Three-phase integrated busbar

Abstract

The invention relates to a three-phase integrated busbar, which comprises three groups of unit assemblies corresponding to a U phase, a V phase and a W phase, an injection molding shell for integrating and fixing the three groups of unit assemblies, and connecting steel rings arranged on two sides of the injection molding shell, and is characterized in that each unit assembly comprises a connecting terminal, an enameled wire with one end connected with the connecting terminal, and a connecting steel sleeve fixed on the connecting terminal; the injection molding shell is provided with a connecting port for exposing the connecting terminal, the three groups of enameled wires are divided into an upper layer structure and a lower layer structure in the injection molding shell, and the three groups of enameled wires penetrate out in different directions of the injection molding shell. The overall structure is iterated, the PI enameled wires with better conductivity, oil resistance and high temperature resistance are used for replacing braided wires and hard connection pins, after the enameled wires and the connection terminals are welded, oil-resistant and high-temperature-resistant insulating materials are subjected to insert injection molding, and integration is achieved.

Description

Technical Field

[0001] The present application relates to the technical field of electrical connection elements, and in particular to a three-phase integrated busbar. Background Art

[0002] At present, when the three-phase output copper bar of the three-phase motor stator is connected to the three-phase copper bar of the controller assembly, a copper bar support seat and a three-phase transfer copper bar are usually required to achieve this. The three-phase motor output copper bar products are mainly welded with copper bar braided wire (some products use crimping terminals), using resistance welding combined with silver soldering sheets, and then the braided wire is covered with heat shrink tubing for insulation.

[0003] This type of lead-out copper busbar structure requires welding and assembly of multiple parts during the production process. Its heat shrink tubing needs to reach temperature resistance level F. Fluororubber heat shrink tubing, silicone tube, glass fiber tube and other high temperature resistant auxiliary materials are commonly used. The motor has air cooling, water cooling and oil cooling, so the auxiliary materials have oil resistance requirements. Therefore, its material cost, manufacturing cost and management cost are relatively high. In addition, the lead-out structure is not easy to fix, making it difficult to achieve automated installation, and it is easy to form a mess in the outgoing part, affecting the appearance and safety of the motor. The installation process is relatively complicated, and it occupies a large structural space with low integration. Summary of the invention

[0004] The purpose of this application is to provide a three-phase integrated busbar with an iterative overall structure. It uses PI enameled wire with better conductivity, oil resistance and high temperature resistance to replace braided wires and hard-connected pins. After the enameled wires are welded to the connecting terminals, they are insert-injected with oil-resistant and high-temperature resistant insulating materials for integrated integration. It solves the problems of the original solution, such as high cost, great manufacturing difficulty, waste of man-hours, difficulty in automated installation, and hidden dangers in appearance and safety.

[0005] The three-phase integrated busbar provided in this application adopts the following technical solution:

[0006] A three-phase integrated busbar comprises three groups of unit components corresponding to the U phase, the V phase and the W phase, an injection molded shell which integrates and fixes the three groups of unit components and connecting steel rings arranged on both sides of the injection molded shell, the unit components comprise connecting terminals, enameled wires connected to the connecting terminals at one end and connecting steel sleeves fixed on the connecting terminals, the injection molded shell is provided with a connecting port for exposing the connecting terminals, the three groups of enameled wires are divided into an upper and lower three-layer structure in the injection molded shell, and the three groups of enameled wires pass through the injection molded shell in different directions.

[0007] As a preferred technical solution of the present application, the connecting terminal includes a lap surface portion, a welding fixed portion, and a bending portion connecting the lap surface portion and the welding fixed portion. The lap surface portion is provided with a connecting hole for fixing the connecting steel sleeve, and bending plates for tightly wrapping and fixing the enameled wire are provided on both sides of the welding fixed portion.

[0008] As a preferred technical solution of the present application, the connecting terminal is stamped from a plate with a thickness set to 2 mm and a material set to any one of T2 copper, aluminum, nickel and their alloys; the surface of the connecting terminal is nickel-plated with a nickel layer thickness of 3-10 μm.

[0009] As a preferred technical solution of the present application, each group of unit components is provided with one or more enameled wires, which are round copper wires consisting of an inner layer of copper rod and an outer layer of polyimide paint film. The diameter of the copper rod is φ3mm and the thickness of the polyimide paint film is 0.13mm.

