plurality of busbars 110 form a main body portion 120. The main body portion 120 includes a first wall surface 121 and a second wall surface 122, which are opposed to each other. The first wall surface 121 is closer to the central axis of the motor 200 than the second wall surface 122. The welding hooks of the plurality of busbars 110 include a first welding hook 131 and a second welding hook 132. At least a portion of the first welding hook 131 protrudes from the first wall surface 121, and at least a portion of the second welding hook 132 protrudes from the second wall surface 122. By arranging the plurality of welding hooks 131 and 132 with different orientations, the present invention avoids the welding hooks from being concentrated in the same position, effectively utilizes space, increases the distance between adjacent welding hooks, reduces wire entanglement, wire cutting, and welding difficulties, and improves assembly efficiency.

[0148] It should be noted that the multiple bus bars 110 include at least three phase bus bars 111 and a neutral bus bar 112, wherein at least three phase bus bars 111 are spaced apart, and the welding hook of each phase bus bar 111 is a second welding hook 132, and the neutral bus bar 112 is arranged on one side of at least three phase bus bars 111, and the welding hook of the neutral bus bar 112 is a first welding hook 131. Different types of welding hooks are respectively arranged on different types of bus bars 110, which simplifies the preparation of different types of bus bars 110 and the connection of windings, shortens the distance between the windings and the welding hooks, thereby shortening the length of the windings and reducing the difficulty of welding the windings.

[0149] The distribution of the multiple phase bus bars 111 includes at least radial spacing distribution and axial spacing stacking arrangement. The radial spacing arrangement can reduce the axial space requirement of the bus assembly 100. The axial spacing arrangement can reduce the radial space requirement of the bus assembly 100.

[0150] The openings of different types of welding hooks face different directions. For example, the opening of the first welding hook 131 faces the central axis of the motor 200, facilitating the passage of the stator winding terminal 220 through the opening into the first welding hook 131. Multiple second welding hooks 132 are provided, with their free ends bent toward the same side. The space between two second welding hooks 132 accommodates only one winding terminal 220. This ensures even distribution of the winding terminals 220, ample welding space for the winding terminals 220, and prevents interference between the welded terminals 220. The number of first welding hooks 131 and second welding hooks 132 is the same, with a first welding hook 131 located inside adjacent pairs of second welding hooks 132. When connecting the winding terminals 220, the user can select the nearest welding hook for welding, reducing the difficulty of welding the windings. Specifically, to ensure electrical insulation between the multiple busbars 110, the busbars 110 are mounted on the insulating member 140. The busbar assembly 100 further includes a positioning portion 150 disposed on the insulating member 140. The positioning portion 150 is configured to cooperate with the stator frame 210 of the motor 200, thereby achieving a reliable connection between the busbar assembly 100 and the stator frame 210. It is worth noting that the busbar assembly 100 further includes a mounting notch 143 disposed on the insulating member 140. At least a portion of the first welding hook 131 is located within the mounting notch 143. When the winding terminal 220 extends into the first welding hook 131, the mounting notch 143 effectively avoids the winding terminal 220 due to the relatively compact space inside the insulating member 140, providing space for the winding welding and improving welding efficiency.

[0151] Furthermore, at least three phase busbars 111 have the same structure, which can reduce the number of molds used to prepare busbar 110, reduce the difficulty of processing busbar 110, improve production efficiency, reduce the production cost of the busbar, and effectively enhance the competitiveness of the product. The main section of each phase busbar 111 includes a first main section 1111, a second main section 1112, and a third main section 1113 that are connected. At least three phase busbars 111 include three phase copper bars, wherein the first main section 1111 of any phase copper bar is located outside the other two phase copper bars, the second main section 1112 of any phase copper bar is located between the other two phase copper bars, and a portion of the third main section 1113 of any phase copper bar is located inside the other two phase copper bars, thereby preventing the three phase copper bars from interfering with each other during assembly.

[0152] Furthermore, the first main body segment 1111 is a first arc segment, the second main body segment 1112 is a second arc segment, and the third main body segment 1113 is a third arc segment. The radius R1 of the circle where the first arc segment is located, the radius R2 of the circle where the second arc segment is located, and the radius R3 of the circle where the third arc segment is located satisfy R1>R2>R3, thereby effectively preventing interference problems during the assembly process of multiple phase bus bars 111.

