Motor for driving vehicle
By adopting annular busbars and simplified winding wire end shapes in the motor stator, combined with stamping busbars and overmolding technology, the deformation and insulation problems of traditional motor winding wire ends are solved, achieving a more efficient manufacturing process and performance improvement.
Patent Information
- Application Number
- CN202311365160.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-10-20
- Publication Date
- 2025-04-22
AI Technical Summary
The winding wire ends in the stator of a conventional motor are complex in shape and are easily deformed during welding, and additional potting processes are required to ensure insulation and creepage distance.
The annular busbar component and a simplified winding wire end shape are used to connect the wire end to the busbar in the radial direction, the stamped busbar is used and the insulation is enhanced by overmolding, and the busbar is reinforced to increase creepage distance.
Reduces the deformation risk at the ends of the winding wire, reduces the manufacturing time and rework rate, improves the performance and insulation of the busbar, avoids additional potting processes, and simplifies the manufacturing process.
Smart Images
Figure CN119864978A_ABST
Abstract
Description
Technical Field
[0001] Embodiments of the present disclosure relate generally to electric machines for driving vehicles, and more particularly to windings and busbars in a stator of a concentrated winding electric machine. Background Art
[0002] In recent years, electric motors have been widely used as drive units of vehicles in the transmission systems of hybrid or all-electric vehicles. Electric motors are used to convert electrical energy into mechanical energy and / or mechanical energy into electrical energy, and generally include a fixed part called a stator and a movable part called a rotor that is movably arranged relative to the fixed part.
[0003] Traditionally, the shape of the wire ends of the windings in the stator of the motor is relatively complex. When the windings are welded to the busbar, the shape of the wire ends of the windings is easily deformed. In addition, in order to ensure the insulation and creepage distance between the windings, an additional potting process is required for the busbar. Summary of the invention
[0004] An embodiment of the present disclosure provides a motor for driving a vehicle, the motor comprising an annular busbar component; and a plurality of windings; wherein each of the plurality of windings comprises two wire ends, and the two wire ends of each winding are connected to the busbar component along a radial direction of the busbar component.
[0005] In some embodiments, the busbar component includes a plurality of busbars, and the two wire ends of each winding are connected to corresponding two busbars of the plurality of busbars in a radial direction.
[0006] In some embodiments, two wire ends of a first winding among the multiple windings are connected to first and second busbars among the multiple busbars in a radial direction, and two wire ends of a second winding adjacent to the first winding among the multiple windings are connected to first and third busbars among the multiple busbars in a radial direction, the first busbar is associated with zero voltage, and the second and third busbars are associated with different voltages among the UVW three-phase voltages.
[0007] In some embodiments, each of the plurality of busbars includes a plurality of connection portions protruding in a radial direction, and the two wire ends of each winding are connected to the corresponding two busbars in a radial direction through corresponding two connection portions respectively located on the corresponding two busbars.
[0008] In some embodiments, the plurality of busbars are a plurality of stamped busbars.
[0009] In some embodiments, each stamped busbar of the plurality of stamped busbars includes an opening.
[0010] In some embodiments, each of the plurality of busbars has a common center, and the plurality of busbars are nested and arranged on the same horizontal plane relative to the center.
[0011] In some embodiments, the plurality of bus bars are nested and arranged on the same horizontal plane relative to the center of the circle, including at least one of the following: each of the plurality of bus bars is nested and arranged on the same horizontal plane relative to the center of the circle with a different opening position; and each of the plurality of bus bars is nested and arranged on the same horizontal plane relative to the center of the circle with a different connection portion position.
[0012] In some embodiments, the busbar component is formed by overmolding to form an overmolded busbar component.
[0013] In some embodiments, the overmolded busbar component comprises a plurality of protrusions, one protrusion of the plurality of protrusions being located: between two wire ends of one winding; or between two adjacent wire ends of two adjacent windings.
[0014] The embodiments of the present disclosure change the shape of the wire ends of the windings so that the wire ends of the windings can be connected to the busbars in a radial direction. In this way, the wire ends of the windings are not easily deformed, which reduces the manufacturing time and rework rate. In addition, the embodiments of the present disclosure reduce the manufacturing difficulty and cost of the busbars and improve the performance of the busbars by using stamped busbars. In addition, the embodiments of the present disclosure enhance the insulation of the busbars by overmolding the busbars, and increase the creepage distance between the wire ends of the windings by reinforcing the overmolded busbars, i.e., adding multiple protrusions or ribs, without the need for an additional potting process.