[0010] As a preferred technical solution of the present application, the injection-molded shell is made of polystyrene (PPS) and has a thickness of 2 mm, which fits tightly with the three sets of unit components.

[0011] As a preferred technical solution of the present application, the connecting steel sleeve is configured as a prefabricated nut made of carbon steel with a nickel-plated surface, and is riveted into the connecting hole of the connecting terminal by pressure riveting.

[0012] As a preferred technical solution of the present application, the injection molded shell includes a linear body, a first output end arranged at one end of the linear body, a second output end arranged on one side of the first output end, and a third output end extending from the end of the second output end. The connection terminals of the three groups of unit components of U phase, V phase and W phase are distributed in a linear manner on the same side of the linear body, and the connection terminals are separated by partitions.

[0013] As a preferred technical solution of the present application, the enameled wires of the three-phase unit assembly are output from three output ends respectively, and the connection ends of the enameled wires of the three-phase unit assembly are distributed in a circle, and the connection ends of the enameled wires are oriented in the same direction.

[0014] As a preferred technical solution of the present application, the enameled wires of the three-phase unit assembly are mixed and output at three output ends.

[0015] In summary, the present application includes at least one of the following beneficial technical effects:

[0016] 1. This application is used for the three-phase output line assembly of the flat wire motor. It is a conductive connector that uses copper busbar terminals and enameled wire as current conductors, and integrates the UVW three-phases into one through injection molding. It replaces the original copper busbar terminal + braided copper wire + hard-connected pins + heat shrink tube to form each phase, and then installs them separately on the motor. The material cost is greatly reduced, and the process complexity reduces the number of welding, braiding, crimping, casing and other processes. The product is highly integrated and can be installed automatically.

[0017] 2. In terms of performance, the paint film of PPS and PI enameled wire can reach H-class insulation grade and excellent oil resistance; the entire product has high vibration reliability and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present application;

[0019] Figure 2 is a schematic diagram of the structure of the connecting terminal in an embodiment of the present application;

[0020] Figure 3 is a schematic structural diagram of a U-phase unit assembly in an embodiment of the present application;

[0021] Figure 4 It is a structural diagram of another implementation method of the embodiment of the present application;

[0022] In the figure, 1. connecting terminal; 11. overlapping surface part; 12. welding fixing part; 13. bending part; 14. connecting hole; 15. bending plate; 2. enameled wire; 3. injection molded shell; 31. connecting port; 32. straight body; 33. first output end; 34. second output end; 35. third output end; 36. partition; 4. connecting steel ring; 5. connecting steel sleeve. DETAILED DESCRIPTION

[0023] The following is combined with Figure 1 -Attached Figure 4 , further details of this application are given.

[0024] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0025] Embodiment: This application proposes a three-phase integrated busbar, referring to Figure 1-4 The device includes three groups of unit components corresponding to the U phase, V phase, and W phase, an injection molded housing 3 for integrating and fixing the three groups of unit components, and a connecting steel ring 4 for fixing the injection molded housing 3 to the installation target. Among them, the three groups of unit components have the same structural composition, and the difference lies in the number of bends and the size. The injection molded housing 3 integrates and compounds the three groups of unit components together. When the injection molded housing 3 is injected, the connecting steel ring 4 is also injected, and the entire busbar is connected to the counterpart through the connecting steel ring 4.

[0026] In this embodiment, a U-phase unit assembly is taken as an example for description. The U-phase unit assembly includes a connecting terminal 1 , an enameled wire 2 and a connecting steel sleeve 5 .

[0027] The connecting terminal 1 includes a lap surface portion 11, a welding fixing portion 12 and a bending portion 13. The lap surface portion 11 is configured as a rectangular plate with a circular connecting hole 14 in the middle for installing and fixing the connecting steel sleeve 5; one end of the lap surface portion 11 is connected to the bending portion 13, and the other side of the bending portion 13 is connected to the welding fixing portion 12. The welding fixing portion 12 is perpendicular to the lap surface portion 11, and both sides of the welding fixing portion 13 are bent in a direction away from the lap surface portion 11 to form a bending plate 15. The bending plates 15 on both sides can be folded toward the middle and cooperate with the welding fixing portion 12 to tightly wrap and fix the enameled wire 2.

