Motor and motor system for vehicle

Abstract

The invention relates to an electric machine and an electric machine system for a vehicle. The motor comprises a busbar assembly and a stator support (20) which are used for a stator in the motor, the busbar assembly is provided with a busbar holder (10) which is made of insulating materials and used for fixedly arranging busbar conductors, the busbar holder (10) comprises a main body part (11) and a flange part (13), the main body part (11) is integrally in an annular disc shape, and the flange part (13) is formed on the radial outer side of the main body part (11). The flange part (13) continuously extends in the circumferential direction and is provided with a first pairing structure (14) at the radial outer end, the stator support (20) is cylindrical as a whole and is provided with a second pairing structure (23) continuously extending in the circumferential direction on the radial inner side surface, and the first pairing structure (14) and the second pairing structure are complementary in shape. Therefore, the busbar holder (10) is fixedly connected with the stator support (20). The motor system comprises the motor and a speed change device connected with the motor.

Description

Technical Field

[0001] The present invention relates to the technical field of electric motors, and in particular to an electric motor and an electric motor system for a vehicle. Background Art

[0002] Some current motors are equipped with a busbar assembly. This assembly includes multiple busbars, or busbar conductors, that electrically connect multiple coils arranged circumferentially and provide a current path to an external power supply or other power electronic device. For example, Chinese patent document CN 108039787 B discloses a busbar assembly comprising an annular busbar holder and multiple busbars held by the holder.

[0003] The busbar assembly is usually arranged at one axial end of a stator core wound with a plurality of coils. The busbar holder is provided with a plurality of lugs distributed in a circumferential direction, and the lugs form snap-fit ​​connection parts for fixed connection with the stator bracket.

[0004] However, the snap-fit ​​connection between the busbar holder and the stator bracket only restricts the busbar assembly's relative movement under normal circumstances. In a vibrating environment, the busbar holder cannot be stably and continuously secured, causing the busbar assembly to wobble, potentially breaking wiring in the motor. This can be particularly serious in vehicles, where the motor is in motion.

[0005] Furthermore, especially when the motor is used in a vehicle, the shaking of the busbar assembly may also affect the positional accuracy of the three-phase terminals on the busbar assembly, thereby introducing stress between the terminals and the connecting counterparts on the transmission housing and possibly causing failure of the terminals. Summary of the Invention

[0006] Therefore, an object of the present invention is to provide a motor in which a busbar assembly can be stably held, thereby improving operational reliability, particularly in a vibrating environment. Furthermore, it is preferable to provide a motor system for a vehicle in which the busbar assembly of the motor can be stably held, thereby improving operational reliability, particularly in a vibrating environment.

[0007] According to one aspect of the present invention, the above-mentioned object is achieved by an electric motor. The electric motor includes a busbar assembly and a stator support for use in a stator of the motor, wherein the busbar assembly has a busbar holder made of an insulating material for fixing and disposing the busbar conductors, the busbar holder including a main body portion having an overall annular disc shape and a flange portion formed radially outwardly of the main body portion, wherein the flange portion extends continuously in the circumferential direction and is configured with a first mating structure at a radially outer end, and the stator support is generally cylindrical in shape and is configured with a second mating structure extending continuously in the circumferential direction on its radially inner surface, wherein the first mating structure and the second mating structure are configured in complementary shapes to securely connect the busbar holder and the stator support to each other.

[0008] In a preferred embodiment, the first matching structure is configured as a convex arc surface, and the second matching structure is configured as a concave arc surface.

[0009] In a preferred embodiment, the busbar holder is provided with axial through holes distributed along the circumferential direction.

[0010] Here, preferably, a step portion is provided between the main body portion and the flange portion in a radial direction of the busbar holder, wherein the step portion protrudes beyond the flange portion axially outside the motor, and wherein the axial through hole is completely provided at the step portion.

[0011] Here, preferably, the radial outer side surface of the step portion, the axial outer side surface of the flange portion and the radial inner side surface of the stator bracket jointly form an annular groove, and the annular groove is filled with a potting material.

