Motor for electronic hydraulic brake system

Abstract

The invention discloses a motor for an electronic hydraulic brake system. The motor comprises a stator assembly and a rotor assembly, the stator assembly comprises a motor shell, a stator core, a stator framework, a magnet exciting coil, a Busbar assembly, a power supply connector, a bearing and a bearing ring; the stator core is fixedly arranged on the inner circumference of the motor shell; the stator framework is mounted at the axial end part of the stator iron core; the magnet exciting coil is wound on the stator framework; the Busbar assembly is electrically connected with the magnet exciting coil and is fixed on the stator framework; the power supply connector is arranged in the motor shell and is electrically connected with the Busbar assembly; the bearing ring is fixed at the axial end part in the motor shell, and the bearing is arranged in the bearing ring; the rotor assembly comprises a hollow shaft, a magnetic shoe, a magnetic shoe support, a rotor steel sleeve and a Yoke. The periphery of the hollow shaft is fixedly sleeved with the magnetic shoe support, the Yoke is fixedly installed on the outer side of the magnetic shoe support, the magnetic shoe is fixedly attached to the outer surface of the Yoke, and the periphery of the magnetic shoe is fixedly sleeved with the rotor steel sleeve.

Description

Technical Field

[0001] This application relates to the field of automotive braking system technology, and more specifically, to a motor for an electro-hydraulic braking system. Background Technology

[0002] Electro-hydraulic Braking System (EHB) is a key component of automotive braking systems, and its performance directly affects the braking effect and safety of the entire vehicle. Existing EHB motors typically consist of a stator assembly and a rotor assembly. Furthermore, current technologies often employ integral injection molding or split composite mold structures for the busbar assembly and power connectors, resulting in complex molds, high costs, and low production efficiency. The coil connection method is complex, with numerous wire ends, occupying a large space and affecting insulation and pressure resistance. The seal between the housing and the valve block often uses radial O-ring seals, leading to a complex valve block structure and high material consumption. The hollow rotor shaft requires machining multiple planes to accommodate bread-shaped magnets, resulting in high machining difficulty and cost, and a low rotor dynamic balance level, impacting NVH (noise, vibration, and harshness) performance.

[0003] Therefore, there is an urgent need for an EHB motor that is more compact, lower in cost, and has better performance. Summary of the Invention

[0004] The purpose of this application is to provide a motor for an electro-hydraulic braking system, which achieves compactness, lightweight, low cost and high performance by optimizing the busbar assembly, power connector, coil connection method, sealing structure and rotor structure.

[0005] The specific technical solution is as follows: This application provides a motor for an electro-hydraulic braking system, comprising: A stator assembly includes a motor housing, a stator core, a stator frame, an excitation coil, a busbar assembly, a power connector, a bearing, and a bearing race. The stator core is fixedly disposed on the inner circumference of the motor housing. The stator frame is mounted on the axial end of the stator core. The excitation coil is wound on the stator frame. The busbar assembly is electrically connected to the excitation coil and fixed on the stator frame. The power connector is disposed inside the motor housing and electrically connected to the busbar assembly. The bearing race is fixed to the axial end inside the motor housing, and the bearing is mounted inside the bearing race. The busbar assembly includes stacked U-phase, V-phase, and W-phase conductive busbars, each of which is a one-sixth annular copper plate and is fixed and insulated by a separate plastic component. The power connector includes three power terminals, which are fixed and insulated by insert injection molding components and connected to the U-phase, V-phase, and W-phase conductive busbars. The rotor assembly includes a hollow shaft, a magnetic tile, a magnetic tile support, a rotor steel sleeve, and a yoke. The magnetic tile support is fixedly sleeved on the outer periphery of the hollow shaft, the yoke is fixedly installed on the outside of the magnetic tile support, the magnetic tile is fixedly attached to the outer surface of the yoke, and the rotor steel sleeve is fixedly sleeved on the outer periphery of the magnetic tile for fixing and protecting the magnetic tile.

[0006] In some embodiments of this application, the stator assembly further includes three wire-to-plate connection terminals. The first ends of the three wire-to-plate connection terminals are respectively fixed to the U-phase busbar, the V-phase busbar, and the W-phase busbar by resistance welding, and the second ends are respectively connected to the three power terminals to form a plug-in engagement. The wire-to-plate connection terminals are standard 250 series female terminals.

[0007] In some embodiments of this application, the Busbar assembly is interference-fitted with the motor stator frame, and the U-phase busbar, the V-phase busbar and the W-phase busbar are all provided with slots, and the motor stator frame is provided with a barb structure that engages with the three slots.