[0153] Furthermore, the second arc segment and the third arc segment include a second arc segment and a third arc segment located on the axial end face of the phase bus bar 111, and the second arc segment and the third arc segment include endpoints that are far away from each other, and the angles formed by the two endpoints and the perpendicular to the central axis of the motor 200 are less than 180°, which is convenient for mold forming.

[0154] Regarding the connection between the multiple main segments of the phase busbar 111, for example, the first main segment 1111 is welded to the outer circumference of the second main segment 1112. The second main segment 1112 and the third main segment 1113 are integrally formed. Dividing a single phase busbar 111 into multiple segments improves material utilization. The first main segment 1111 and the second weld hook 132 thereon constitute one busbar segment, while the second main segment 1112, the third main segment, and the second weld hook 132 thereon constitute another busbar segment.

[0155] Furthermore, the second welding hook 132 includes a connecting portion 1321 and an extending portion 1322. The connecting portion 1321 extends axially and is located on the axial end surface of the main body section. The connecting portion 1321 is used to mount the terminal assembly 230 of the motor 200. One end of the extending portion 1322 is connected to the connecting portion 1321, and the other end of the extending portion 1322 extends radially away from the central axis of the motor 200 and then bends.

[0156] Furthermore, a portion of the insulating member 140 extends away from the first wall 121 to form an assembly portion 141, and one assembly portion 141 is located between the two second welding hooks 132. The busbar assembly 100 also includes an assembly interface 142, which is provided on the assembly portion 141 and is used to install the terminal assembly 230 of the motor 200.

[0157] Furthermore, the phase bus bar 111 also includes a release groove 1323, which is arranged at the connection between the connecting portion 1321, the extension portion 1322 and the main section. The release groove 1323 can release the stress during the forming process of the second welding hook 132. The release groove 1323 can provide partial deformation margin to prevent fatigue fracture at the connection between the connecting portion 1321, the extension portion 1322 and the main section.

[0158] Furthermore, the main section of the neutral bus bar 112 includes a plurality of fourth main sections distributed at intervals, any two of the plurality of fourth main sections have the same structure, and a plurality of first welding hooks 131 are distributed at intervals on each fourth main section.

[0159] Furthermore, the fourth main body segment is a fourth arc segment, and the central angle corresponding to the fourth arc segment is less than 180°.

[0160] According to a second aspect of the present invention, there is provided a motor 200, such as Figures 7 to 10 As shown, the motor 200 includes a housing and a busbar assembly 100 provided by any of the above designs, with the busbar assembly 100 disposed within the housing. The motor 200 also includes a stator frame 210 disposed on one axial side of the busbar assembly 100. The stator frame 210 has windings connected to the weld hooks of the busbar assembly 100.

[0161] The motor 200 provided by the present invention includes the busbar assembly 100 provided by any of the above designs, and therefore has all the beneficial effects of the busbar assembly 100, which will not be described in detail here.

[0162] The busbar assembly 100 includes a plurality of spaced-apart busbars 110. Each busbar 110 includes a main section and welding hooks disposed on the main section. The multiple main sections of the busbars 110 form a main body 120. The main body 120 includes a first wall 121 and a second wall 122, which are opposed to each other. The first wall 121 is closer to the central axis of the motor 200 than the second wall 122. The welding hooks of the busbars 110 include a first welding hook 131 and a second welding hook 132. At least a portion of the first welding hook 131 protrudes from the first wall 121, and at least a portion of the second welding hook 132 protrudes from the second wall 122. By arranging the welding hooks 131 and 132 in different orientations, the present invention avoids the welding hooks from being concentrated in the same position, effectively utilizes space, increases the distance between adjacent welding hooks, reduces wire entanglement, wire cutting, and welding difficulties, and improves assembly efficiency.

[0163] It should be noted that the multiple bus bars 110 include at least three phase bus bars 111 and a neutral bus bar 112, wherein at least three phase bus bars 111 are spaced apart, and the welding hook of each phase bus bar 111 is a second welding hook 132, and the neutral bus bar 112 is arranged on one side of at least three phase bus bars 111, and the welding hook of the neutral bus bar 112 is a first welding hook 131. Different types of welding hooks are respectively arranged on different types of bus bars 110, which simplifies the preparation of different types of bus bars 110 and the connection of windings, shortens the distance between the windings and the welding hooks, thereby shortening the length of the windings and reducing the difficulty of welding the windings.