[0012] Here, preferably, the motor further includes a sealing ring, an inner boss portion is configured on a radial inner side surface of the stator bracket, and the sealing ring is axially arranged between the flange portion and the inner boss portion.

[0013] Here, preferably, a positioning groove for the sealing ring is formed at the radial outer side of the axial outer end surface of the inner boss portion.

[0014] Advantageously, the main body portion protrudes beyond the step portion on the axial outer side of the motor, and the cavity region is formed on the axial inner side of the main body portion.

[0015] In an advantageous embodiment, the busbar holder is formed in one piece from a plastic material.

[0016] According to another aspect of the present invention, the above object is achieved by a motor system for a vehicle, wherein the motor system includes a motor constructed according to the above embodiment and a speed change device connected to the motor.

[0017] By means of embodiments according to the present invention, particularly by means of first and second matching structures extending continuously in the circumferential direction, a stable connection is achieved between the busbar assembly, particularly the busbar holder, and the stator bracket, thereby reducing the degree of shaking of the busbar assembly in a vibrating environment. Furthermore, by filling the annular groove formed by the step portion, flange portion, and stator bracket of the busbar holder with potting material, the stable connection between the busbar holder and the stator bracket can be strengthened. In particular, the potting material can be filled into any gaps that may exist between the first and second matching structures, thereby reducing or even preventing the possibility of instability of the busbar assembly caused by such gaps, and consequently, the possibility of breakage of the connected cables. At the same time, the potting material is filled in the annular groove, preventing it from entering the coil area via the axial through-hole, thereby not affecting the cooling effect of the coil area. As a result, the motor and the motor system including the motor can have improved operational reliability, particularly in a vibrating environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Features, advantages, and technical effects of exemplary embodiments of the present invention will be described below with reference to the accompanying drawings.

[0019] Figure 1 shows an axial cross-sectional view of a motor according to one embodiment;

[0020] Figure 2 Shown Figure 1 An axial cross-sectional view of a busbar holder of a busbar assembly of a motor;

[0021] Figure 3 Shown according to Figure 2 a top view of the busbar retainer; and

[0022] Figure 4 Shown according to Figure 1 A partial axial half-section view of the stator bracket of the motor. DETAILED DESCRIPTION

[0023] One embodiment of the present invention provides an electric machine, in particular a radial electric machine. The electric machine can be a component of an electric machine system for a vehicle.

[0024] The motor system includes a motor according to an embodiment of the present invention and a speed change device connected to the motor, particularly the rotor shaft. The motor system can be used in hybrid vehicles or pure electric vehicles. In this embodiment, the motor system can be used in a P1 hybrid module of a hybrid vehicle. The motor is advantageously based on the P1 architecture and is arranged at the rear end of the crankshaft of the vehicle engine.

[0025] Figure 1 FIG. 1 shows an axial cross-sectional view of a motor according to an embodiment. Figure 1As shown, the motor includes a stator 40 and a rotor 50 that are arranged concentrically as a whole. In this embodiment, the motor is constructed as an inner rotor type motor. Here, the stator 40 is generally sleeve-shaped and surrounds the rotor 50. It should be noted that within the scope of this document, unless otherwise specified, the terms "axial", "radial" and "circumferential direction" all refer to the motor rotation axis, that is, the central axis of the stator 40 (see FIG. Figure 1 ( hereinafter referred to as "the dot-dash line"). Specifically, "axial direction" refers to the direction of the stator central axis or a direction parallel to the stator central axis. "Radial direction" refers to a direction perpendicular to and intersecting the stator central axis. "Circumferential direction" refers to a direction around the stator central axis.

[0026] In this embodiment, the motor includes a busbar assembly for a stator 40 and a stator support 20 .

[0027] The busbar assembly includes a busbar holder 10 made of an insulating material, such as plastic, and a busbar conductor (not shown) fixed to the busbar holder 10 .

[0028] Figure 2 and Figure 3 Shown respectively Figure 1 Axial cross-sectional view and top view of the busbar holder 10 in the busbar assembly of the motor.