[0008] In some embodiments of this application, an O-ring is provided at the interface between the power connector and the valve block, and an annular groove is provided on the outer wall of the insert injection molded part, and the O-ring is embedded in the annular groove.

[0009] In some embodiments of this application, the connection between the U-phase busbar, the V-phase busbar, the W-phase busbar and the motor stator coil is a delta connection. Each phase winding of the motor stator coil consists of four coils connected in series, and each phase winding has two wire ends, which are connected to the corresponding U-phase busbar, V-phase busbar or W-phase busbar.

[0010] In some embodiments of this application, the two wire ends connected to the V-phase busbar are located in the first stator slot, and the distance between the stator slot where the two wire ends connected to the other two phase busbars are located and the first stator slot does not exceed 3 slot pitches.

[0011] In some embodiments of this application, the split plastic component includes an upper support frame, a lower support frame, and an insulating plate. The Busbar assembly is fixed to the lower support frame, and the insulating plate is used to insulate each phase conductor from each other. The upper support frame is installed on the lower support frame, together forming three fixing grooves. The power terminal, which is encapsulated in the insert injection molded part, is fixed in the fixing groove.

[0012] In some embodiments of this application, the lower support frame includes a first horizontal portion and a first vertical portion connected to each other. The first horizontal portion is provided with a first mounting groove for fixing the U-phase conductive busbar, the V-phase conductive busbar, the W-phase conductive busbar, and the insulating plate. The first vertical portion is provided with three open slots. The first horizontal portion is provided with a second mounting groove connecting the open slots and the first mounting groove. The wire-to-plate connection terminal is disposed in the second mounting groove. A locking groove is provided at each end of the first horizontal portion. The upper support frame includes a second horizontal portion and a second vertical portion connected to each other. The second vertical portion includes three locking plates. A hook is provided at each end of the second horizontal portion. The two hooks are respectively locked into the corresponding locking grooves. The upper support frame is installed on the lower support frame, and the three locking plates abut against the corresponding open slots to form three fixing grooves.

[0013] In some embodiments of this application, a radial O-ring seal is used between the motor housing and the valve block, a radial O-ring seal is used at the bottom of the motor housing, and the stator assembly and the rotor assembly are filled in the inner cavity of the motor housing in a gapless manner; the outer contour of the stator assembly is adapted to the shape of the inner wall of the motor housing, and the gap between the two is less than a preset threshold.

[0014] In some embodiments of this application, the stator core is T-shaped and there are 12 of them; the number of magnetic tiles is 10.

[0015] The beneficial effects of the embodiments of this application are as follows: The busbar assembly and power connector in this application adopt a split structure and standard terminal connection, which simplifies the mold, reduces cost, and ensures reliable connection. Furthermore, all coils are connected in series, resulting in fewer wire ends and simpler wiring, thus improving insulation and withstand voltage performance. This application optimizes the housing structure, reduces material usage, and simplifies the sealing structure, further reducing costs. Simultaneously, the simplified rotor structure increases processing efficiency, improves dynamic balance, and significantly enhances NVH performance. The overall motor structure is compact and lightweight, making it suitable for compact braking systems such as one-box systems. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 A schematic diagram of the stator assembly in an electric motor for an electro-hydraulic braking system is provided as an embodiment of this application. Figure 2 An exploded view of a motor connector assembly in an electric motor for an electro-hydraulic braking system, provided as an embodiment of this application; Figure 3 This application provides a schematic diagram of the structure of a motor connector assembly in an electric motor for an electro-hydraulic braking system. Figure 4 Stator coil winding and wiring diagrams provided for embodiments of this application; Figure 5 A schematic diagram of the overall structure of the motor housing in an electric motor used in an electro-hydraulic braking system, provided in an embodiment of this application; Figure 6 A schematic diagram of the bottom structure of a motor housing for an electro-hydraulic braking system provided in this application embodiment; Figure 7 An exploded view of a stator assembly in an electric motor for an electro-hydraulic braking system, provided as an embodiment of this application; Figure 8 A schematic diagram of the structure of a motor stator in an electric motor used in an electro-hydraulic braking system, provided in an embodiment of this application; Figure 9 A schematic diagram of the assembly structure of a rotor assembly in an electric motor for an electro-hydraulic braking system, provided as an embodiment of this application; Figure 10An exploded view of the rotor assembly in a motor used in an electro-hydraulic braking system, provided as an embodiment of this application. Detailed Implementation

[0018] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0019] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The terms "comprising" and "having," and any variations thereof, in the embodiments and drawings of this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices.

[0020] This application discloses a motor for an electro-hydraulic braking system, which has advantages such as compact structure, low cost, and good NVH performance, and is mainly suitable for automotive brake-by-wire systems. Detailed descriptions follow.