[0164] The distribution of the multiple phase bus bars 111 includes at least radial spacing distribution and axial spacing stacking arrangement. The radial spacing arrangement can reduce the axial space requirement of the bus assembly 100. The axial spacing arrangement can reduce the radial space requirement of the bus assembly 100.

[0165] The openings of different types of welding hooks face different directions. For example, the opening of the first welding hook 131 faces the central axis of the motor 200, facilitating the passage of the stator winding terminal 220 through the opening into the first welding hook 131. Multiple second welding hooks 132 are provided, with their free ends bent toward the same side. The space between two second welding hooks 132 accommodates only one winding terminal 220. This ensures even distribution of the winding terminals 220, ample welding space for the winding terminals 220, and prevents interference between the welded terminals 220. The number of first welding hooks 131 and second welding hooks 132 is the same, with a first welding hook 131 located inside adjacent pairs of second welding hooks 132. When connecting the winding terminals 220, the user can select the nearest welding hook for welding, reducing the difficulty of welding the windings. Specifically, to ensure electrical insulation between the multiple busbars 110, the busbars 110 are mounted on the insulating member 140. The busbar assembly 100 further includes a positioning portion 150 disposed on the insulating member 140. The positioning portion 150 is configured to cooperate with the stator frame 210 of the motor 200, thereby achieving a reliable connection between the busbar assembly 100 and the stator frame 210. It is worth noting that the busbar assembly 100 further includes a mounting notch 143 disposed on the insulating member 140. At least a portion of the first welding hook 131 is located within the mounting notch 143. When the winding terminal 220 extends into the first welding hook 131, the mounting notch 143 effectively avoids the winding terminal 220 due to the relatively compact space inside the insulating member 140, providing space for the winding welding and improving welding efficiency.

[0166] Furthermore, at least three phase busbars 111 have the same structure, which can reduce the number of molds required to prepare busbar 110, lower the difficulty of processing busbar 110, improve production efficiency, reduce the production cost of the busbar, and effectively enhance the competitiveness of the product. The main section of each phase busbar 111 includes a first main section 1111, a second main section 1112, and a third main section 1113 that are connected. At least three phase busbars 111 include three phase copper bars. The first main section 1111 of any phase copper bar is located outside the other two phase copper bars, the second main section 1112 of any phase copper bar is located between the other two phase copper bars, and a portion of the third main section 1113 of any phase copper bar is located inside the other two phase copper bars, which can prevent the three phase copper bars from interfering with each other during assembly. For example, the three phase copper bars include a first phase copper bar 111a, a second phase copper bar 111b, and a third phase copper bar 111c, which are interspersed. Specifically, a portion of the first main section 1111 of the first-phase copper bar 111a is located outside the second-phase copper bar 111b and the third-phase copper bar 111c, a portion of the second main section 1112 of the first-phase copper bar 111a is located between the second-phase copper bar 111b and the third-phase copper bar 111c, and a portion of the third main section 1113 of the first-phase copper bar 111a is located inside the second-phase copper bar 111b and the third-phase copper bar 111c.

[0167] Specifically, if Figure 7 As shown, motor 200 is a 12-slot motor 200. The stator of motor 200 includes 12 stator teeth. A stator frame 210 is mounted on the stator teeth. Each stator tooth is provided with a winding (enameled wire). Each winding has two terminals 220 (a starting terminal and an ending terminal). The 12 windings on the 12 stator teeth have a total of 24 terminals 220. The motor 200 is connected in a Y-type connection, with four parallel connections. After the Y-type connection is completed on the busbar assembly 100, three connecting portions 1321 are provided for welding the terminal blocks 231. These connecting portions 1321 serve as current interfaces.

[0168] Further, if Figure 8 As shown, the motor 200 also includes a casing, and the bus assembly 100 is arranged in the casing. The motor 200 also includes a stator frame 210, which is connected to one axial side of the bus assembly 100. The windings arranged on the stator frame 210 can be connected to the welding hooks of the bus assembly 100.

[0169] In a possible design, further, the stator frame 210 includes a frame body and a matching portion, wherein the matching portion is provided on a side of the frame body close to the bus assembly 100 , and the matching portion is connected to the positioning portion 150 of the bus assembly 100 .

