Busbar assembly, motor and vehicle

Abstract

The invention provides a busbar assembly, a motor and a vehicle, the busbar assembly comprises a plurality of first busbars, a second busbar, a copper bar connecting piece and an injection molding connecting piece, each first busbar is provided with a first connecting part, and the second busbar is provided with a second connecting part; the multiple first connecting parts are arranged at intervals, the first connecting parts and the second connecting parts are arranged at intervals, the copper bar connecting pieces are fixedly connected with the multiple first connecting parts, the surfaces of the multiple first connecting parts are coated with the injection molding connecting pieces in an injection molding mode, and the surfaces of the second connecting parts and the joints of the copper bar connecting pieces and the first connecting parts are arranged. According to the busbar assembly, the motor and the vehicle, the space utilization rate in the motor can be improved, the process complexity of the busbar assembly is reduced, and the connection stability of the busbar assembly is guaranteed.

Description

Technical Field

[0001] The present application relates to the technical field of vehicles, and in particular to a busbar assembly, a motor and a vehicle. Background Art

[0002] Inside the motor of a vehicle, the motor stator is usually electrically connected to the motor controller through a busbar. The stator coils of the motor stator are connected to the busbar through their connection ends. The busbar is connected to the motor controller through a three-phase copper busbar connector, thereby realizing the connection between the motor stator and the motor controller.

[0003] Currently, the busbar is usually separately arranged from the copper busbar connector. The busbar and the copper busbar connector with a split structure occupy a large space, and the process complexity is high during the assembly process, which easily causes unstable connection between the two. Summary of the Invention

[0004] The busbar assembly, motor and vehicle provided by the present application can improve the space utilization rate inside the motor, reduce the process complexity of the busbar assembly, and ensure the connection stability of the busbar assembly.

[0005] The present application provides a busbar assembly, which includes a plurality of first busbars, a second busbar, a copper busbar connector and an injection molding connector. Each first busbar has a first connection portion, and the second busbar has a second connection portion. The plurality of first connection portions and between the first connection portion and the second connection portion are arranged at intervals. The copper busbar connector is fixedly connected to the plurality of first connection portions, and the injection molding connector is coated on the surfaces of the plurality of first connection portions, the surface of the second connection portion and the connection between the copper busbar connector and the first connection portion by injection molding.

[0006] For the busbar assembly as described above, the copper busbar connector includes three independently arranged outgoing line copper busbars, and each outgoing line copper busbar has a connection hole for electrically connecting to the motor controller; the busbar assembly further includes three insulating sleeves, and the three insulating sleeves are respectively sleeved on the outer surfaces of the three outgoing line copper busbars and are arranged to avoid the corresponding connection holes.

[0007] For the busbar assembly as described above, the busbar assembly further includes a fixing component, one end of the fixing component is connected to the copper busbar connector, and the other end is connected to the housing of the motor.

[0008] For the busbar assembly as described above, the fixing component includes a plurality of fixing parts. The fixing part includes a clamping part and a connecting part connected to each other. The clamping part includes two oppositely arranged buckles, and the copper busbar connector is clamped between the two buckles. The fixing part is detachably connected to the housing through the connecting part.

[0009] The busbar assembly as described above, wherein the busbar assembly includes three first busbars, each first busbar includes a first pin group, the first pin group is connected to the first connection part, and the three first pin groups are respectively electrically connected to the output ends of the three-phase windings of the stator. The second busbar includes three second pin groups arranged at intervals, the three second pin groups are all connected to the second connection part, and the three second pin groups are respectively electrically connected to the neutral point ends of the three-phase windings of the stator.

[0010] The busbar assembly as described above, wherein perpendicular to the extending direction of the injection-molded connector, the three first busbars and one second busbar are arranged in a structure of at least two layers; along the extending direction of the injection-molded connector, the three first pin groups and the three second pin groups are arranged alternately.

[0011] The busbar assembly as described above, wherein the first pin group has at least one first connection pin, the second pin group has at least one second connection pin, and the number of the first connection pins is equal to the number of the second connection pins.

[0012] The busbar assembly as described above, wherein there is a gap D between each of the first busbars and between the first busbar and the second busbar, and the gap D has the following range: D≥1.5mm.

[0013] On the other hand, the present application also provides a motor, including a stator having three-phase windings, wherein the above-mentioned busbar assembly is further included, and the busbar assembly is electrically connected to the windings.

[0014] On yet another aspect, the present application also provides a vehicle, wherein the vehicle includes the above-mentioned motor.

