Motor flat wire winding busbar arrangement structure and integral forming method thereof

Abstract

The invention relates to a busbar arrangement structure of a motor flat wire winding and an integral forming method of the busbar arrangement structure in the field of motor winding parts. Flat cables of a busbar are fixed according to an installation sequence through an encapsulation inner mold with a flat wire groove and a copper wire bracket; the pouring cavity for wrapping the busbar is formed through the matching of the pouring outer mold and the pouring inner mold, and the busbar and the copper wire bracket are subjected to pouring sealant integrated pouring, so that a flat cable of the busbar is sealed in a pouring sealant colloid after pouring, the protection property of the busbar is enhanced, the overall welding and fixing of a welding machine are facilitated, and the production efficiency is improved. In addition, through a lower inner pouring gate and an upper inner pouring gate which are formed in the core shaft and a lower outer pouring gate and an upper outer pouring gate which are formed in the pouring inner mold, communication between the pouring cavity and the center pouring gate is achieved, one-time pouring of pouring sealant is achieved, and the sealing quality is improved. And the forming uniformity and the pouring efficiency are improved.

Description

Technical Field

[0001] The invention relates to a motor busbar arrangement structure, in particular to a motor flat wire winding busbar arrangement structure applied in the field of motor winding parts and an integral forming method thereof. Background Art

[0002] The motor bus is composed of copper bars, cages and connectors. It has a compact and modular structure, which is easy to assemble and maintain. As a key conductive component inside the motor, it is responsible for transmitting current to the motor windings evenly and efficiently to ensure the normal operation of the motor. At the same time, the bus design focuses on heat dissipation and electrical safety, uses high-quality materials and optimizes the structural layout to improve motor performance and operational reliability.

[0003] The Chinese patent with the existing publication number CN118336966A discloses a motor busbar, which includes an injection-molded integral insulating base and a conductor busbar arranged on the insulating base. The insulating base is provided with a groove for the main body to be embedded, a limiter to prevent the main body from rotating circumferentially, and a restraint to prevent the main body from being separated from the groove. When assembling the busbar to the insulating base, the main body is allowed to abut against the restraint before being embedded in the groove and tilted into the groove. Such a design simplifies the installation steps and improves the assembly efficiency. Compared with the traditional assembly method, this design reduces the steps that require precise alignment and fixation, making the installation process faster and more convenient. Once the main body is embedded in the groove, the restraint returns to the initial position to limit the main body from being separated from the groove. This design ensures a stable connection between the busbar and the insulating base, avoids loosening or falling off that may occur during the operation of the motor, and thus ensures the stable operation of the motor system.

[0004] The above patent discloses an insulating base and a conductor busbar arranged on the insulating base to improve the stability and insulation of the busbar installation. However, the existing busbar has a complex wiring distribution and is fixed by restraints and grooves, which not only causes the problem of numerous installation parts and cumbersome installation, but also, during the welding process, the movement of the welding gun in a small space and the sputtering of welding sparks can easily cause thermal damage to the busbar and the retaining parts. Summary of the invention

[0005] In view of the above-mentioned prior art, the technical problem to be solved by the present invention is that the existing motor busbar is prone to collision damage and thermal damage during the welding process.

[0006] In order to solve the above problems, the present invention provides a motor flat wire winding busbar arrangement structure and an integral forming method thereof, comprising a bottom plate, the bottom plate is fixedly connected to a potting outer mold by a lower locking bolt, a potting inner mold clamped with the bottom plate is nested in the potting outer mold, a mandrel plugged with the potting inner mold is nested in the potting inner mold, a copper wire bracket extending to the outside of the potting outer mold is abutted on the top of the mandrel, an upper cover extending to the outside of the copper wire bracket is abutted on the top of the copper wire bracket, and an upper locking bolt passing through the copper wire bracket and threadedly connected to the potting outer mold is passed through the upper cover; The outer wall of the potting inner mold is provided with a flat wire groove for accommodating the bus wire, and the end of the bus wire is plugged into the copper wire bracket; a potting cavity is formed between the inner wall of the potting outer mold and the outer wall of the potting inner mold, a central runner running through the core shaft is provided at the center position, a plurality of lower ingates connected with the central runner are provided on the lower end face of the core shaft, and the lower ingates are connected with the lower part of the potting cavity through the lower external runner provided on the lower end face of the potting inner mold; a plurality of upper ingates connected with the central runner are provided on the upper end face of the core shaft, and the upper ingates are connected with the upper part of the potting cavity through the upper external runner provided on the upper end face of the potting inner mold; the potting inner mold adopts a split splicing structure.

[0007] In the above motor flat wire winding busbar arrangement structure, a large number of busbar wires are fixed in position and integrally cast by cooperating with the potting outer mold and the potting inner mold, thereby enhancing the protection of the busbar.

