Energy-saving electronic water pump with bus

Abstract

The present invention relates to the technical field of energy-saving water pumps, and specifically to an energy-saving electronic water pump with a bus. The multi-layer bus structure of the present application adopts an independent conductive copper bus, which has a larger cross-sectional area and lower resistance than traditional circuit boards, can effectively carry large currents, meet the needs of high-power applications, and avoid the risk of circuit board burning in traditional designs; the heat spreader design embedded in each layer of insulation, especially its L-shaped structure extending to the water pump housing, significantly increases the contact area with the housing and greatly improves the heat dissipation efficiency. This not only reduces the operating temperature of the motor, but also extends the life of the equipment and further improves the energy utilization efficiency. The multi-layer structure design allows the number of layers to be flexibly combined according to different motor parameters and application requirements, which improves the flexibility and adaptability of the design and facilitates future upgrades and optimizations.

Description

Technical Field

[0001] The invention relates to the technical field of energy-saving water pumps, and in particular to an energy-saving electronic water pump with a busbar. Background Art

[0002] With the improvement of energy efficiency and environmental protection awareness, the demand for energy-saving motors and electronic water pumps is growing. However, the existing motor and electronic water pump designs still have some limitations in terms of energy efficiency, especially in high-power or high-current application scenarios.

[0003] Traditional motor designs often use a one-piece stator structure where the magnet wire can be wound from beginning to end for simple circuit connections. However, this design may not be flexible enough in some applications to meet specific performance requirements or space constraints.

[0004] To address this problem, some manufacturers have begun to use split (spliced) stators. This design uses separate T-shaped stator segments, each of which is wound separately and then spliced ​​together. This approach increases design flexibility, but also brings new challenges, especially in terms of circuit connections.

[0005] Currently, a common solution is to use a circuit board to connect the magnet wires of each T-shaped stator block. Although this method works well in low-power motors, it faces serious problems in high-power or high-current applications. Circuit boards often cannot withstand high currents and may burn out, which not only affects equipment performance but also poses a safety hazard.

[0006] In addition, existing designs often overlook heat dissipation. When operating at high power, insufficient heat dissipation may lead to reduced efficiency, shortened equipment life, and even cause safety issues.

[0007] Therefore, a new type of motor and electronic water pump design is urgently needed, which can effectively solve the connection problem in high current applications, improve heat dissipation efficiency, enhance structural flexibility, and have good modularity and maintainability. Such a design can not only improve energy efficiency, but also extend equipment life and reduce maintenance costs, thereby achieving better energy saving effects in long-term use. Summary of the invention

[0008] In order to solve the above problems, the present invention discloses an energy-saving electronic water pump with a bus.

[0009] In order to achieve the above object, the present application discloses an energy-saving electronic water pump with a bus, comprising:

[0010] A multi-layer busbar structure, including a fixed base layer, an intermediate busbar layer and a driving connection layer;

[0011] Each layer includes independent conductive copper bars and interlayer insulation modules;

[0012] In the multi-layer busbar structure, each layer of the insulating member is embedded with a heat spreader, and the heat spreader includes:

[0013] An outer end extending to the inner wall of the water pump housing is used to contact the water pump housing to improve heat dissipation efficiency;

[0014] The outer end is bent in an L-shape to form a bent portion parallel to the water pump housing;

[0015] The bent portion is provided with a plurality of positioning slots corresponding to the positioning protrusions on the inner wall of the water pump housing.

[0016] Wherein: the intermediate bus layer is provided with a through hole;

[0017] The fixing base layer is provided with a fixing buckle, and the fixing buckle passes through the through hole of the middle bus layer and is snapped into the locking hole of the driving connection layer to form an integral structure.

[0018] The fixing buckle comprises:

[0019] Two elastic arms are arranged in parallel, and the outer end of each elastic arm is provided with a limit block protruding outwards;

[0020] A ferrule matched with the limit block;

[0021] The outer side of the limit block is provided with a plurality of sawtooth structures along the length direction, and the inner side of the clamping sleeve is provided with a corresponding sawtooth structure.

[0022] The conductive copper busbar in the driving connection layer is used to be electrically connected to the built-in driving board of the water pump, and the conductive copper busbar is detachably connected and matched with the insulating member through a detachable structure.