[0015] The busbar assembly of the present application includes a plurality of first busbars, one second busbar, a copper bar connector and an injection-molded connector. The first connection part of the first busbar and the copper bar connector are connected by welding, which ensures the connection stability between the two, enables them to always maintain electrical connection, enables the multi-phase electricity of the plurality of first busbars to be connected to the motor controller through the copper bar connector, and adopts an injection-molded connector. The phase-separated first busbars and second busbars, as well as the connection parts between the first busbars and the copper bar connector, are injection-molded into one body by injection molding, thereby realizing the process steps of welding first and then injection molding. While improving the connection stability of the first busbar, the second busbar and the copper bar connector, it also avoids the contact between the plurality of first busbars and between the first busbar and the second busbar. Moreover, the first busbar, the second busbar and the copper bar connector are integrally arranged by injection molding, which improves the integration degree of the parts and the space utilization rate inside the motor, and reduces the production process complexity of the busbar assembly. Description of the Drawings

[0016] Figure 1Schematic diagram of the overall structure of the busbar assembly provided by the embodiment of the present application;

[0017] Figure 2 Schematic diagram of the structure of the busbar assembly provided by the embodiment of the present application from another angle;

[0018] Figure 3 Schematic diagram of the copper bar connector of the busbar assembly provided by the embodiment of the present application;

[0019] Figure 4 Schematic diagram of the injection-molded connector of the busbar assembly provided by the embodiment of the present application;

[0020] Figure 5 First schematic diagram of the first busbar of the busbar assembly provided by the embodiment of the present application;

[0021] Figure 6 Second schematic diagram of the first busbar of the busbar assembly provided by the embodiment of the present application;

[0022] Figure 7 Third schematic diagram of the first busbar of the busbar assembly provided by the embodiment of the present application;

[0023] Figure 8 Schematic diagram of the second busbar of the busbar assembly provided by the embodiment of the present application.

[0024] Explanation of the reference numerals in the drawings:

[0025] 10. First busbar; 11. First connection part; 12. First pin group; 121. First connection pin; 20. Second busbar; 21. Second connection part; 22. Second pin group; 221. Second connection pin; 30. Copper bar connector; 31. Outlet copper bar; 311. Connection hole; 40. Injection-molded connector; 50. Insulating sleeve; 60. Fixing component; 61. Fixing piece; 611. Clamping part; 612. Connection part; 613. Buckle. Detailed implementation manners

[0026] In order to be able to more clearly understand the above-mentioned objects, features and advantages of the present disclosure, the solutions of the present disclosure will be further described below. It should be noted that, without conflict, the embodiments of the present disclosure and the features in the embodiments may be combined with each other.

[0027] In the following description, many specific details are set forth in order to fully understand the present disclosure, but the present disclosure may also be implemented in other ways different from those described herein; obviously, the embodiments in the specification are only a part of the embodiments of the present disclosure, rather than all the embodiments.

[0028] Such as Figures 1 to 8As shown in the figure, the embodiment of the present application provides a busbar assembly, which includes a plurality of first busbars 10, a second busbar 20, a copper busbar connector 30, and an injection molded connector 40. Each first busbar 10 has a first connection portion 11, and the second busbar 20 has a second connection portion 21. The plurality of first connection portions 11 are spaced apart from each other and from the second connection portion 21. The copper busbar connector 30 is fixedly connected to the plurality of first connection portions 11, and the injection molded connector 40 is coated on the surfaces of the plurality of first connection portions 11, the surface of the second connection portion 21, and the connection between the copper busbar connector 30 and the first connection portion 11 by injection molding.

[0029] Specifically, the copper busbar connector 30 is fixedly connected to the plurality of first connection portions 11 by welding. The welding connection method can not only ensure the connection stability between the copper busbar connector 30 and the plurality of first connection portions 11, but also enable electrical connection between the copper busbar connector 30 and the plurality of first connection portions 11.

[0030] In specific implementation, the busbar assembly of the embodiment of the present application includes a plurality of first busbars 10, a second busbar 20, a copper busbar connector 30, and an injection molded connector 40. The first busbars 10 are used to connect multiple output ends of the motor stator winding, and the second busbar 20 is used to connect multiple neutral point ends of the motor stator winding. The plurality of first busbars 10 are connected to the motor controller through the copper busbar connector 30, enabling the motor controller to control the motor. The second busbar 20 can connect the multiple neutral point ends of the motor stator winding together, so that the neutral point ends of the winding can maintain an equipotential connection.