[0028] In this embodiment, the connecting terminal 1 is formed by plate stamping, the thickness of the plate is set to 2mm, and the material is set to any one of T2 copper, aluminum, nickel and their alloys. In this embodiment, T2 copper is used; the surface of the connecting terminal 1 is nickel-plated, and the thickness of the nickel layer is 3-10μm. The processing flow of the connecting terminal 1 is copper plate blanking stamping two-dimensional forming, bending 1-3 (90°), bending 1-1 and 1-2 (65°), and nickel plating of the connecting terminal 1.

[0029] Each unit assembly is provided with one or more enameled wires 2. In this embodiment, the unit assembly of the U phase is provided with three enameled wires 2, and the three enameled wires 2 are horizontally arranged side by side. The enameled wire 2 is made of round copper wire, which is composed of an inner layer of red copper rod and an outer layer of polyimide paint film. The diameter of the red copper rod is φ3mm, and the thickness of the polyimide paint film is 0.13mm, so that the enameled wire 2 has excellent properties such as oil resistance and 200°C high temperature resistance.

[0030] The connecting steel sleeve 5 uses an M8 steel sleeve as a prefabricated nut, which is made of carbon steel and nickel-plated on the surface. It is riveted to the connecting hole 14 of the overlapping surface part 11 of the connecting terminal 1 by pressure riveting. The connecting steel sleeve 5 can effectively fix the terminal position, facilitate precise injection molding, and facilitate assembly with the opponent.

[0031] When processing the U-phase unit assembly, the three U-phase enameled wires 2 are three-dimensionally bent in sequence, and the paint film of 20mm length is removed from both ends of the enameled wires 2. One end of the three enameled wires 2 is aligned and attached to the welding fixing part 12 for welding and fixing. The bending plate 15 is pressed and flattened after welding to ensure that the welding piece is completely melted, and then the contact resistance of the welding position is checked to be ≤10μΩ. The φ8 connection hole 14 of the connection terminal 1 is riveted with an M8 steel sleeve prefabricated nut. The same applies to V and W phases.

[0032] The injection molded housing 3 includes an integrally injection molded linear body 32, a first output end 33 arranged at one end of the linear body 32, a second output end 34 arranged at one side of the first output end 33, and a third output end 35 extending from the end of the second output end 34. The connection terminals 1 of the three groups of unit components of the U phase, V phase, and W phase are distributed in a straight line on the upper surface of the linear body 32. Three connection ports 31 are arranged on the upper surface of the linear body 32. The overlapping surface part 11 of the connection terminal 1 and the connection steel sleeve 5 are exposed at the connection port 31. The three connection ports 31 are separated by a partition 36. The connection steel ring 4 is fixed to the side of the injection molded housing 3. In this embodiment, a connection steel ring 4 is respectively arranged at the far end of the linear body 32, the outer side of the first output end 33, and the outer side of the second output end 34.

[0033] The injection molded shell 3 is made of polystyrene (PPS), black, temperature resistant to 180°C, 2mm thick, and fits tightly with the enameled wire 2, ensuring the insulation and voltage resistance reliability of the three-phase integrated busbar as a whole. It effectively solves the problems of displacement leakage, dimensional tolerance, electromagnetic interference, etc. caused by the loose coating of the heat shrink tube in the past, and has good heat dissipation and lightweight advantages.

[0034] The enameled wires 2 of U phase, V phase and W phase are output from three output terminals respectively, among which U phase (U1, U2, U3) is output from the upper side of the third output terminal 35, V phase (V1, V2, V3) is output from the side of the second output terminal 34, and W phase (W1, W2, W3) is output from the upper side of the first output terminal 33. The external output connection terminals of the enameled wires 2 (U1, U2, U3, V1, V2, V3, W1, W2, W3) are distributed in a circle, and the connection terminals are oriented in the same direction. In this embodiment, the three groups of enameled wires 2 are divided into three layers of upper, middle and lower structures in the injection molded housing 3. The three enameled wires 2 of U phase (U1, U2, U3) are located in the bottom layer, and the corresponding connecting terminal 1 is located at the farthest end; the three enameled wires 2 of V phase (V1, V2, V3) are located in the middle layer, and the corresponding connecting terminal 1 is located in the middle; the three enameled wires 2 of W phase (W1, W2, W3) are located in the top layer, and the corresponding connecting terminal 1 is located at the nearest end.