[0015] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the present disclosure, nor is it intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other objects, features and advantages of the present disclosure will become more apparent through a more detailed description of exemplary embodiments of the present disclosure with reference to the accompanying drawings.
[0017] Figure 1 It is a schematic diagram of traditional winding.
[0018] Figure 2 is a schematic diagram of conventional bus components.
[0019] Figure 3 It is a schematic diagram of the connection method of traditional winding and traditional busbar components.
[0020] Figure 4 is a schematic diagram of a winding according to an embodiment of the present disclosure.
[0021] Figure 5 It is a schematic diagram of the connection method between the winding and the busbar component according to an embodiment of the present disclosure.
[0022] Fig. 6A is a schematic diagram of a busbar in a busbar component according to an embodiment of the present disclosure.
[0023] Figure 6B is another schematic diagram of a busbar in a busbar component according to an embodiment of the present disclosure.
[0024] Figure 7 FIG. 4 is a schematic diagram of a nested arrangement of multiple busbars in a busbar component according to an embodiment of the present disclosure.
[0025] Figure 8 is a schematic diagram of an overmolded busbar component according to an embodiment of the present disclosure.
[0026] Fig. 9 is a schematic diagram of a plurality of protrusions of an overmolded busbar component according to an embodiment of the present disclosure.
[0027] In the various drawings, the same or corresponding reference numerals represent the same or corresponding parts. DETAILED DESCRIPTION
[0028] The preferred embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the preferred embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to make the present disclosure more thorough and complete, and to fully convey the scope of the present disclosure to those skilled in the art.
[0029] As used herein, the term "including" and its variations mean open inclusion, i.e., "including but not limited to". Unless otherwise stated, the term "or" means "and / or". The term "based on" means "based at least in part on". The terms "an example embodiment" and "an embodiment" mean "at least one example embodiment". The term "another embodiment" means "at least one additional embodiment". The terms "first", "second", etc. may refer to different or the same objects. Other explicit and implicit definitions may also be included below.
[0030] As described above, conventionally, the shape of the wire end of the winding in the stator of the motor is relatively complicated, and when the winding is welded to the busbar, the shape of the wire end of the winding is easily deformed. Figure 1FIG. 1 shows a schematic diagram of a conventional winding 100. The conventional winding 100 includes two wire ends. The shapes of the two wire ends are relatively complex. Figure 1 In the example of , each wire end includes two bent sections. The first wire end includes a first section 110-1 and a second section 120-1 bent relative to the first section 110-1, and the second wire end includes a first section 110-2 and a second section 120-2 bent relative to the first section 110-2.
[0031] The two wire ends of the conventional winding 100 can be welded to Figure 2 On the conventional busbar component 200 shown. Figure 3 A schematic diagram of a connection method 300 of a conventional winding 100 and a conventional busbar component 200 is shown. Figure 3 A conventional winding 100 is described with its wire ends connected to a conventional busbar component 200, however Figure 3 The connection method 300 shown is also applicable to other conventional windings connected to the conventional busbar component 200. Figure 3 As shown, the second section 120-1 of the first wire end of the conventional winding 100 extends along the radial direction of the conventional busbar component 200 to a predetermined busbar in the conventional busbar component 200, such as a busbar associated with zero voltage. Thus, the first section 110-1 of the first wire end can be welded to a predetermined busbar of the conventional busbar component 200, such as a busbar associated with zero voltage, along the tangential direction. In this context, along the tangential direction or radial direction of the busbar component means having a small angle relative to the tangential direction or radial direction of the busbar component, such as 5 degrees or any other appropriately small angle.
[0032] Similarly, the second section 120-2 of the second wire end of the conventional winding 100 extends along the radial direction of the conventional busbar component 200 to another predetermined busbar in the conventional busbar component 200, such as a busbar associated with one of the UVW three-phase voltages. Thus, the first section 110-2 of the second wire end can be welded to another predetermined busbar of the conventional busbar component 200, such as a busbar associated with one of the UVW three-phase voltages, along the tangential direction. Since the shape of the wire end is relatively complex, including the first section for welding and the second section for extension, the shape of the wire end is easily deformed during welding.