[0031] The connection between the first connection portion 11 of the first busbar 10 and the copper busbar connector 30 is achieved by welding, ensuring the connection stability between the two, enabling them to always maintain electrical connection, and allowing the polyphase electricity of the plurality of first busbars 10 to be connected to the motor controller through the copper busbar connector 30. By using the injection molded connector 40, the spaced-apart first busbars 10 and the second busbar 20, as well as the connection between the first busbar 10 and the copper busbar connector 30, are injection molded into one body through injection molding, thus realizing the process steps of welding first and then injection molding. While improving the connection stability of the first busbar 10, the second busbar 20, and the copper busbar connector 30, it also avoids contact between the plurality of first busbars 10 and between the first busbar 10 and the second busbar 20, improves the space utilization rate inside the motor, and reduces the process complexity of the busbar assembly.

[0032] Specifically, Figure 4The specific structure of the injection-molded connector 40 in the embodiment of the present application is shown. However, since the injection-molded connector 40 is formed by injection molding, its specific shape depends on the preset positions of the first bus bar 10, the second bus bar 20, and the copper bus bar connector 30, and injection molding is performed according to the preset positions to enclose the first bus bar 10, the second bus bar 20, and the copper bus bar connector 30 therein. Therefore Figure 4 It is only a schematic structure of a specific embodiment.

[0033] As Figures 1 to 3 shown, for the bus bar assembly in the embodiment of the present application, the copper bus bar connector 30 includes three independently arranged outgoing wire copper bars 31, and each outgoing wire copper bar 31 has a connection hole 311 for electrically connecting to the motor controller; the bus bar assembly further includes three insulating sleeves 50, and the three insulating sleeves 50 are respectively sleeved on the outer surfaces of the three outgoing wire copper bars 31 and are arranged to avoid the corresponding connection holes 311.

[0034] During specific implementation, the control wires of the motor controller are connected to the three outgoing wire copper bars 31 through the cooperation between the connection bolts and the connection holes 311. The three insulating sleeves 50 are sleeved on the outer surfaces of the three outgoing wire copper bars 31, which can prevent the outgoing wire copper bars 31 from interfering with other parts inside the motor housing or interfering with each other among the three outgoing wire copper bars 31, thereby causing the situation of electric leakage of the outgoing wire copper bars 31, making the motor controller unable to accurately control the motor. Moreover, the insulating sleeves 50 are arranged to avoid the corresponding connection holes 311, which will not affect the wiring between the motor controller and the motor and reduces the assembly difficulty.

[0035] As Figure 1 and Figure 2 shown, for the bus bar assembly in the embodiment of the present application, the bus bar assembly further includes a fixing assembly 60. One end of the fixing assembly 60 is connected to the copper bus bar connector 30, and the other end is connected to the motor housing. The fixing assembly 60 can fix the copper bus bar connector 30 to the motor housing to avoid the situation that the copper bus bar connector 30 shakes during the conduction process and collides with other parts inside the housing.

[0036] Specifically, the fixing assembly 60 is connected to the outer surface of the insulating sleeve 50 and does not directly contact the copper bus bar connector 30, thereby avoiding affecting the conduction of the copper bus bar connector 30.

[0037] As Figure 1 and Figure 2As shown in the figure, the busbar assembly of the embodiment of the present application, wherein the fixing component 60 includes a plurality of fixing members 61. The fixing member 61 includes a clamping portion 611 and a connecting portion 612 connected to each other. The clamping portion 611 includes two oppositely arranged buckles 613. The copper busbar connecting member 30 is clamped between the two buckles 613. The outer surface of the connecting portion 612 has a connecting thread, and the fixing member 61 is detachably connected to the housing through the connecting portion 612.

[0038] During specific implementation, the copper busbar connecting member 30 is clamped between the two buckles 613 of the clamping portion 611. The arrangement of the two buckles 613 of the clamping portion 611 facilitates the clamping and disassembly of the copper busbar connecting member 30. Moreover, the fixing member 61 is detachably connected to the housing through the connecting portion 612 with a thread on its outer surface, enabling the housing and the fixing member 61 to be freely connected and separated. When the copper busbar connecting member 30 or the housing is damaged, it can be disassembled from the fixing member 61 for easy replacement or repair.

[0039] As Figures 5 to 8 shown in the figure, the busbar assembly of the embodiment of the present application, wherein the busbar assembly includes three first busbars 10. Each first busbar 10 includes a first pin group 12, and the first pin group 12 is connected to the first connecting portion 11. The three first pin groups 12 are respectively electrically connected to the output ends of the three-phase windings of the stator. The second busbar 20 includes three second pin groups 22 arranged at intervals. The three second pin groups 22 are all connected to the second connecting portion 21, and the three second pin groups 22 are respectively electrically connected to the neutral point ends of the three-phase windings of the stator.