[0008] As a further improvement of the present application, a pouring head that passes through the upper cover and the copper wire bracket is abutted above the core shaft, and a runner closing mechanism is installed in the core shaft, and the runner closing mechanism includes an upper fixed block nested at the opening position of the outer end of the upper inner runner and a lower fixed block nested at the opening position of the outer end of the lower inner runner; an upper blocking block arranged opposite to it is provided below the upper fixed block, and an upper connecting rod nested in the core shaft is hinged at the lower part of the upper blocking block, and a horizontal extrusion rod horizontally slidably connected to the core shaft is hinged at the lower end of the upper connecting rod; a lower blocking block arranged opposite to it is provided above the lower fixed block, and a lifting ring nested in the core shaft and vertically slidably connected to the core shaft is fixedly connected above the lower blocking block, and the lifting ring is hinged to the horizontal extrusion rod through the lower connecting rod; A sliding disk is fixedly connected to the inner end of the horizontal extrusion rod, a horizontal extrusion cavity is opened in the mandrel, which is vertically connected to the central runner and horizontally penetrates the mandrel, a limit ring sleeved on the outer side of the horizontal extrusion rod is fixedly connected to the inner wall of the horizontal extrusion cavity, and a first limit spring sleeved on the horizontal extrusion rod is provided between the limit ring and the sliding disk; An elastic pin is nested on the side of the horizontal extrusion rod away from the central runner, and a positioning cylinder is provided near the outer end opening of the horizontal extrusion cavity and is sleeved on the outside of the horizontal extrusion rod. An abutment ring for limiting the movement of the elastic pin is fixedly connected to the inner wall of the positioning cylinder, and an unlocking cylinder slidably connected to the positioning cylinder is nested on the side of the positioning cylinder away from the sliding disk, and a third limit spring sleeved on the unlocking cylinder is provided between the unlocking cylinder and the positioning cylinder.

[0009] As a further improvement of the present application, the copper wire bracket is provided with a central circular hole, a plurality of rectangular holes equidistantly distributed circumferentially, and a plurality of through holes equidistantly distributed circumferentially, the central circular hole is arranged at the center position of the copper wire bracket, the rectangular hole is arranged between the central circular hole and the through hole, the upper end of the rectangular hole abuts against the lower end surface of the lower cylinder of the upper cover, and the through hole is engaged with the upper locking bolt; the bus includes a connector row and a flat wire row, the head of the connector row penetrates the copper wire bracket and its tail extends into the rectangular hole, and both end portions of the flat wire row extend into the rectangular hole.

[0010] As a further improvement of the present application, an upper sealing ring is nested between the potting outer mold and the copper wire bracket, and a lower sealing ring is nested between the potting outer mold and the bottom plate.

[0011] As a further improvement of the present application, both the potting outer mold and the potting inner mold are annular structures. The potting inner mold includes a plurality of splicing unit blocks distributed in a circle and abutted end to end. A ring is sleeved on the bottom of the splicing unit block, and the upper end surface of the bottom plate is provided with an annular protrusion sleeved on the outside of the ring.

[0012] As a further improvement of the present application, the splicing unit blocks are arc-shaped blocks and the number is at least three, splicing seams are formed between adjacent splicing unit blocks, and a pair of splicing seams on both sides of at least one splicing unit block are arranged in parallel.

[0013] As a further improvement of the present application, a vertical extrusion cavity connected to the central runner is opened in the pouring head, a vertical extrusion rod is nested in the vertical extrusion cavity, a vertical limit spring is sleeved on the outside of the vertical extrusion rod, a pointer extending to the top of the pouring head is fixedly connected to the upper end of the vertical extrusion rod, and a pressure indicator tube is sleeved on the outside of the pointer.

[0014] As a further improvement of the present application, the elastic bayonet is a strip block with an isosceles trapezoidal cross-section and a pointed lower end, a second limit spring abutting against the elastic bayonet is nested in the horizontal extrusion rod, the abutment ring is an annular structure with a right-angled triangle cross-section, and the inclined surface of the abutment ring is parallel to the inclined surface of the elastic bayonet.

[0015] As a further improvement of the present application, the positioning cylinder and the unlocking cylinder are both hollow cylinders with one end open and arranged horizontally, a rounded corner is provided at the circumferential edge of the left opening of the unlocking cylinder, and the outer diameter of the unlocking cylinder is smaller than the inner diameter of the abutment ring.