[0023] The conductive copper busbar is provided with a U-shaped opening, and the U-shaped opening comprises:

[0024] Clamping arms, located on both sides of the U-shaped opening, are used to fix and compress the magnet wire;

[0025] The central column, located at the bottom of the U-shaped opening, is used to make close contact with the electromagnetic wire;

[0026] Stress relief grooves are arranged on both sides of the bottom of the U-shaped opening to relieve stress concentration during compression.

[0027] Furthermore, a rotatable conical ejector rod is provided in the middle of the ferrule, and the ejector rod can be inserted between the two elastic arms and tightly matched with the elastic arms through threads.

[0028] The number of layers of the multi-layer busbar structure is combined according to the number of T-blocks of the motor and the connection method of the electromagnetic wires to meet the high current demand.

[0029] A supporting plate is arranged on the inner side of the heat spreader.

[0030] An arc-shaped elastic support plate is arranged on the inner side of the support plate, one end of the elastic support plate extends to the edge of the bending portion, and the other end extends to the side of the support plate, and the bending portion thereof protrudes outward.

[0031] The multi-layer busbar structure of the present application uses an independent conductive copper busbar, which has a larger cross-sectional area and lower resistance than traditional circuit boards. It can effectively carry large currents, meet the needs of high-power applications, and avoid the risk of circuit board burnout in traditional designs. The heat spreader design embedded in each layer of insulation, especially its L-shaped structure extending to the water pump housing, significantly increases the contact area with the housing and greatly improves the heat dissipation efficiency. This not only reduces the operating temperature of the motor, but also extends the life of the equipment and further improves energy efficiency. The multi-layer structure design allows for flexible combination of layers according to different motor parameters and application requirements, improves the flexibility and adaptability of the design, and facilitates future upgrades and optimizations. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a schematic structural diagram of a multi-layer busbar structure in an embodiment of the present application;

[0033] Figure 2 This is a schematic diagram of the structure of the heat sink in the embodiment of the present application;

[0034] Figure 3 This is a schematic diagram of a structure in which a multi-layer bus structure is spliced ​​together in an embodiment of the present application;

[0035] Figure 4 for Figure 3 A partial enlarged schematic diagram in the middle;

[0036] Figure 5 It is a schematic diagram of the structure of the U-shaped opening in the embodiment of the present application. DETAILED DESCRIPTION

[0037] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. The principles and features of the present invention are described below in conjunction with the drawings. The examples are only used to explain the present invention and are not used to limit the scope of the present invention.

[0038] The terms "including" and other expressions with similar meanings in the specification or claims of the present invention and the above-mentioned drawings are intended to cover non-exclusive inclusions, such as a process, method or system, or device comprising a series of steps or units is not limited to the listed steps or units.

[0039] Example 1: Figure 1-4 As shown, an energy-saving electronic water pump with a bus bar comprises:

[0040] The multi-layer busbar structure includes a fixed base layer 100, an intermediate busbar layer 101 and a drive connection layer 102; wherein the number of layers of the multi-layer busbar structure is combined according to the number of T-blocks of the motor and the connection mode of the electromagnetic wire to meet the large current demand; the drive connection layer 102 is the uppermost layer and is used to connect the drive board; the fixed base layer 100 is the lowermost layer and is used to provide stability support;

[0041] Each layer includes an independent conductive copper bus 105 and an interlayer insulation module 103; the interlayer insulation module 103 is used to ensure electrical isolation between the layers to prevent short circuits;

[0042] In the multi-layer busbar structure, each layer of the insulating member 103 is embedded with a heat spreader 104, and the heat spreader 104 includes:

[0043] An outer end extending to the inner wall of the water pump housing is used to contact the water pump housing to improve heat dissipation efficiency;

[0044] The outer end is bent in an L-shape to form a bent portion 106 parallel to the water pump housing. The bent portion 106 is used to contact the water pump housing to increase the contact area with the housing.

[0045] The bending portion 106 is provided with a plurality of positioning slots 107 corresponding to the positioning protrusions on the inner wall of the water pump housing to ensure stable installation.