[0170] In this design, the stator frame 210 includes a frame body and a mating portion. The mating portion is located on the side of the frame body near the busbar assembly 100 and connects to the positioning portion 150 of the busbar assembly 100, thereby achieving a precise connection between the frame body and the busbar assembly 100. The motor 200 also includes a stator core 211. The stator frame 210 is mounted on the stator core 211, and the windings are arranged on the stator frame 210.

[0171] In one possible design, motor 200 further includes a control assembly disposed on the other axial side of busbar assembly 100, the control assembly including a controller and a terminal assembly 230. Terminal assembly 230 includes a terminal block 231 connected between connection portion 1321 of busbar assembly 100 and the controller.

[0172] In this design, one end of terminal block 231 is connected to the controller, and the other end of terminal block 231 is connected to connector 1321, thereby connecting the winding to the controller through busbar assembly 100 and terminal block 231. Furthermore, terminal block assembly 230 includes a terminal frame 232, on which a portion of terminal block 231 is mounted. A portion of terminal frame 232 extends into assembly interface 142 of busbar assembly 100, thereby achieving connection of the insulated portion.

[0173] Further, if Figure 10 As shown, the connection terminal 231 and the terminal frame 232 can be integrally formed by injection molding, or can be assembled from two independent parts.

[0174] It should be noted that the connection terminals 231 and the connection portion 1321 are connected by resistance welding. Of course, they can also be connected by other welding methods such as ultrasonic welding or other fixed connection methods. Optionally, the number of the connection terminals 231 is three.

[0175] According to a third aspect of the present invention, an electric power steering system is provided, comprising the motor 200 provided by any of the above designs.

[0176] The electric power steering system provided by the present invention includes the motor 200 provided by any of the above designs, and therefore has all the beneficial effects of the motor 200, which will not be described in detail here.

[0177] The motor 200 is a 12-slot motor 200. The stator of the motor 200 includes 12 stator teeth. The stator frame 210 is provided on the stator teeth. Each stator tooth is provided with a winding (enameled wire). Each winding has two terminals 220 (a starting end and an ending end). The 12 windings on the 12 stator teeth have a total of 24 terminals 220. Figure 11As shown, the wiring form of the motor 200 is a Y-type connection, with 4 parallel connections. After the bus assembly 100 completes the Y-type connection, three connecting parts 1321 can be provided for welding of the terminal 231, and the connecting part 1321 serves as a current interface. The bus assembly 100 of the motor 200 includes a plurality of busbars 110 arranged at intervals, and the busbars 110 are insulated from each other. The busbar 110 is a conductor, and the busbar 110 is used to connect the winding ends that need to be connected together in the multiple windings of the stator of the motor 200, thereby realizing the electrical connection of the multiple winding ends and realizing the bus function. Each busbar 110 includes a main body section and a welding hook, and the welding hook is provided on the main body section. For a busbar 110, the number of welding hooks is at least one. Among them, the main body sections of the multiple busbars 110 are used to form a support skeleton for the bus, and the welding hooks are used to connect with the windings. The main sections of the plurality of busbars 110 are bent and / or curved around the central axis of the motor 200 to form a main body 120. The main body 120 includes a first wall 121 facing the central axis and a second wall 122 facing away from the first wall 121. Specifically, when the main section is an arc segment, or when the main body 120 is annular, the first wall 121 is an inner contour surface, and the second wall 122 is an outer contour surface. The plurality of busbars 110 include a plurality of welding hooks, and the plurality of welding hooks include two types of welding hooks facing in different directions, namely, a first welding hook 131 and a second welding hook 132. At least a portion of the first welding hook 131 is arranged to protrude from the first wall 121, that is, at least a portion of the first welding hook 131 is exposed beyond the first wall 121, that is, the first welding hook 131 is an inner welding hook. At least a portion of the second welding hook 132 is disposed protruding from the second wall surface 122, that is, at least a portion of the second welding hook 132 is exposed beyond the second wall surface 122, and the second welding hook 132 is an external welding hook. By disposing the plurality of welding hooks, such as the first welding hook 131 and the second welding hook 132, in different orientations, the present invention avoids the plurality of welding hooks from being concentrated in the same position, rationally utilizes space, increases the distance between adjacent welding hooks, reduces the difficulty of wire entanglement, wire cutting, and welding, and improves assembly efficiency.