[0016] As a further improvement of the present application, a method for integrally forming a motor flat wire winding busbar arrangement structure comprises the following steps: Step 1: Insert the connector row into the copper wire bracket and insert the connector row into the inverted upper cover; Step 2: Splice the splicing unit blocks in a ring shape and use a ring to bind them to form a potting inner mold, and then insert it upside down into the copper wire bracket; Step 3, inserting the mandrel into the potting inner mold and aligning the lower ingates with the lower ingates of the potting inner mold; Step 4: insert the flat wire row into the flat wire groove on the outer wall of the potting inner mold and insert the two ends of the flat wire row into the rectangular holes of the copper wire bracket; Step 5: Place the upper sealing ring under the inverted potting outer mold and then place it on the upper cover, and then tighten the locking bolts to fix the potting outer mold and the upper sealing ring on the upper cover; Step 6: Place the lower sealing ring on top of the inverted potting outer mold, then connect the bottom of the bottom plate to the lower sealing ring, and use the lower locking bolts to connect and fix the bottom plate to the potting outer mold; Step 7: Flip the assembled whole so that its upper cover faces upward, and then inject thermosetting potting glue into the central runner, using the connecting vessel principle to fill the potting cavity evenly, and then heat and cure it, and wait for cooling to form; Step eight, demolding, first remove the upper cover, potting outer mold and bottom plate, then remove the ring and core shaft; then, remove the splicing unit blocks of the potting inner mold one by one along the splicing seam to obtain a finished product including the potting glue, bus bar and copper wire bracket connected as one.

[0017] In summary, the present invention fixes the bus wiring in accordance with the installation sequence through a potting inner mold with a flat wire groove and a copper wire bracket, and forms a potting cavity that wraps the bus through the cooperation of the potting outer mold and the potting inner mold, and casts the potting glue on the bus and the copper wire bracket as a whole, so that the bus wiring is sealed in the potting glue after casting, thereby enhancing the protection of the bus, facilitating the welding machine to perform overall welding and fixation, reducing the thermal damage to the bus by welding sparks, and improving the efficiency of subsequent installation and the safety of welding. In addition, the potting cavity is connected with the center runner through the lower entrapment and upper entrapment provided on the core shaft and the lower outer runner and upper outer runner provided on the potting inner mold, so as to realize one-time pouring of the potting glue and improve the uniformity of molding and pouring efficiency. In addition, the potting inner mold with a split splicing mechanism is convenient for disassembly and demoulding. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A schematic diagram of the three-dimensional structure of this application; Figure 2 This is a schematic diagram of the transverse cross-sectional structure of the present application at the lower ingates; Figure 3 This is a schematic diagram of the cross-sectional structure of the present application at the upper ingates; Figure 4 It is a three-dimensional explosion assembly schematic diagram of this application; Figure 5 This is a schematic diagram of the assembly structure of the copper wire bracket in this application; Figure 6This is a schematic diagram of the assembly structure of the encapsulation inner mold and the mandrel in this application; Figure 7 This is a schematic diagram of the assembly of the potting inner mold in this application; Figure 8 This is a schematic diagram of the bottom view of the potting inner mold in this application; Fig. 9 It is a three-dimensional structural schematic diagram of the core shaft in this application; Fig.10 It is a schematic diagram of the flow of the potting compound in the runner; Fig.11 It is a schematic diagram of the assembly of this application and the pouring head; Fig.12 for Fig.11 A schematic diagram of a transverse cross-sectional structure; Fig.13 for Fig.12 A schematic diagram of the enlarged structure at A in the middle; Fig.14 for Fig.12 A schematic diagram of the enlarged structure at B in the middle; Fig.15 This is a schematic diagram of the assembly of the lower fixing block and the lower blocking block in this application; Fig.16 It is a schematic diagram of the transfer structure of the horizontal extrusion rod and the mandrel in this application; Fig.17 Schematic diagram of the force structure of the horizontal extrusion rod after the potting glue is filled.

[0019] Description of the numbers in the figure: 1. Copper wire bracket; 101. Center circular hole; 102. Rectangular hole; 103. Through hole; 2. Connector row; 3. Flat wire row; 4. Upper cover; 5. Potting inner mold; 501. Flat wire groove; 502. Lower outer runner; 503. Upper outer runner; 504. Splicing unit block; 505. Splicing seam; 6. Ring; 7. Mandrel; 701. Center runner; 702. Lower inner runner; 703. Upper inner runner; 704. Horizontal extrusion cavity; 8. Potting outer mold; 9. Upper sealing ring; 10. Upper locking bolt; 11. Lower sealing ring; 12. Bottom plate; 13. Lower locking bolt; 14. Filling cavity; 15. Pouring head; 1501. Vertical extrusion cavity; 16. Upper fixed block; 17. Upper blocking block; 18. Upper connecting rod; 19. Horizontal extrusion rod; 20. Sliding disk; 21. Limiting ring; 22. First limiting spring; 23. Elastic bayonet; 24. Second limiting spring; 25. Positioning cylinder; 26. Abutment ring; 27. Unlocking cylinder; 28. Third limiting spring; 29. ​​Lower fixed block; 30. Lower blocking block; 31. Lifting ring; 32. Lower connecting rod; 33. Vertical extrusion rod; 34. Vertical limiting spring; 35. Pointer; 36. Pressure indicating cylinder. DETAILED DESCRIPTION

[0020] Two implementation modes of the present application are described in detail below with reference to the accompanying drawings.