[0040] It should be noted that Figures 5 to 7 is a schematic structural diagram of the three first busbars 10. Since the intervals between the output ends of the three-phase windings of the motor stator are different from the intervals between the three outgoing copper busbars 31, the first connecting portions 11 of the three first busbars 10 are set to different shapes, so as to realize that one end of the first connecting portion 11 is connected to the outgoing copper busbar 31 and the other end is connected to the first pin group 12, and the first pin group 12 can be connected to the output end of the winding. The shape of the first connecting portion 11 includes but is not limited to Figures 5 to 7 the shapes shown in the figure, as long as it can play the role of connecting the outgoing copper busbar 31 and the output end of the winding.

[0041] During specific implementation, the setting of the first pin group 12 facilitates the connection between the first busbar 10 and the output end of the winding, and the setting of the second pin group 22 facilitates the connection between the second busbar 20 and the neutral point end of the winding, enabling the windings of the stator to form a complete circuit with the first busbar 10, the second busbar 20, and the outgoing copper busbar 31.

[0042] As Figure 1As shown, in the busbar assembly of the embodiment of the present application, along the direction perpendicular to the extension direction of the injection-molded connector 40, three first busbars 10 and one second busbar 20 are arranged in a structure of at least two layers, that is, the busbars in different layers are at different heights; along the extension direction of the injection-molded connector 40, three first pin groups 12 and three second pin groups 22 are arranged alternately with each other.

[0043] It should be noted that after the busbar assembly is installed on the motor, the direction perpendicular to the extension direction of the injection-molded connector 40 is the axial direction of the stator, and the extension direction of the injection-molded connector 40 is the circumferential direction of the stator.

[0044] In specific implementation, three first busbars 10 and one second busbar 20 are arranged in a structure of at least two layers, avoiding direct contact between the first busbar 10 and the second busbar 20 to form a current path; three first pin groups 12 and three second pin groups 22 are arranged alternately with each other, and are arranged to match the winding arrangement order of the stator, so that the three first pin groups 12 are respectively connected to the output ends of the three-phase windings, and the three second pin groups 22 are respectively connected to the neutral point ends of the three-phase windings.

[0045] Specifically, along the axial direction of the stator, three first busbars 10 and one second busbar 20 are arranged in a two-layer structure. The three first busbars 10 are in the same layer and are spaced from each other. The second busbar 20 is an independent layer. The two-layer structure makes the overall space occupied by the busbar assembly smaller.

[0046] As Figures 5 to 8 shown, in the busbar assembly of the embodiment of the present application, among them, the first pin group 12 has at least one first connection pin 121, the second pin group 22 has at least one second connection pin 221, and the number of the first connection pins 121 is equal to the number of the second connection pins 221.

[0047] In specific implementation, the number of the first connection pins 121 in the first pin group 12 and the number of the second connection pins 221 in the second pin group 22 are both equal to the number of coils in the winding, that is, equal to the number of coils corresponding to each pole and each phase of the motor stator. In this way, it can be ensured that the output ends and neutral point ends of multiple coils in one pole and one phase can be respectively connected to the first connection pins 121 and the second connection pins 221, so as to ensure the control of the motor by the motor controller.

[0048] Specifically, the first connection pin 121 is vertically connected to the first connection part 11 and is welded to the output end of the winding, and the second connection pin 221 is vertically connected to the second connection part 21 and is welded to the neutral point end of the winding.

[0049] The busbar assembly of the embodiment of the present application, wherein there is a gap D between each of the first busbars 10 and between the first busbar 10 and the second busbar 20, and the gap D has the following range: D≥1.5mm.

[0050] During specific implementation, the gap D between each of the first busbars 10 and between the first busbar 10 and the second busbar 20 is maintained at 1.5mm or more, which can ensure that there is no mutual influence, avoid the situation of mutual discharge caused by too close distance, and thus avoid the situation of electrical connection between each other.

[0051] The embodiment of the present application also provides a motor, including a stator having a three-phase winding. Among them, the above-mentioned busbar assembly is further included, and the busbar assembly is electrically connected to the winding.

[0052] The embodiment of the present application also provides a vehicle, wherein the vehicle includes the above-mentioned motor.