[0046] The core structure of the heat spreader 104 is a sealed flat container. The container has a fine capillary structure inside and is filled with a small amount of working fluid. Its working principle is based on the heat pipe principle, which transfers heat through the phase change process of the fluid. In the heat source area, the working fluid absorbs heat and evaporates; the steam quickly diffuses to the cold end of the container and condenses, releasing heat; the condensed liquid flows back to the heat source area through capillary action, forming a continuous circulation process.

[0047] The multi-layer busbar structure uses a conductive copper busbar. Compared with the traditional circuit board solution, the conductive copper busbar has a larger cross-sectional area, which is conducive to greatly reducing the resistance of the circuit. Lower resistance means less energy loss under the same current, which directly improves energy utilization efficiency.

[0048] In addition, the heat spreader 104 uses the principle of heat conduction to quickly transfer the heat generated by the current to the water pump housing, and then dissipates it into the environment through the housing. The L-shaped design increases the contact area with the housing and improves the heat conduction efficiency. The heat spreader 104 improves the heat dissipation efficiency, allowing the water pump motor to operate at a lower temperature. According to the relationship between motor efficiency and temperature, a lower operating temperature can improve the efficiency of the motor, thereby reducing energy loss and achieving energy-saving effects.

[0049] In a possible implementation, a supporting plate 109 is disposed inside the vapor chamber 104. The vapor chamber 104 is used to enhance the structural strength of the vapor chamber and further provide support therefor.

[0050] An arc-shaped elastic support plate 110 is provided inside the support plate 109, one end of the elastic support plate 110 extends to the edge of the bent portion 106, and the other end extends to the side of the support plate 109, and its bent portion protrudes outward. The arc-shaped elastic support plate 110 is elastic and allows a certain degree of deformation. This elastic structure may help alleviate the stress caused by the thermal expansion of the heat spreader 104; the outwardly protruding arc design provides a certain elastic space to absorb and buffer external pressure or vibration.

[0051] For example, it is assumed that the parameters of the electronic water pump are:

[0052] Motor parameters: Number of slots: 6; Number of poles: 4; Number of phases: 3

[0053] Winding configuration: Concentrated winding; 2 coils per phase (6 slots / 3 phases = 2 coils / phase);

[0054] T-block: Use 1 T-block for each phase; a total of 3 T-blocks are required (corresponding to three phases);

[0055] Electromagnetic wire connection method:

[0056] According to the actual application requirements, the busbar scheme can be flexibly adjusted to change the parallel number of each phase coil; the parallel number can be 1, 2, 3 or more to meet different current requirements;

[0057] The connection method between phases can be flexibly selected according to needs, either Y-type connection (also called star connection) or △-type connection (i.e. triangle connection);

[0058] Then, based on the characteristics of the above electronic water pump, a 3-layer busbar structure can be set up:

[0059] Layer 1 (bottom layer): Phase A and Phase B;

[0060] Layer 2 (middle layer): phase C and neutral point;

[0061] Layer 3 (top layer): includes interfaces and copper bars for connecting to the driver board, as well as drive signal and power connection points, using standardized connector interfaces such as board-to-board connectors or pin arrays;

[0062] Specific bus:

[0063] Layer 1 (Phase A and Phase B): T-blocks are connected to Phase A and Phase B respectively. Two parallel connection points are designed for each phase, corresponding to the two coils of each phase. Considering the circular structure of the water pump, a fan-shaped design is adopted.

[0064] Layer 2 (Phase C and Neutral Point): Connect the T-block of Phase C, design two parallel connection points for Phase C, design a Y-type connected neutral point in the center area, and reserve a terminal area for connection to the inverter.

[0065] Use engineering plastics or other high-performance insulating materials as interlayer insulation modules for interlayer insulation, and design through holes for connecting coil lead wires;

[0066] T-Block Integration:

[0067] Reserve installation positions for T-blocks on the 1st and 2nd layers;

[0068] The designed snap-on structure ensures that the T-block is firmly connected.