[0021] The first implementation method: Figure 1-10 A motor flat wire winding busbar arrangement structure is shown, comprising a bottom plate 12, the bottom plate 12 is fixedly connected to a potting outer mold 8 through a lower locking bolt 13, a potting inner mold 5 clamped with the bottom plate 12 is nested in the potting outer mold 8, a core shaft 7 plugged therein is nested in the potting inner mold 5, a copper wire bracket 1 extending to the outside of the potting outer mold 8 is abutted above the core shaft 7, an upper cover 4 extending to the outside of the copper wire bracket 1 is abutted above the copper wire bracket 1, and an upper locking bolt 10 passing through the copper wire bracket 1 and threadedly connected to the potting outer mold 8 is passed through the upper cover 4; The outer wall of the potting inner mold 5 is provided with a flat wire groove 501 for accommodating the bus wire, and the end of the bus wire is plugged into the copper wire bracket 1; a potting cavity 14 is formed between the inner wall of the potting outer mold 8 and the outer wall of the potting inner mold 5, and a central runner 701 is provided at the center position of the core shaft 7, and a plurality of lower ingates 702 connected to the central runner 701 are provided on the lower end surface of the core shaft 7, and the lower ingates 702 are connected to the lower part of the potting cavity 14 through the lower external runner 502 provided on the lower end surface of the potting inner mold 5; a plurality of upper ingates 703 connected to the central runner 701 are provided on the upper end surface of the core shaft 7, and the upper ingates 703 are connected to the upper part of the potting cavity 14 through the upper external runner 503 provided on the upper end surface of the potting inner mold 5; the potting inner mold 5 adopts a split splicing structure.

[0022] Specifically, the busbar wiring is fixed in the order of installation by means of the potting inner mold 5 and the copper wire bracket 1 provided with a flat wire groove 501, and the potting outer mold 8 cooperates with the potting inner mold 5 to form a potting cavity 14 that wraps the busbar, and then the potting outer mold 8 and the potting inner mold 5 are clamped and fixed by the upper cover 4 and the bottom plate 12, and at the same time, the potting cavity 14 and the center runner 701 are connected by means of the lower inner runner 702 and the upper inner runner 703 provided on the core shaft 7 and the lower outer runner 502 and the upper outer runner 503 provided on the potting inner mold 5, so as to facilitate the subsequent one-time casting and molding; in addition, the upper cover 4 and the bottom plate 12 connected to the potting outer mold 8 by bolts and the potting inner mold 5 with a split splicing structure are convenient for disassembly and demolding.

[0023] Compared with the traditional busbar arrangement structure in which a retaining frame is used to fix the busbar wiring, the present invention uses a potting inner mold 5 with a flat wire groove 501 and a copper wire bracket 1 to fix the busbar wiring in the installation order, and forms a potting cavity 14 that wraps the busbar through a potting outer mold 8 and a potting inner mold 5 to integrally cast the busbar and the copper wire bracket 1 with potting glue, so that the busbar wiring is sealed in the potting glue after casting, thereby enhancing the protection of the busbar and facilitating the welding machine to perform integral welding. Welding fixation reduces the thermal damage of welding sparks to the bus, improves the efficiency of subsequent installation and the safety of welding, and in addition, the lower endocastor 702 and the upper endocastor 703 provided on the core shaft 7 and the lower extrocastor 502 and the upper extrocastor 503 provided on the encapsulating inner mold 5 are used to connect the encapsulating cavity 14 with the central runner 701, so as to realize one-time pouring of the encapsulating compound and improve the uniformity of molding and the pouring efficiency; in addition, the encapsulating inner mold 5 with a split splicing mechanism is convenient for disassembly and demoulding.

[0024] See also Figure 5 The copper wire bracket 1 is provided with a central circular hole 101, a plurality of rectangular holes 102 equidistantly distributed around the circumference, and a plurality of through holes 103 equidistantly distributed around the circumference. The central circular hole 101 is arranged at the center position of the copper wire bracket 1, and the rectangular hole 102 is arranged between the central circular hole 101 and the through hole 103. The upper end of the rectangular hole 102 abuts against the lower end surface of the lower cylinder of the upper cover 4, and the through hole 103 is connected and matched with the upper locking bolt 10; the bus bar includes a connector bar 2 and a flat wire bar 3. The head of the connector bar 2 passes through the copper wire bracket 1 and its tail extends into the rectangular hole 102. Both ends of the flat wire bar 3 extend into the rectangular hole 102.

[0025] Specifically, the joint row 2 and the flat wire row 3 are stably fixed to facilitate subsequent integral casting.

[0026] See also Figure 2 An upper sealing ring 9 is nested between the potting outer mold 8 and the copper wire bracket 1 , and a lower sealing ring 11 is nested between the potting outer mold 8 and the bottom plate 12 .