[0178] Specifically, the distribution of the multiple phase busbars 111 includes at least: radial spacing distribution and axial spacing stacking arrangement. The radial spacing arrangement can reduce the axial space requirement of the busbar assembly 100. The axial spacing arrangement can reduce the radial space requirement of the busbar assembly 100.

[0179] The openings of different types of welding hooks face different directions. For example, the opening of the first welding hook 131 faces the central axis of the motor 200, facilitating the passage of the stator winding terminal 220 through the opening into the first welding hook 131. Multiple second welding hooks 132 are provided, with their free ends bent toward the same side. The space between two second welding hooks 132 accommodates only one winding terminal 220. This ensures even distribution of the winding terminals 220, ample welding space for the winding terminals 220, and prevents interference between the welded terminals 220. The number of first welding hooks 131 and second welding hooks 132 is the same, with a first welding hook 131 located inside adjacent pairs of second welding hooks 132. When connecting the winding terminals 220, the user can select the nearest welding hook for welding, reducing the difficulty of welding the windings. Specifically, to ensure electrical insulation between the multiple busbars 110, the busbars 110 are mounted on the insulating member 140. The busbar assembly 100 further includes a positioning portion 150 disposed on the insulating member 140. The positioning portion 150 is configured to cooperate with the stator frame 210 of the motor 200, thereby achieving a reliable connection between the busbar assembly 100 and the stator frame 210. It is worth noting that the busbar assembly 100 further includes a mounting notch 143 disposed on the insulating member 140. At least a portion of the first welding hook 131 is located within the mounting notch 143. When the winding terminal 220 extends into the first welding hook 131, the mounting notch 143 effectively avoids the winding terminal 220 due to the relatively compact space inside the insulating member 140, providing space for the winding welding and improving welding efficiency.

[0180] According to a fourth aspect of the present invention, a vehicle is provided, comprising the electric power steering system provided by any one of the above designs.

[0181] The vehicle provided by the present invention includes the electric power steering system provided by any of the above designs, and therefore has all the beneficial effects of the electric power steering system, which will not be described in detail here. It is worth noting that the vehicle can be a traditional fuel vehicle or a new energy vehicle. Among them, new energy vehicles include pure electric vehicles, extended-range electric vehicles, hybrid vehicles, fuel cell electric vehicles, hydrogen engine vehicles, etc.

[0182] In the present invention, the term "plurality" refers to two or more, unless otherwise specified. Terms such as "installed," "connected," "connected," and "fixed" should be interpreted broadly. For example, "connected" can mean fixed, removable, or integral; and "connected" can mean directly or indirectly through an intermediary. Those skilled in the art will understand the specific meanings of these terms in the present invention based on specific circumstances.

[0183] Throughout this specification, terms such as "one embodiment," "some embodiments," and "specific embodiments" mean that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of these 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 any one or more embodiments or examples.

[0184] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A busbar assembly for a motor, characterized in that: include: a plurality of busbars arranged at intervals, each busbar comprising a main body section and a welding hook provided on the main body section, the plurality of main body sections of the plurality of busbars constituting a main body portion, the main body portion comprising a first wall surface and a second wall surface opposite to each other, the first wall surface being closer to the central axis of the motor than the second wall surface; The plurality of welding hooks of the plurality of bus bars include a first welding hook and a second welding hook, at least a portion of the first welding hook protrudes from the first wall surface, and at least a portion of the second welding hook protrudes from the second wall surface; The confluence assembly further includes: an insulating member, wherein the plurality of bus bars are connected to the insulating member at intervals; a mounting notch provided on the inner side wall of the insulating member, wherein at least a portion of the first welding hook is located in the mounting notch; There are multiple installation notches, and there are multiple first welding hooks. The multiple installation notches and the multiple first welding hooks are arranged in a one-to-one correspondence.

2. The busbar assembly according to claim 1, wherein: The plurality of bus bars include: at least three phase bus bars, wherein the at least three phase bus bars are spaced apart and the welding hook of each phase bus bar is the second welding hook; A neutral bus bar is provided on one side of the at least three phase bus bars, and the welding hook of the neutral bus bar is the first welding hook.

3. The busbar assembly according to claim 2, wherein: At least three of the phase bus bars are spaced apart in radial direction; or At least three phase bus bars are stacked and spaced apart in the axial direction.

4. The busbar assembly according to claim 2, wherein: The opening of the first welding hook faces the central axis of the motor; and / or There are multiple second welding hooks, and free ends of the multiple second welding hooks are bent toward the same side.