[0029] According to this embodiment, see Figure 1 、 Figure 2 and Figure 3 The busbar holder 10 is provided with a main body 11, a step portion 12 and a flange portion 13 in order from the inside to the outside in the radial direction. In some other embodiments, the busbar holder can only include the main body and the flange portion. The busbar holder 10 is preferably an integrated structure.

[0030] Back to Figure 1 、 Figure 2 and Figure 3 In the illustrated embodiment, the main body 11 is generally annular and disc-shaped, with a central through-hole capable of passing the rotor shaft of the motor's rotor 50. The stepped portion 12 is generally annular and surrounds the main body 11. A flange 13 is formed radially outward of the main body 11 and the stepped portion 12, and extends continuously in the circumferential direction.

[0031] See especially Figure 1 and Figure 2On the axially outer side of the motor, that is, the side of the busbar holder 10 facing away from the stator 40, in particular the stator core, the main body 11 protrudes from the step 12, and the step 12 protrudes from the flange 13. Here, on the axially inner side of the motor, that is, the side of the busbar holder 10 facing the stator 40, in particular the stator core, the main body 11, the step 12, and the flange 13 can be configured to be substantially flush. Furthermore, a cavity region is configured on the axially inner side of the main body 11 to accommodate components within the motor.

[0032] Figure 4 Shown according to Figure 1 A partial axial half-section view of the stator support 20 of the motor. Figure 1 and Figure 4 As shown, the stator support 20 is cylindrical in shape and is provided with a sleeve portion 21 and an inner boss portion 22 in sequence from the outside to the inside in the radial direction. Figure 1 and Figure 4 On the axially outer side of the motor, the sleeve portion 21 protrudes axially from the inner boss portion 22 .

[0033] According to this embodiment, see Figures 1 to 4 The flange portion 13 of the busbar holder 10 extends continuously in the circumferential direction and is configured with a first matching structure 14 at the radially outer end, thereby forming a surrounding portion that extends continuously in the circumferential direction. The radially inner surface of the sleeve portion 21 of the stator support 20 is configured with a second matching structure 23, thereby forming a corresponding surrounding portion that extends continuously in the circumferential direction. The first matching structure 14 and the second matching structure 23 are configured in a complementary manner so that the busbar holder 10 and the stator support 20 are fixedly connected to each other through complete complementary shapes in the circumferential direction. In this embodiment, see in particular Figure 1 、 Figure 2 and Figure 4 The first matching structure 14 is configured as a convex arc surface, and the second matching structure 23 is configured as a concave arc surface of an annular groove extending continuously in the circumferential direction. This matching arc surface structure is easy to manufacture and facilitates the assembly of the busbar holder 10 on the stator support 20. As a result, a stable connection is achieved between the busbar assembly, especially the busbar holder 10, and the stator support 20, reducing the degree of shaking of the busbar assembly in a vibrating environment.

[0034] The radially outer side of the step portion 12, the axially outer side of the flange portion 13, and the radially inner side of the stator support 20 together form an annular groove, which is filled with potting material. This strengthens the connection between the busbar holder 10 and the stator support 20. In particular, the potting material can fill any gaps between the first matching structure 14 and the second matching structure 23, reducing or even eliminating instability of the busbar assembly caused by such gaps, thereby reducing the probability of breakage between the busbar conductors and the connected coil cables.

[0035] The motor also includes a sealing ring 30. In this embodiment, the sealing ring 30 is an O-ring. In this embodiment, the outer diameter of the sealing ring 30 matches the inner diameter of the sleeve portion 21 of the stator support 20. The sealing ring 30 is axially arranged between the flange portion 13 and the inner boss portion 22. A positioning groove 24 for the sealing ring 30 is configured radially outward of the axially outer end surface of the inner boss portion 22. This positions the sealing ring 30 radially adjacent to the contact point between the first and second mating structures 14, preventing potting material that has flowed through the gap between the first and second mating structures from continuing to flow into the motor's interior.