[0027] Specifically, the sealing performance of the potting cavity 14 is improved by the upper sealing ring 9 and the lower sealing ring 11 .

[0028] See also Figure 4-7 Both the potting outer mold 8 and the potting inner mold 5 are annular structures. The potting inner mold 5 includes a plurality of splicing unit blocks 504 distributed in a circle and abutted end to end. A ring 6 is sleeved on the bottom of the splicing unit block 504, and an annular protrusion sleeved on the outside of the ring 6 is provided on the upper end surface of the bottom plate 12.

[0029] Specifically, the stabilizing ring shape of the splicing unit block 504 is fixed by the collar 6 and the annular protrusion arranged on the upper end surface of the bottom plate 12 .

[0030] See also Figure 7 and Figure 8 The splicing unit blocks 504 are arc-shaped blocks and the number is at least three. Splicing seams 505 are formed between adjacent splicing unit blocks 504. A pair of splicing seams 505 on both sides of at least one splicing unit block 504 are arranged in parallel.

[0031] Specifically, it is convenient to disassemble the cast splicing unit block 504 .

[0032] See also Figure 2 , Fig. 9 and Fig.10 The core shaft 7 is a cylindrical structure, the central runner 701 is a composite vertical cavity, the upper part of the central runner 701 is a truncated cone-shaped cavity structure that is wide at the top and narrow at the bottom, and the lower part is a columnar cavity structure, the number of lower ingates 702 is multiple and is a strip-shaped concave cavity structure with a rectangular cross-section, and the number of upper ingates 703 is multiple and is a horizontally arranged concave cavity column structure.

[0033] Specifically, when pouring the potting compound, the upper ingrown channel 703 connected to the upper portion of the potting cavity 14 is used to facilitate the discharge of gas in the potting cavity 14, reduce the generation of cavities, and improve the uniformity of pouring.

[0034] For further explanation of the structural features of the arrangement, see Figure 2 and 4 , a method for integrally forming a motor flat wire winding busbar arrangement structure, comprising the following steps: Step 1: insert the connector row 2 into the copper wire bracket 1, and put the connector row 2 into the inverted upper cover 4; Step 2: annularly splice the splicing unit blocks 504 and use the collar 6 to bind and shape them to obtain a potting inner mold 5, which is then inverted and inserted into the copper wire bracket 1; Step 3, insert the mandrel 7 into the potting inner mold 5 and align the lower inner runner 702 with the lower outer runner 502 of the potting inner mold 5; Step 4: insert the flat wire row 3 into the flat wire groove 501 on the outer wall of the potting inner mold 5 and insert both ends of the flat wire row 3 into the rectangular holes 102 of the copper wire bracket 1; Step 5: Place the upper sealing ring 9 under the inverted potting outer mold 8 and then place it on the upper cover 4, and then tighten the locking bolts 10 to fix the potting outer mold 8 and the upper sealing ring 9 on the upper cover 4; Step 6: Place the lower sealing ring 11 on the inverted potting outer mold 8, then connect the bottom plate 12 to the lower sealing ring 11, and use the lower locking bolts 13 to connect and fix the bottom plate 12 to the potting outer mold 8; Step 7, please refer to 2. Figure 3 and Fig.10, turn the assembled whole over so that its upper cover 4 faces upward, and then inject thermosetting potting glue into the central runner 701, and use the connecting vessel principle to make the potting cavity 14 filled evenly, and then heat and cure it, and wait for cooling to form; Step eight, demolding, first remove the upper cover 4, the potting outer mold 8 and the bottom plate 12, then remove the ring 6 and the core shaft 7; then, remove the splicing unit blocks 504 of the potting inner mold 5 one by one along the splicing seam 505 to obtain a finished product including the potting glue colloid, the bus bar and the copper wire bracket 1 connected as one.