[0053] During specific implementation, the vehicle includes a motor, the motor includes a busbar assembly, the busbar assembly includes a plurality of first busbars 10, a second busbar 20, a copper busbar connector 30 and an injection molding connector 40. The first connection part 11 of the first busbar 10 and the copper busbar connector 30 are connected by welding, which ensures the connection stability between the two, enables the two to always maintain electrical connection, enables the multi-phase electricity of the plurality of first busbars 10 to be connected to the motor controller through the copper busbar connector 30, and adopts the injection molding connector 40. The spaced-apart first busbar 10 and the second busbar 20, and the connection part between the first busbar 10 and the copper busbar connector 30 are injection molded into one body by injection molding, thereby realizing the process steps of welding first and then injection molding. While improving the connection stability of the first busbar 10, the second busbar 20 and the copper busbar connector 30, it also avoids the contact between the plurality of first busbars 10 and between the first busbar 10 and the second busbar 20, improves the space utilization rate inside the motor, and reduces the process complexity of the busbar assembly.

[0054] It should be noted that in this article, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article, or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article, or device. Without further limitation, an element defined by the statement "comprising an..." does not exclude the existence of additional identical elements in the process, method, article, or device comprising the said element.

Claims

1. A busbar assembly, characterized in that, It includes a plurality of first busbars (10), a second busbar (20), a copper busbar connector (30) and an injection-molded connector (40). Each of the first busbars (10) has a first connection portion (11), and the second busbar (20) has a second connection portion (21). The plurality of first connection portions (11) and between the first connection portion (11) and the second connection portion (21) are all arranged at intervals. The copper busbar connector (30) is fixedly connected to the plurality of first connection portions (11), and the injection-molded connector (40) is coated on the surfaces of the plurality of first connection portions (11), the surface of the second connection portion (21) and the connection part between the copper busbar connector (30) and the first connection portion (11) by injection molding.

2. The busbar assembly according to claim 1, wherein The copper busbar connector (30) includes three independently arranged outgoing line copper busbars (31), and each of the outgoing line copper busbars (31) has a connection hole (311) for electrically connecting to a motor controller; the busbar assembly further includes three insulating sleeves (50), and the three insulating sleeves (50) are respectively sleeved on the outer surfaces of the three outgoing line copper busbars (31) and are arranged to avoid the corresponding connection holes (311).

3. The bus bar assembly according to claim 1, wherein, The busbar assembly further includes a fixing assembly (60), one end of the fixing assembly (60) is connected to the copper busbar connector (30), and the other end is connected to the housing of the motor.

4. The bus bar assembly according to claim 3, wherein, The fixing assembly (60) includes a plurality of fixing members (61), and the fixing member (61) includes a connected clamping portion (611) and a connecting portion (612). The clamping portion (611) includes two oppositely arranged clamping buckles (613), and the copper busbar connector (30) is clamped between the two clamping buckles (613), and the fixing member (61) is detachably connected to the housing through the connecting portion (612).

5. The bus bar assembly according to claim 1, wherein, The busbar assembly includes three of the first busbars (10), and each of the first busbars (10) includes a first pin group (12). The first pin group (12) is connected to the first connection portion (11), and the three first pin groups (12) are respectively used for electrically connecting to the output ends of the three-phase windings of the stator. The second busbar (20) includes three spaced second pin groups (22), and the three second pin groups (22) are all connected to the second connection portion (21), and the three second pin groups (22) are respectively used for electrically connecting to the neutral point ends of the three-phase windings of the stator.

6. The busbar assembly according to claim 5, characterized in that, Perpendicular to the extending direction of the injection-molded connector (40), the three first busbars (10) and one second busbar (20) are arranged in a structure of at least two layers; along the extending direction of the injection-molded connector (40), the three first pin groups (12) and the three second pin groups (22) are alternately arranged.

7. The bus bar assembly according to claim 5, wherein, The first pin group (12) has at least one first connection pin (121), and the second pin group (22) has at least one second connection pin (221), and the number of the first connection pins (121) is set to be equal to the number of the second connection pins (221).

8. The bus bar assembly according to claim 1, wherein, There is a gap D between each of the first busbars (10) and between the first busbar (10) and the second busbar (20), and the gap D has the following range: D ≥ 1.5 mm.

9. A motor, comprising a stator, the stator having a three-phase winding, characterized in that, It further includes a busbar assembly as described in any one of claims 1 to 8, and the busbar assembly is arranged to be electrically connected to the winding.

10. A vehicle, characterized in that, The vehicle includes a motor as described in claim 9.

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