[0069] Example 2: Figure 1 , 3 As shown in 4, the intermediate bus layer 101 has a through hole 111;

[0070] The fixing base layer 100 is provided with a fixing buckle 112, which passes through the through hole 111 of the middle bus layer 101 and is inserted into the locking hole 113 of the driving connection layer 102 to form an integral structure. The through hole is designed so that the fixing buckle 112 can pass through, thereby achieving interlayer connection.

[0071] The fixing buckle 112 includes:

[0072] Two elastic arms 114 are arranged in parallel, and the outer end of each elastic arm 114 is provided with a limit block 115 protruding outwards;

[0073] A clamping sleeve 116 matched with the limit block 115;

[0074] The outer side of the limit block 115 is provided with a plurality of sawtooth structures 117 along the length direction, and the inner side of the clamping sleeve 116 is provided with a corresponding sawtooth structure 117. The sawtooth structure 117 increases the stability and reliability of the connection and prevents accidental loosening.

[0075] A rotatable conical ejector rod 118 is disposed in the middle of the ferrule 116 . The ejector rod 118 can be inserted between the two elastic arms 114 and tightly matched with the elastic arms 114 through threads.

[0076] When assembling the multi-layer busbar structure, the fixing buckle 112 first passes through the through hole 111 of the middle busbar layer 101. Then, the elastic arm 114 is slightly compressed to allow the stopper 115 to pass through the locking hole 113 of the drive connection layer 102. After being fully inserted, the elastic arm 114 returns to its original state, and the stopper 115 is stuck in the locking hole 113.

[0077] Next, the ferrule 116 is pushed into place, and its internal serration structure engages with the serration structure 117 on the stop block 115. Finally, the conical ejector rod 118 is rotated to be inserted between the elastic arms 114 and closely matched with them through threads, further strengthening the fixing effect.

[0078] The solution of this embodiment adopts a multiple locking mechanism to ensure the high stability and reliability of the structure. Secondly, it is easy to assemble and disassemble, and can be easily maintained or replaced when necessary. The conical top rod allows precise adjustment of the fixing force, which increases the adaptability of the structure. Finally, the serrated structure design effectively prevents loosening due to vibration, further improving the stability and durability of the overall structure.

[0079] Embodiment 3: The conductive copper busbar 105 in the driving connection layer 102 is used to electrically connect to the built-in driving board of the water pump. The conductive copper busbar 105 is detachably connected to the insulating member 103 via a detachable structure.

[0080] Among them, the specific implementation methods of the detachable structure include:

[0081] Detachable structures may include but are not limited to the following:

[0082] a) Snap-on connection: Complementary snap-on structures are designed on the conductive copper bus 105 and the insulating member to achieve quick connection and separation through snap-on;

[0083] b) Bolt fixing: Use specially designed bolts to fix the conductive copper busbar 105 on the insulating member, and the connection and separation can be achieved by tightening or loosening the bolts;

[0084] c) Slot design: slots are designed on the insulating member, and the conductive copper busbar 105 can slide into or out of these slots to achieve connection and separation.

[0085] The conductive copper busbar 105 of the drive connection layer 102 is a detachable structure for electrically connecting to the built-in drive board of the water pump, thereby improving the flexibility and maintainability of the system and providing convenience for possible future upgrades or replacements.

[0086] Example 4: Figure 1 and 5 As shown, the conductive copper bus 105 is provided with a U-shaped opening 120, and the U-shaped opening 120 includes:

[0087] Clamping arm 121, located on both sides of the U-shaped opening 120, for fixing and clamping the electromagnetic wire 122;

[0088] The clamping arms 121 are symmetrically arranged on both sides and are in an arc or straight shape, the same as the copper busbar body, to ensure good conductivity and mechanical strength; the inner side may be designed with tiny protrusions or textures to increase friction;

[0089] The central column 123 is located at the bottom of the U-shaped opening 120 and is used to be in close contact with the electromagnetic wire 122; the central column 123 is specifically located at the bottom center of the U-shaped opening 120, slightly higher than the bottom of the U-shaped opening 120, to ensure close contact with the electromagnetic wire 122; the top can be designed to be an arc or a plane to optimize the contact area;

[0090] The stress relief groove 124 is arranged on both sides of the bottom of the U-shaped opening 120 to relieve stress concentration during compression. The stress relief groove 124 can be designed to be arc-shaped or V-shaped, optimized according to the stress analysis results, and the depth is usually 1 / 4 to 1 / 3 of the thickness of the copper bar; it is used to disperse and redistribute the stress generated during compression to prevent the copper bar from deforming or cracking.