[0035] Second implementation method: Figure 11-17 A motor flat wire winding busbar arrangement structure is shown. Based on the first embodiment, a pouring head 15 penetrating the upper cover 4 and the copper wire support 1 is abutted on the core shaft 7, and a runner closing mechanism is installed in the core shaft 7. The runner closing mechanism includes an upper fixing block 16 nested at the outer end opening position of the upper ingrate 703 and a lower fixing block 29 nested at the outer end opening position of the lower ingrate 702; An upper blocking block 17 is provided below the upper fixed block 16 and is arranged opposite to it. An upper connecting rod 18 is hingedly connected to the lower part of the upper blocking block 17 and is nested in the core shaft 7. A horizontal extrusion rod 19 is hingedly connected to the lower end of the upper connecting rod 18 and is horizontally slidably connected to the core shaft 7; a lower blocking block 30 is provided above the lower fixed block 29 and is arranged opposite to it. A lifting ring 31 is fixedly connected to the upper part of the lower blocking block 30 and is nested in the core shaft 7 and is vertically slidably connected to the core shaft 7. The lifting ring 31 is hingedly connected to the horizontal extrusion rod 19 through a lower connecting rod 32; The inner end of the horizontal extrusion rod 19 is fixedly connected with a sliding plate 20, and a horizontal extrusion cavity 704 is provided in the mandrel 7, which is vertically connected with the central runner 701 and horizontally penetrates the mandrel 7. A limit ring 21 sleeved on the outer side of the horizontal extrusion rod 19 is fixedly connected to the inner wall of the horizontal extrusion cavity 704, and a first limit spring 22 sleeved on the horizontal extrusion rod 19 is provided between the limit ring 21 and the sliding plate 20; An elastic pin 23 is nested on the side of the horizontal extrusion rod 19 away from the central runner 701, and a positioning cylinder 25 is provided near the outer end opening of the horizontal extrusion cavity 704 and is sleeved on the outside of the horizontal extrusion rod 19. An abutment ring 26 for limiting the movement of the elastic pin 23 is fixedly connected to the inner wall of the positioning cylinder 25, and an unlocking cylinder 27 slidably connected to the positioning cylinder 25 is nested on the side of the positioning cylinder away from the sliding disk 20, and a third limit spring 28 sleeved on the unlocking cylinder 27 is provided between the unlocking cylinder 27 and the positioning cylinder 25.

[0036] Specifically, when the potting cavity 14 is filled, the internal pressure of the potting fluid in the central runner 701 gradually increases, and the potting fluid squeezes the sliding plate 20, and the sliding plate 20 drives the horizontal extrusion rod 19 to move outward, and the horizontal extrusion rod 19 pushes the upper blocking block 17 to move upward through the upper connecting rod 18 until the upper blocking block 17 contacts the upper fixed block 16, and the upper blocking block 17 and the upper fixed block 16 cooperate to block the upper ingrow 703, isolating the upper ingrow 703 from the upper extrogenous runner 503. At the same time, the horizontal extrusion rod 19 drives the lower blocking block 30 to move downward through the lower connecting rod 32 and the lifting ring 31 until the lower blocking block 30 contacts the lower fixed block 29, and the lower blocking block 30 and the lower fixed block 29 cooperate to block the outer end opening of the lower ingrate 702, and isolate the lower ingrate 702 and the lower extrogenous runner 502, that is, the potting cavity 14 is blocked after the filling is completed, reducing the gate residue of the potting glue in the potting cavity 14 after heating and curing, so as to facilitate the subsequent disassembly of the core shaft 7 and the potting inner mold 5.

[0037] See also Fig.13 The elastic bayonet 23 is a strip block with an isosceles trapezoidal cross section and a pointed lower end. A second limit spring 24 abutting against the elastic bayonet 23 is nested in the horizontal extrusion rod 19. The abutment ring 26 is an annular structure with a right-angled triangle cross section. The inclined surface of the abutment ring 26 is parallel to the inclined surface of the elastic bayonet 23.

[0038] Specifically, when the horizontal extrusion rod 19 drives the upper blocking block 17 and the lower blocking block 30 to reach the maximum stroke position, the elastic pin 23 moves to the left side of the abutment ring 26. After the pouring head 15 is evacuated, that is, the internal pressure of the central runner 701 disappears, the abutment ring 26 abuts and limits the elastic pin 23, so that the upper blocking block 17 and the lower blocking block 30 remain stationary, thereby making the encapsulation cavity 14 in a closed state.

[0039] See also Fig.13 Both the upper blocking block 17 and the lower blocking block 30 extend into the core shaft 7 and are vertically slidably connected to the core shaft 7. A accommodating cavity for accommodating the upper blocking block 17, the lower blocking block 30, and the lifting ring 31 is opened in the core shaft 7, and the accommodating cavity is connected to the horizontal extrusion cavity 704.

[0040] See also Fig.13 The positioning cylinder 25 and the unlocking cylinder 27 are both hollow cylinders with one end open and arranged horizontally. A rounded corner is provided at the circumferential edge of the left opening of the unlocking cylinder 27. The outer diameter of the unlocking cylinder 27 is smaller than the inner diameter of the abutting ring 26.

[0041] Specifically, when the upper blocking block 17 and the lower blocking block 30 need to return to their initial positions, the sliding disk 20 and the unlocking cylinder 27 are squeezed at the same time, and the elastic latch 23 returns to the horizontal squeezing rod 19 under the squeezing of the unlocking cylinder 27 and moves to the left side of the abutment ring 26 under the push of the unlocking cylinder 27.

[0042] See also Fig.12 and Fig.14 A vertical extrusion chamber 1501 connected to the central runner 701 is provided in the pouring head 15, a vertical extrusion rod 33 is nested in the vertical extrusion chamber 1501, a vertical limit spring 34 is sleeved on the outside of the vertical extrusion rod 33, a pointer 35 extending to the top of the pouring head 15 is fixedly connected to the upper end of the vertical extrusion rod 33, and a pressure indicator tube 36 is sleeved on the outside of the pointer 35.