5. The busbar assembly according to claim 4, characterized in that: The number of the first welding hooks is the same as the number of the second welding hooks, and one of the first welding hooks is provided inside two adjacent second welding hooks among the plurality of second welding hooks.

6. The busbar assembly according to any one of claims 2 to 5, characterized in that: The confluence assembly further includes: A positioning portion is provided on the insulating member, and the positioning portion is used to cooperate with the stator frame of the motor.

7. The busbar assembly according to any one of claims 2 to 5, characterized in that: At least three of the phase bus bars have the same structure, and the main body section of each phase bus bar includes a first main body section, a second main body section, and a third main body section that are connected; At least three of the phase bus bars include three phase copper bars, wherein a portion of a first main section of any one of the three phase copper bars is located outside the other two of the three phase copper bars, a portion of a second main section of any one of the phase copper bars is located between the other two phase copper bars, and a portion of a third main section of any one of the phase copper bars is located inside the other two phase copper bars.

8. The busbar assembly according to claim 7, characterized in that: The first main segment is a first arc segment, the second main segment is a second arc segment, and the third main segment is a third arc segment. The radius R1 of the circle where the first arc segment is located, the radius R2 of the circle where the second arc segment is located, and the radius R3 of the circle where the third arc segment is located satisfy R1>R2>R3.

9. The bus assembly according to claim 8, characterized in that: The central angle corresponding to the first arc segment is less than 180°; and / or The second arc segment and the third arc segment include a second arc segment and a third arc segment located on the axial end surface of the phase bus bar, and the second arc segment and the third arc segment include endpoints that are far away from each other, and the angles formed by the two endpoints and the perpendicular to the central axis of the motor are less than 180°.

10. The busbar assembly according to claim 7, wherein: The first main body segment is welded to the outer circumferential surface of the second main body segment; The second main body section and the third main body section are an integrated structure.

11. The busbar assembly according to claim 2, wherein: The second welding hook comprises: a connecting portion extending in the axial direction and located on the axial end surface of the main body section, wherein the connecting portion is used for mounting a terminal assembly of the motor; An extension portion, one end of which is connected to the connecting portion, and the other end of which is radially extended away from the central axis of the motor and then bent.

12. The busbar assembly according to claim 11, wherein: A portion of the insulating member extends away from the first wall surface to form a mounting portion, and one of the mounting portions is located between two of the second welding hooks; The confluence assembly further includes: An assembly interface is provided on the assembly portion, and the assembly interface is used to install the terminal assembly of the motor.

13. The busbar assembly according to claim 12, wherein: The phase bus bar further comprises: A release groove is provided at the connection between the connecting portion, the extending portion and the main body segment.

14. The busbar assembly according to any one of claims 8 to 13, characterized in that: The main section of the neutral bus bar includes a plurality of fourth main sections distributed at intervals, any two of the plurality of fourth main sections have the same structure, and a plurality of the first welding hooks are distributed at intervals on each of the fourth main sections.

15. The busbar assembly according to claim 14, wherein: The fourth main body segment is a fourth arc segment, and the central angle corresponding to the fourth arc segment is less than 180°.

16. A motor, characterized in that: include: chassis; The busbar assembly according to any one of claims 1 to 15, wherein the busbar assembly is arranged in the housing; as well as The stator frame is arranged on one axial side of the busbar assembly. The stator frame has a winding, and the winding is connected to the welding hook of the busbar assembly.

17. The motor according to claim 16, characterized in that The stator frame comprises: Framework body; The matching portion is provided on a side of the frame body close to the busbar assembly, and the matching portion is connected to the positioning portion of the busbar assembly.

18. The motor according to claim 16, characterized in that The motor further comprises: A control assembly is provided on the other side of the confluence assembly in the axial direction, and the control assembly has a controller; The terminal assembly includes a connection terminal connected between the connection portion of the busbar assembly and the controller.

19. The motor according to claim 18, characterized in that The terminal assembly further comprises: A terminal skeleton, a portion of the wiring terminal is arranged on the terminal skeleton, and a portion of the terminal skeleton is installed at the assembly interface of the busbar assembly.

20. An electric power steering system, characterized in that: include: A motor as claimed in any one of claims 16 to 19.

21. A vehicle, characterized in that: include: The electric power steering system as claimed in claim 20.

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