[0091] When connecting the electromagnetic wire 122, strip off the insulation layer at the end of the electromagnetic wire 122 to expose the conductor of appropriate length, insert the pre-treated electromagnetic wire 122 into the U-shaped opening 120, ensure that the electromagnetic wire 122 is in close contact with the central column 123, use special tools to press the clamping arm 121, fix the electromagnetic wire 122, ensure that the electromagnetic wire 122 is firmly clamped, and at the same time, it can be reinforced by welding without filler or with filler to make the electrical connection more secure and reduce the risk of loosening or falling off.

[0092] The clamping arm 121, the central column 123 and the stress release groove 124 provide a stable connection and good electrical performance of the electromagnetic wire 122, and are also convenient for assembly and maintenance.

[0093] The technical means disclosed in the scheme of the present invention are not limited to the technical means disclosed in the above-mentioned implementation mode, but also include technical schemes composed of any combination of the above-mentioned technical features. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications are also regarded as the protection scope of the present invention.

Claims

1. An energy-saving electronic water pump with a bus, characterized in that: include: A multi-layer busbar structure, including a fixed base layer, an intermediate busbar layer and a driving connection layer; Each layer includes independent conductive copper bars and interlayer insulation modules; In the multi-layer busbar structure, each layer of the insulating member is embedded with a heat spreader, and the heat spreader includes: An outer end extending to the inner wall of the water pump housing is used to contact the water pump housing to improve heat dissipation efficiency; The outer end is bent in an L-shape to form a bent portion parallel to the water pump housing; The bent portion is provided with a plurality of positioning slots corresponding to the positioning protrusions on the inner wall of the water pump housing.

2. The energy-saving electronic water pump according to claim 1, characterized in that: in: The middle bus layer is provided with through holes; The fixing base layer is provided with a fixing buckle, and the fixing buckle passes through the through hole of the middle bus layer and is snapped into the locking hole of the driving connection layer to form an integral structure.

3. The energy-saving electronic water pump according to claim 2, characterized in that: The fixing buckle comprises: Two elastic arms are arranged in parallel, and the outer end of each elastic arm is provided with a limit block protruding outwards; A ferrule matched with the limit block; The outer side of the limit block is provided with a plurality of sawtooth structures along the length direction, and the inner side of the clamping sleeve is provided with a corresponding sawtooth structure.

4. The energy-saving electronic water pump according to any one of claims 1 to 3, characterized in that: The conductive copper busbar in the driving connection layer is used to be electrically connected to the built-in driving board of the water pump, and the conductive copper busbar is detachably connected and matched with the insulating member through a detachable structure.

5. The energy-saving electronic water pump according to claim 1, characterized in that: The conductive copper busbar is provided with a U-shaped opening, and the U-shaped opening comprises: Clamping arms, located on both sides of the U-shaped opening, are used to fix and compress the magnet wire; The central column, located at the bottom of the U-shaped opening, is used to make close contact with the electromagnetic wire; Stress relief grooves are arranged on both sides of the bottom of the U-shaped opening to relieve stress concentration during compression.

6. The energy-saving electronic water pump according to claim 3, characterized in that: A rotatable conical ejector rod is arranged in the middle of the ferrule. The ejector rod can be inserted between the two elastic arms and is tightly matched with the elastic arms through threads.

7. The energy-saving electronic water pump according to claim 1, characterized in that: The number of layers of the multi-layer busbar structure is combined according to the number of T-blocks of the motor and the connection method of the electromagnetic wires to meet the high current demand.

8. The energy-saving electronic water pump according to claim 1, characterized in that: A supporting plate is arranged on the inner side of the heat spreader.

9. The energy-saving electronic water pump according to claim 8, characterized in that: An arc-shaped elastic support plate is arranged on the inner side of the support plate, one end of the elastic support plate extends to the edge of the bending portion, and the other end extends to the side of the support plate, and the bending portion thereof protrudes outward.

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