[0021] Figure 1 – Figure 7 An electric motor for an electro-hydraulic braking system according to an embodiment of this application is shown. Figure 1 – Figure 7 As shown, the motor includes a stator assembly 30 and a rotor assembly 31.

[0022] Specifically, the stator assembly 30 includes a motor housing, a stator core 32, a stator frame 33, an excitation coil 34, a busbar assembly 1, a power connector 2, a bearing 35, and a bearing race 36. The stator core 32 is fixedly disposed on the inner circumference of the motor housing. The stator frame 33 is mounted on the axial end of the stator core 32. The excitation coil 34 is wound on the stator frame 33. The busbar assembly 1 is electrically connected to the excitation coil 34 and fixed to the stator frame 33. The power connector 2 is disposed inside the motor housing and is electrically connected to the busbar assembly 1. The bearing race 36 is fixed to the axial end inside the motor housing, and the bearing 35 is mounted inside the bearing race 36. The stator core 32 is T-shaped, and there are 12 of them. The number of magnets 38 is 10. The rotor assembly 31 includes a hollow shaft 37, magnets 38, magnet brackets 39, a rotor steel sleeve 40, and yokes 41. The magnet bracket 39 is fixedly fitted around the outer periphery of the hollow shaft 37. The yokes 41 are fixedly installed on the outside of the magnet bracket 39. The magnets 38 are fixedly attached to the outer surface of the yokes 41, and the rotor steel sleeve 40 is fixedly fitted around the outer periphery of the magnets 38 for fixing and protecting them. The 10 magnets 38 that mate with the hollow shaft 37 are tile-shaped, while the hollow shaft 37 is a simple cylinder, requiring only a simple injection-molded magnet bracket 39 for fixation and support. No internal space is reserved in the motor, and the height of the yokes 41 is correspondingly reduced. The hollow shaft 37 and yokes 41 are connected by interference fit. This rotor assembly 31 undergoes a dynamic balancing process, achieving a dynamic balance level of G2.5, resulting in significant improvement in its NVH performance.

[0023] In some embodiments, such as Figure 2 and Figure 3 As shown, Busbar assembly 1 and power connector 2 constitute the motor connector assembly. Busbar assembly 1 is used inside the motor to efficiently deliver high current (three-phase power) from the power input to the terminals of the stator windings with minimal loss, impedance, and inductance, achieving power distribution and transmission. Power connector 2 is used to provide a reliable, safe, and separable connection between the external wiring harness of the motor and the internal circuitry of the motor (i.e., Busbar assembly 1), providing a separable electrical interface.

[0024] This application employs a simple assembly process and structure. Specifically, the Busbar assembly 1 is the core conductive part, comprising a stacked U-phase conductive bus 3, a V-phase conductive bus 4, and a W-phase conductive bus 5. These three conductive buses are all annular copper plates with an arc length corresponding to a central angle of approximately 60°, formed by stamping, greatly saving copper material. Furthermore, the three conductive buses in the Busbar assembly 1 are fixed and insulated from each other by separate plastic parts. The power connector 2 includes three power terminals 6, namely three long strip copper plates (U, V, and W) stamped from copper plates, which are fixed and insulated by insert injection molding parts 7, and connect to the U-phase conductive bus 3, V-phase conductive bus 4, and W-phase conductive bus 5. Further, a sealing structure is provided at the interface between the power connector 2 and the valve block to achieve a sealed connection. In the specific implementation, the sealing structure is an O-ring seal 10, which has low rubber mold and unit cost.

[0025] In some specific embodiments, the motor connector assembly further includes three wire-to-board connection terminals 8. The first ends of the three wire-to-board connection terminals 8 are respectively fixed to the U-phase busbar 3, V-phase busbar 4, and W-phase busbar 5 by resistance welding, and the second ends are respectively connected to the three power terminals 6 to form a plug-in engagement.