[0036] Also, see Figure 1 、 Figure 2 and Figure 3 The busbar holder 10 is provided with axial through-holes 15 distributed along the circumference. These through-holes allow the stator coil end cables to pass from the axial interior to the axial exterior of the motor, thereby electrically connecting the stator coil end cables to the busbar conductors axially outside the busbar holder 10. The number of axial through-holes 15 is determined based on the number of stator coil ends.

[0037] See especially Figure 1 、 Figure 2 and Figure 3 The axial through holes 15 are completely located at the stepped portion 12 of the busbar holder 10. In other words, the inner wall of each axial through hole 15 is formed from the material at the stepped portion 12. With the aid of the stepped portion 12, especially during the manufacturing process, the ends of the axial through holes 15 on the axially outer side of the motor are higher than the height of the potting material in the annular groove formed by the stepped portion 12 and flange portion 13 of the busbar holder 10, and the sleeve portion 21 of the stator support 20. This prevents the potting material from entering the coil area through the axial through holes 15, thereby preventing the cooling effect of the coil area from being affected.

[0038] Therefore, the motor according to the present embodiment and the motor system including the motor can have improved operational reliability, especially in a vibration environment.

[0039] Obviously, the above embodiments of the present invention are merely examples for the purpose of clearly illustrating the present invention, and are not intended to limit the implementation methods of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the implementation methods here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the claims of the present invention. In the description of the present invention, it should also be noted that the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0040] Reference Signs List

[0041] 10 Busbar retainer

[0042] 11 Main body

[0043] 12 Steps

[0044] 13 Flange

[0045] 14 First pairing structure

[0046] 15 Axial through hole

[0047] 20 stator bracket

[0048] 21 Sleeve

[0049] 22 inner boss

[0050] 23 Second pairing structure

[0051] 24 positioning slots

[0052] 30 sealing ring

[0053] 40 stator

[0054] 50 rotors

Claims

1. A motor comprising a busbar assembly and a stator support (20) for a stator (40) in the motor, wherein: The busbar assembly comprises a busbar holder (10) made of insulating material and used for fixing and arranging a busbar conductor. The busbar holder (10) comprises a main body (11) in the shape of an annular disk as a whole and a flange (13) formed on the radially outer side of the main body (11). The flange (13) extends continuously in the circumferential direction and is provided with a first matching structure (14) at the radially outer end. The stator support (20) is cylindrical in shape as a whole and has a second matching structure (23) extending continuously in the circumferential direction on its radial inner surface. The first matching structure (14) and the second matching structure are constructed in a complementary manner so that the busbar holder (10) and the stator support (20) are fixedly connected to each other.

2. The motor according to claim 1, wherein The first pairing structure (14) is configured as a convex arc surface, and the second pairing structure is configured as a concave arc surface.

3. The motor according to claim 1, wherein The busbar retainer (10) is provided with axial through holes (15) distributed along the circumferential direction.

4. The motor according to claim 3, wherein In the radial direction of the busbar holder (10), a step portion (12) is provided between the main body portion (11) and the flange portion (13), wherein the step portion (12) protrudes from the flange portion (13) on the axial outside of the motor, and the axial through hole (15) is completely provided at the step portion (12).

5. The motor according to claim 4, wherein The radial outer side surface of the step portion (12), the axial outer side surface of the flange portion (13), and the radial inner side surface of the stator bracket (20) together form an annular groove, and the annular groove is filled with a potting material.

6. The motor according to claim 5, wherein The motor further comprises a sealing ring (30). An inner boss portion (22) is configured on the radial inner side surface of the stator bracket (20). The sealing ring (30) is axially arranged between the flange portion (13) and the inner boss portion (22).

7. The motor according to claim 6, wherein A positioning groove (24) for the sealing ring (30) is configured at the axially outer end surface of the inner boss portion (22).

8. The motor according to claim 4, wherein The main body (11) protrudes from the step portion (12) on the axial outer side of the motor, and a cavity area is configured on the axial inner side of the main body (11).

9. The motor according to claim 1, wherein The busbar holder (10) is constructed in one piece from plastic material. 10 . A motor system for a vehicle, comprising the motor according to claim 1 and a speed change device connected to the motor.

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