[0033] In order to at least partially solve the above-mentioned problems and one or more of other potential problems, an example embodiment of the present disclosure proposes a motor for driving a vehicle, wherein the motor includes a ring-shaped busbar component and a plurality of windings. Each of the plurality of windings includes two wire ends. The two wire ends of each winding are connected to the busbar component along the radial direction of the busbar component. The embodiment of the present disclosure connects the wire ends of the windings to the busbar component along the radial direction of the busbar component through a new structure of the windings and the busbar component. In this way, the shape of the wire ends of the windings is simplified, making the wire ends less likely to deform, thereby reducing the manufacturing time and rework rate of the motor.
[0034] Figure 4 A schematic diagram of a winding 400 according to an embodiment of the present disclosure is shown. The winding 400 may include two wire ends, a first wire end 410-1 and a second wire end 410-2. The shapes of the two wire ends 410-1 and 410-2 are simplified relative to the wire ends of the conventional winding 100. As an example, each of the two wire ends 410-1 and 410-2 may include only one section without a bend.
[0035] The two wire ends of the winding may be connected (eg welded or by any other suitable connection means) to the busbar component in a radial direction of the busbar component. Figure 5 5 is a schematic diagram of a connection method 500 of a winding and a busbar component 510 according to an embodiment of the present disclosure. Figure 5 The first winding is described as being connected to the busbar component 510 via its first and second wire ends 520-1 and 520-2, however Figure 5 The connection method 500 shown is also applicable to other windings connected to the busbar component 510. In addition, the busbar component 510 according to the embodiment of the present disclosure will be further combined with Figure 6A-Figure 9 Describe in more detail.
[0036] like Figure 5 As shown, the first wire end 520-1 of the first winding can be connected to the busbar component 510 along the radial direction of the busbar component 510. In addition, the second wire end 520-2 of the first winding can be connected to the busbar component 510 along the radial direction of the busbar component 510. Since the shape of the wire end of the winding according to the embodiment of the present disclosure is simplified relative to the wire end of the traditional winding, it can be directly connected to the busbar component 510 in the radial direction without bending, so the shape of the wire end is not easily deformed during connection, reducing the manufacturing time and rework rate of the motor.
[0037] In some embodiments, the busbar component 510 may include a plurality of busbars. Two wire ends of each winding in the plurality of windings may be connected to corresponding two busbars in the plurality of busbars in a radial direction. For example, a first wire end 520-1 of a first winding may be connected to a busbar associated with zero voltage in the busbar component 510 in a radial direction. A second wire end 520-2 of the first winding may be connected to a busbar associated with one of the UVW three-phase voltages in the busbar component 510 in a radial direction.
[0038] In some embodiments, a portion of the windings (e.g., two adjacent windings) among the plurality of windings may be connected to busbars associated with different phase voltages. Specifically, two wire ends of a first winding among the plurality of windings may be connected to first and second busbars among the plurality of busbars in a radial direction, and two wire ends of a second winding adjacent to the first winding among the plurality of windings may be connected to first and third busbars among the plurality of busbars in a radial direction. The first busbar may be associated with zero voltage, and the second and third busbars may be associated with different voltages among the UVW three-phase voltages, respectively.
[0039] exist Figure 5 In the example of , the first wire end 520-1 of the first winding can be connected to the busbar associated with zero voltage in the busbar component 510 in the radial direction. The second wire end 520-2 of the first winding can be connected to the busbar associated with one of the UVW three-phase voltages (e.g., V-phase voltage) in the busbar component 510 in the radial direction. In addition, the first wire end 530-1 of the second winding adjacent to the first winding can be connected to the busbar associated with zero voltage in the busbar component 510 in the radial direction. The second wire end 530-2 of the second winding can be connected to the busbar associated with another phase voltage (e.g., U-phase voltage) different from the UVW three-phase voltage in the busbar component 510 in the radial direction.
[0040] In some embodiments, each of the plurality of busbars of the busbar component includes a plurality of connection portions protruding in a radial direction. Two wire ends of each winding are connected to corresponding two busbars in a radial direction through corresponding two connection portions respectively located on the corresponding two busbars. Fig. 6A FIG. 6 is a schematic diagram of a busbar 600A in a busbar assembly according to an embodiment of the present disclosure. Fig. 6A Describes a busbar 600A, however Fig. 6A The busbar 600A shown is also applicable to other busbars, such as busbars associated with UVW three-phase voltages or any other suitable busbars. Fig. 6AAs shown, the busbar 600A may include a plurality of connection portions protruding in the radial direction, such as the connection portion 610A. The wire ends of the windings may be connected to the busbar 600A through these connection portions. As an example, the connection portion 610A may be a welding point, and the wire ends of the windings may be welded to the busbar 600A at the welding point.