[0043] Specifically, when the pressure in the central runner 701 increases, the vertical extrusion rod 33 drives the pointer 35 to move upward, and the operator determines the filling process and filling pressure according to the value indicated by the pointer 35 on the pressure indicator tube 36 to improve the potting quality.

[0044] In view of current practical needs, the above-mentioned implementation mode adopted in this application is not limited to the scope of protection. Various changes made within the knowledge scope of technical personnel in this field without departing from the concept of this application still fall within the scope of protection of the present invention.

Claims

1. A motor flat wire winding busbar arrangement structure, characterized in that: The bottom plate (12) is fixedly connected to an outer potting mold (8) via a lower locking bolt (13); an inner potting mold (5) is nested in the outer potting mold (8) and is clamped with the bottom plate (12); a core shaft (7) is nested in the inner potting mold (5) and is plugged into the core shaft (7); a copper wire support (1) extending to the outside of the outer potting mold (8) is abutted above the core shaft (7); an upper cover (4) extending to the outside of the copper wire support (1) is abutted above the copper wire support (1); an upper locking bolt (10) passes through the upper cover (4) and passes through the copper wire support (1) and is threadedly connected to the outer potting mold (8); The outer wall of the potting inner mold (5) is provided with a flat wire groove (501) for accommodating the busbar wire, and the end of the busbar wire is plugged into the copper wire bracket (1); the inner wall of the potting outer mold (8) and the outer wall of the potting inner mold (5) enclose a potting cavity (14); a central runner (701) penetrating the mandrel (7) is provided at the center position of the mandrel (7); a plurality of lower inner runners (702) connected to the central runner (701) are provided on the lower end surface of the mandrel (7); and a plurality of lower inner runners (702) connected to the central runner (701) are provided on the lower end surface of the mandrel (7). The ingates (702) is connected to the lower part of the potting cavity (14) via a lower external pouring channel (502) provided on the lower end surface of the potting inner mold (5); the upper end surface of the mandrel (7) is provided with a plurality of upper ingates (703) connected to the central pouring channel (701); the upper ingates (703) are connected to the upper part of the potting cavity (14) via an upper external pouring channel (503) provided on the upper end surface of the potting inner mold (5); the potting inner mold (5) adopts a split splicing structure.

2. The motor flat wire winding busbar arrangement structure according to claim 1, characterized in that: A pouring head (15) penetrating the upper cover (4) and the copper wire support (1) is abutted against the core shaft (7), and a pouring channel sealing mechanism is installed in the core shaft (7), the pouring channel sealing mechanism comprising an upper fixing block (16) nested at the outer end opening position of the upper inner pouring channel (703) and a lower fixing block (29) nested at the outer end opening position of the lower inner pouring channel (702); an upper blocking block (17) arranged opposite to the upper fixing block (16) is provided below the upper fixing block (16), and the lower portion of the upper blocking block (17) is hinged. An upper connecting rod (18) is connected to the core shaft (7), and a horizontal extrusion rod (19) is hinged at the lower end of the upper connecting rod (18) and is horizontally slidably connected to the core shaft (7); a lower blocking block (30) is arranged opposite to the lower fixed block (29), and a lifting ring (31) is fixedly connected to the upper end of the lower blocking block (30) and is nested in the core shaft (7) and vertically slidably connected to the core shaft (7), and the lifting ring (31) is hinged to the horizontal extrusion rod (19) through a lower connecting rod (32); The inner end of the horizontal extrusion rod (19) is fixedly connected to a sliding plate (20); a horizontal extrusion cavity (704) is provided in the core shaft (7) and is vertically connected to the central runner (701) and horizontally penetrates the core shaft (7); a limit ring (21) sleeved on the outer side of the horizontal extrusion rod (19) is fixedly connected to the inner wall of the horizontal extrusion cavity (704); a first limit spring (22) sleeved on the horizontal extrusion rod (19) is provided between the limit ring (21) and the sliding plate (20); An elastic latch (23) is embedded in the side of the horizontal extrusion rod (19) away from the central pouring channel (701); a positioning cylinder (25) sleeved on the outside of the horizontal extrusion rod (19) is provided near the outer end opening of the horizontal extrusion cavity (704); an abutment ring (26) for limiting the movement of the elastic latch (23) is fixedly connected to the inner wall of the positioning cylinder (25); an unlocking cylinder (27) slidably connected to the positioning cylinder (25) is embedded in the side of the positioning cylinder (25) away from the sliding disk (20); and a third limit spring (28) sleeved on the unlocking cylinder (27) is provided between the unlocking cylinder (27) and the positioning cylinder (25).