[0035] When the entire three-phase integrated busbar is formed, the unit components of the U phase, V phase, and W phase and the connecting steel ring 4 are placed in the injection mold in sequence, and integral injection molding is performed to finally form a three-phase integrated busbar product.

[0036] In another implementation of the embodiment of the present application, the U-phase, V-phase, and W-phase unit assemblies are each provided with two enameled wires 2 (U1, U2, V1, V2, W1, W2), and the six enameled wires 2 are mixed and output at three output ends, (U1, V1) are output from the upper side of the third output end 35, (V2, W1) are output from the second output end 34, and (U2, W2) are output from the first output end 33. The output ends of the three enameled wires 2 (U1, V2, W2) are located on the same circumferential surface, and the output ends of the three enameled wires 2 (U2, V1, W1) are located on the same circumferential surface.

[0037] The embodiments of this specific implementation are all preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. The same components are represented by the same figure marks. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A three-phase integrated busbar, characterized in that: The invention comprises three groups of unit components corresponding to the U phase, the V phase and the W phase, an injection molded shell (3) for integrating and fixing the three groups of unit components, and connecting steel rings (4) arranged on both sides of the injection molded shell (3); the unit components comprise a connecting terminal (1), an enameled wire (2) connected to the connecting terminal (1) at one end, and a connecting steel sleeve (5) fixed on the connecting terminal (1); the injection molded shell (3) is provided with a connecting port (31) for exposing the connecting terminal (1); the three groups of enameled wires (2) are divided into an upper and lower three-layer structure in the injection molded shell (3), and the three groups of enameled wires (2) pass through the injection molded shell (3) in different directions.

2. A three-phase integrated busbar according to claim 1, characterized in that: The connecting terminal (1) comprises an overlapping surface portion (11), a welding fixing portion (12), and a bent portion (13) connecting the overlapping surface portion (11) and the welding fixing portion (12); the overlapping surface portion (11) is provided with a connecting hole (14) for fixing a connecting steel sleeve (5); and bent plates (15) for wrapping and fixing the enameled wire (2) are provided on both sides of the welding fixing portion (12).

3. A three-phase integrated busbar according to claim 1, characterized in that: The connecting terminal (1) is formed by plate stamping, with a thickness of 2 mm and a material of any one of T2 copper, aluminum, nickel and alloys thereof; the surface of the connecting terminal (1) is nickel-plated, with a nickel layer thickness of 3-10 μm.

4. The three-phase integrated busbar according to claim 1, characterized in that: Each unit assembly is provided with one or more enameled wires (2), which are round copper wires and consist of an inner copper rod and an outer polyimide paint film. The diameter of the copper rod is φ3 mm, and the thickness of the polyimide paint film is 0.13 mm.

5. The three-phase integrated busbar according to claim 1, characterized in that: The injection-molded housing (3) is made of polystyrene (PPS) and has a thickness of 2 mm, so that it fits tightly with the three groups of unit components.

6. A three-phase integrated busbar according to claim 1, characterized in that: The connecting steel sleeve (5) is configured as a prefabricated nut made of carbon steel with a nickel-plated surface, and is riveted into the connecting hole (14) of the connecting terminal (1) by pressure riveting.

7. The three-phase integrated busbar according to claim 1, characterized in that: The injection molded housing (3) comprises a straight body (32), a first output end (33) arranged at one end of the straight body (32), a second output end (34) arranged at one side of the first output end (33), and a third output end (35) extending from the end of the second output end (34); the connection terminals (1) of the three groups of unit assemblies of the U phase, the V phase, and the W phase are distributed in a straight line on the same side of the straight body (32); and the connection terminals (1) are separated by barriers (36).

8. A three-phase integrated busbar according to claim 7, characterized in that: The enameled wires (2) of the three-phase unit assembly are output from three output ends respectively, and the connection ends of the enameled wires (2) of the three-phase unit assembly are distributed in a circumference, and the connection ends of the enameled wires (2) are oriented in the same direction.

9. The three-phase integrated busbar according to claim 7, characterized in that: The enameled wires (2) of the three-phase unit assembly are mixed and output at three output ends.

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