[0041] Further, Figure 6B Another schematic diagram of a busbar 600B in a busbar assembly according to an embodiment of the present disclosure is shown. Figure 6B A bus 600B is described, however Figure 6B The busbar 600B shown is also applicable to other busbars, such as a busbar associated with zero voltage or any other suitable busbar. Figure 6B As shown, the busbar 600B may include a plurality of connection portions protruding in the radial direction, such as the connection portion 610B. The wire ends of the windings may be connected to the busbar 600B through these connection portions. For example, the connection portion 610B may be a welding point, and the wire ends of the windings may be welded to the busbar 600B at the welding point.
[0042] In some embodiments, the plurality of busbars of the busbar component may be a plurality of stamped busbars. Stamped busbars may reduce the manufacturing difficulty and cost of the busbars and improve the performance of the busbars. In some embodiments, each of the plurality of stamped busbars may include an opening. The opening may facilitate the manufacturing of the stamped busbars. Fig. 6A and Figure 6B As shown, busbar 600A may include opening 620A, and busbar 600B may include opening 620B. Alternatively, the busbars may not have openings.
[0043] In the above, combined with Fig. 6A and Figure 6B The individual busbars in the busbar assembly are described below. Figure 7 Describe how multiple busbars form a busbar component 700. In some embodiments, each of the multiple busbars of the busbar component 700 may have a common center, and the multiple busbars may be nested and arranged on the same horizontal plane relative to the center. In some embodiments, each of the multiple busbars may be nested and arranged on the same horizontal plane relative to the center in a manner with different opening positions, and / or each of the multiple busbars may be nested and arranged on the same horizontal plane relative to the center in a manner with different connection positions.
[0044] Figure 7 FIG. 1 is a schematic diagram showing a nested arrangement of multiple busbars in a busbar component 700 according to an embodiment of the present disclosure. Figure 7In the example of , the busbar component 700 may include 4 busbars. The 4 busbars may be respectively referred to as the first busbar, the second busbar, the third busbar, and the fourth busbar according to their distance from the center of the circle from near to far (i.e., from inside to outside). The 4 busbars have a common center of the circle and are nested and arranged on the same horizontal plane relative to the center of the circle.
[0045] Furthermore, if Figure 7 As shown, the first busbar has an opening 710-1, the second busbar has an opening 710-2, the third busbar has an opening 710-3, and the fourth busbar has an opening 710-4. The positions of the openings 710-1, 710-2, 710-3, and 710-4 are different and not aligned. It can be seen that the four busbars can be nested and arranged on the same horizontal plane with different opening positions relative to the center of the circle.
[0046] In addition, if Figure 7 As shown, the first busbar has a connection portion 720-1, the second busbar has a connection portion 720-2, the third busbar has a connection portion 720-3, and the fourth busbar has a connection portion 720-4. The positions of the connections 720-1, 720-2, 720-3, and 720-4 are different and not aligned. It can be seen that the four busbars can be nested and arranged on the same horizontal plane relative to the center of the circle in a manner where the positions of the connections are different.
[0047] In some embodiments, the busbar component 700 may be formed by overmolding to form an overmolded busbar component. Figure 8 is a schematic diagram of an overmolded busbar component 800 according to an embodiment of the present disclosure. As described above, the conventional busbar component 200 cannot ensure the insulation between the windings and requires an additional potting process, which will significantly increase the complexity, manufacturing cost and time of the motor. The embodiment of the present disclosure can enhance the insulation of the busbar by overmolding the busbar without significantly increasing the complexity, manufacturing cost and time of the motor.
[0048] In some embodiments, the overmolded busbar component 800 may include a plurality of protrusions. The protrusions may be alternatively referred to as tendons or ribs. One of the plurality of protrusions may be located between two wire ends of a winding. Alternatively or additionally, one of the plurality of protrusions may be located between two adjacent wire ends of two adjacent windings.
[0049] Fig. 9 FIG. 8 is a schematic diagram showing a plurality of protrusions of an overmolded busbar component 800 according to an embodiment of the present disclosure. Fig. 9As shown, the first winding includes two wire ends 920-1 and 920-2, and the second winding adjacent to the first winding includes two wire ends 940-1 and 940-2, and the wire ends 920-2 and 940-1 of the two windings are adjacent. The protrusion 910 can be located between the two wire ends 920-1 and 920-2 of the first winding. In addition, the protrusion 930 can be located between the two adjacent wire ends 920-2 and 940-1 of the adjacent first and second windings.