3. The motor flat wire winding busbar arrangement structure according to claim 2, characterized in that: The copper wire support (1) is provided with a central circular hole (101), a plurality of rectangular holes (102) equidistantly distributed around the circumference, and a plurality of through holes (103) equidistantly distributed around the circumference. The central circular hole (101) is arranged at the central position of the copper wire support (1), and the rectangular hole (102) is arranged between the central circular hole (101) and the through hole (103). The upper end of the rectangular hole (102) abuts against the lower end surface of the lower barrel of the upper cover (4), and the through hole (103) is engaged with the upper locking bolt (10). The busbar comprises a connector bar (2) and a flat wire bar (3). The head of the connector bar (2) passes through the copper wire support (1) and the tail thereof extends into the rectangular hole (102). Both ends of the flat wire bar (3) extend into the rectangular hole (102).

4. The motor flat wire winding busbar arrangement structure according to claim 3, characterized in that: An upper sealing ring (9) is nested between the potting outer mold (8) and the copper wire support (1), and a lower sealing ring (11) is nested between the potting outer mold (8) and the bottom plate (12).

5. The motor flat wire winding busbar arrangement structure according to claim 4, characterized in that: The potting outer mold (8) and the potting inner mold (5) are both annular structures. The potting inner mold (5) comprises a plurality of splicing unit blocks (504) distributed in a circle and butted end to end. A collar (6) is sleeved on the bottom of the splicing unit block (504). The upper end surface of the bottom plate (12) is provided with an annular protrusion sleeved on the outside of the collar (6).

6. The motor flat wire winding busbar arrangement structure according to claim 5, characterized in that: The splicing unit blocks (504) are arc-shaped blocks and the number is at least three. Splicing seams (505) are formed between adjacent splicing unit blocks (504), and a pair of splicing seams (505) on both sides of at least one splicing unit block (504) are arranged in parallel.

7. The motor flat wire winding busbar arrangement structure according to claim 2, characterized in that: The pouring head (15) is provided with a vertical extrusion chamber (1501) in communication with the central pouring channel (701), a vertical extrusion rod (33) is nested in the vertical extrusion chamber (1501), a vertical limit spring (34) is sleeved on the outside of the vertical extrusion rod (33), a pointer (35) extending to the top of the pouring head (15) is fixedly connected to the upper end of the vertical extrusion rod (33), and a pressure indicator tube (36) is sleeved on the outside of the pointer (35).

8. The motor flat wire winding busbar arrangement structure according to claim 2, characterized in that: The elastic bayonet (23) is a strip-shaped block with an isosceles trapezoidal cross section and a pointed tip at the lower end. A second limit spring (24) abutting against the elastic bayonet (23) is nested in the horizontal extrusion rod (19). The abutment ring (26) is an annular structure with a right-angled triangle cross section. The inclined surface of the abutment ring (26) is parallel to the inclined surface of the elastic bayonet (23).

9. The motor flat wire winding busbar arrangement structure according to claim 8, characterized in that: The positioning cylinder (25) and the unlocking cylinder (27) are both hollow cylinders with one end open and arranged horizontally. A rounded corner portion is provided at the circumferential edge of the left opening of the unlocking cylinder (27). The outer diameter of the unlocking cylinder (27) is smaller than the inner diameter of the abutment ring (26).

10. The motor flat wire winding busbar arrangement structure according to claim 6, characterized in that: The overall forming method includes the following steps: Step 1: insert the connector row (2) into the copper wire bracket (1), and place the connector row (2) into the inverted upper cover (4); Step 2: annularly splice the splicing unit blocks (504) and use a collar (6) to bind and shape them to obtain a potting inner mold (5), which is then inverted and inserted into the copper wire bracket (1); Step three, inserting the mandrel (7) into the potting inner mold (5) and aligning the lower inner runner (702) with the lower outer runner (502) of the potting inner mold (5); Step 4: insert the flat wire row (3) into the flat wire groove (501) on the outer wall of the potting inner mold (5) and insert the two ends of the flat wire row (3) into the rectangular holes (102) of the copper wire bracket (1); Step 5: Place the upper sealing ring (9) below the inverted potting outer mold (8) and then place it on the upper cover (4), then screw on the locking bolts (10) to fix the potting outer mold (8) and the upper sealing ring (9) on the upper cover (4); Step 6: Place the lower sealing ring (11) on top of the inverted potting outer mold (8), then connect the bottom plate (12) to the lower sealing ring (11), and use the lower locking bolts (13) to connect and fix the bottom plate (12) to the potting outer mold (8); Step 7, the assembled whole is turned over so that the upper cover (4) faces upward, and then a thermosetting potting glue is injected into the central runner (701), and the potting cavity (14) is filled evenly by using the communicating vessel principle, and then heated and cured, and waited for cooling to form; Step eight, demoulding, first remove the upper cover (4), the potting outer mold (8) and the bottom plate (12), then remove the collar (6) and the core shaft (7); then, remove the splicing unit blocks (504) of the potting inner mold (5) one by one along the splicing seam (505), and obtain a finished product including the potting glue body, the bus bar and the copper wire bracket (1) connected as one.

Images