[0050] As described above, the conventional busbar component 200 cannot ensure the creepage distance between the wire ends of the windings, and an additional potting process is required, which significantly increases the complexity of the motor and the manufacturing cost and time. The embodiments of the present disclosure can increase the creepage distance between the wire ends of the windings by reinforcing the busbar after overmolding, that is, adding a plurality of protrusions or ribs, without the need for an additional potting process.
[0051] The embodiments of the present disclosure have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The selection of terms used herein is intended to best explain the principles of the embodiments, practical applications, or technical improvements to the technology in the market, or to enable other persons of ordinary skill in the art to understand the embodiments disclosed herein.
[0052] Reference numerals list
[0053] 100 traditional winding
[0054] 110-1 First section of first line end
[0055] 110-2 First section of the second line end
[0056] 120-1 Second section of the first line end
[0057] 120-2 The second section at the end of the second line
[0058] 200 Traditional busbar components
[0059] 400 winding
[0060] 410-1 First line end
[0061] 410-2 Second line end
[0062] 510 busbar components
[0063] 520-1 First line end of the first winding
[0064] 520-2 The second line end of the first winding
[0065] 530-1 First line end of the second winding
[0066] 530-2 The second line end of the second winding
[0067] 600A busbar
[0068] 610A connection
[0069] 620A opening
[0070] 600B Bus
[0071] 610B connection
[0072] 620B opening
[0073] 700 busbar components
[0074] 710-1 Opening of the first busbar
[0075] 710-2 Opening of the second busbar
[0076] 710-3 Opening of the third busbar
[0077] 710-4 Opening of the fourth busbar
[0078] 720-1 Connection part of the first bus
[0079] 720-2 Connection part of the second bus
[0080] 720-3 Connection of the third bus
[0081] 720-4 Fourth busbar connection
[0082] 800 busbar components
[0083] 910 bulge
[0084] 920-1 Wire end of the first winding
[0085] 920-2 Wire end of the first winding
[0086] 930 bulge
[0087] 940-1 Wire end of the second winding
[0088] 940-2 Wire end of the second winding
Claims
1. A motor for driving a vehicle, comprising: An annular busbar component; and Multiple windings; Each of the plurality of windings includes two wire ends, and the two wire ends of each winding are connected to the busbar component along a radial direction of the busbar component. 2 . The motor according to claim 1 , wherein the busbar member includes a plurality of busbars, and the two wire ends of each winding are connected to corresponding two busbars of the plurality of busbars in a radial direction.
3. The motor according to claim 2, wherein two wire ends of a first winding among the plurality of windings are connected to first and second busbars among the plurality of busbars in a radial direction, and two wire ends of a second winding adjacent to the first winding among the plurality of windings are connected to first and third busbars among the plurality of busbars in a radial direction, the first busbar is associated with zero voltage, and the second and third busbars are associated with different voltages among the UVW three-phase voltages.
4. The motor according to claim 2, wherein each of the plurality of busbars comprises a plurality of connection portions protruding in a radial direction, and the two wire ends of each winding are connected to the corresponding two busbars in a radial direction through corresponding two connection portions respectively located on the corresponding two busbars. The electric machine of claim 2 , wherein the plurality of busbars are a plurality of stamped busbars. 6 . The electric machine of claim 5 , wherein each of the plurality of stamped busbars includes an opening. 7 . The motor according to claim 2 , wherein each of the plurality of busbars has a common center, and the plurality of busbars are nested and arranged on the same horizontal plane relative to the center.
8. The motor according to claim 7, wherein the plurality of busbars are nested and arranged on the same horizontal plane relative to the center of the circle, comprising at least one of the following: Each of the plurality of busbars is nested and arranged on the same horizontal plane with respect to the center of the circle in a manner such that the opening positions of the busbars are different; and Each of the plurality of busbars is nested and arranged on the same horizontal plane with respect to the center of the circle in a manner that the positions of the connection portions are different.
9. The electric machine according to any one of claims 1 to 8, wherein the busbar component is formed by overmolding to form an overmolded busbar component.
10. The electric machine according to any one of claims 1 to 8, wherein the overmolded busbar component comprises a plurality of protrusions, one of the plurality of protrusions being located: between the wire ends of a winding; or Between two adjacent wire ends of two adjacent windings.