[0026] In other specific embodiments, the split plastic component includes an upper support frame 11, a lower support frame 12, and an insulating plate 13. The Busbar assembly 1 is fixed to the lower support frame 12, and the insulating plate 13 ensures that the phase conductors are insulated from each other. The upper support frame 11 is mounted on the lower support frame 12, together forming three fixing slots. The power terminal 6, encased in the insert injection molded part 7, is fixed within the fixing slots. In a specific implementation, the lower support frame 12 includes a first horizontal portion 14 and a first vertical portion 15 connected to each other. The first horizontal portion 14 has a first mounting slot for sequentially stacking and fixing the W-phase conductor 5, V-phase conductor 4, insulating plate 13, and U-phase conductor 3. The first vertical portion 15 has three opening slots 16, and the first horizontal portion 14 has a second mounting slot connecting the opening slots 16 and the first mounting slot, for accommodating the wire-to-plate connection terminal 8, which is disposed within the second mounting slot. The wire-to-plate connection terminal 8 is preferably a standard 250 series female terminal, one end of which is firmly connected to the corresponding conductive busbar (3, 4, 5) by resistance welding. The upper support frame 11 includes a second horizontal part 18 and a second vertical part 19 connected to each other. A locking groove 17 is provided at each end of the first horizontal part 14, and correspondingly, a hook 21 is provided at each end of the second horizontal part 18 for locking into the locking grooves 17 at both ends of the first horizontal part 14 of the lower support frame 12. The second vertical part 19 includes three locking plates 20. When the upper support frame 11 is installed on the lower support frame 12 by the cooperation of the hooks 21 and the locking grooves 17, the three locking plates 20 abut against the corresponding opening grooves 16, thereby forming three stable fixing grooves together with the lower support frame 12.

[0027] In this embodiment, the Busbar assembly 1 and the power connector 2 are connected using a standard 250 series female terminal. Since it is a standard part, it can be used in large quantities, so the cost is low. In addition, the Busbar assembly 1 and the standard 250 series female terminal are connected by resistance welding, which is a mature process and has low cost. The power connector 2 and the standard 250 series female terminal are connected by a simple plug-in method, which has high production efficiency and low cost.

[0028] The power connector 2 consists of three power terminals 6 encapsulated within an insert injection molded part 7 using an insert injection molding process. The insert injection molded part 7, encapsulating the power terminals 6, is installed in a fixing groove formed by an upper support frame 11 and a lower support frame 12. The inner end of the power terminal 6 forms a plug-in fit with the other end of the wire-to-plate connection terminal 8 to achieve electrical connection. An annular groove is formed on the outer wall of the insert injection molded part 7, into which an O-ring seal 10 is embedded. When the assembly is installed on the valve block, the O-ring seal 10 is compressed, achieving a reliable static radial seal.

[0029] The entire Busbar assembly 1 is installed with the motor stator frame via its lower support frame 12 using an interference fit. Simultaneously, slots 9 are provided on the U-phase conductor bus 3, V-phase conductor bus 4, and W-phase conductor bus 5. The motor stator frame has a resilient hook structure that engages with the three slots 9. During assembly, pressure is applied to ensure an interference fit between the Busbar assembly 1 and the motor stator frame. Simultaneously, the resilient hook structure deforms and engages in the slots 9, forming a double safety mechanism to prevent loosening and achieving bidirectional locking.

[0030] In terms of electrical connection, the U-phase busbar 3, V-phase busbar 4, and W-phase busbar 5 are connected to the motor stator coils in a delta configuration. Each phase winding of the motor stator coil consists of four coils connected in series, and each phase winding has two wire ends. These two wire ends are connected to the corresponding U-phase busbar 3, V-phase busbar 4, or W-phase busbar 5. Furthermore, the two wire ends connected to the V-phase busbar 4 are located in the first stator slot, and the distance between the stator slot containing the two wire ends connected to the other two phase busbars and the first stator slot does not exceed three slot pitches. That is, the motor stator coils and Busbar assembly 1 are connected in a delta configuration. Each phase winding consists of all four coils connected in series, with only two wire ends led out. The two wire ends of the V-phase are located in the same stator slot, while the wire ends of the U-phase and W-phase are respectively arranged in slots no more than three slot pitches to the left and right of the slot containing the V-phase wire end. This design allows the other four wire ends to be easily fixed and routed to adjacent positions on the left and right sides of the V-phase, such as... Figure 4 As shown, the coil utilizes the motor stator frame structure and employs an external wiring method, which improves its insulation and high-voltage withstand capability. These six wire ends are ultimately connected to the U, V, and W phase busbars (3, 4, 5) via resistance welding. This wiring method is simple and compact, improving insulation reliability.

[0031] In this embodiment, the busbar assembly uses a one-sixth annular copper plate, saving approximately two-thirds of the copper material. It also employs separate plastic parts and standard terminals, simplifying the mold structure and significantly reducing production costs. Furthermore, the busbar assembly utilizes both interference fit and barbed slot fixing methods to completely eliminate the risk of loosening. The power connector uses standard terminal plugging, ensuring reliable contact and easy assembly, resulting in a reliable and stable overall connection. A standard O-ring sealing structure is used, providing reliable sealing, low cost, easy assembly, and excellent sealing performance. The separate support frame and insulation plate design result in a compact structure, reliably ensuring insulation performance between phases and between phases and ground, providing good insulation. In addition, the coil wiring method is simplified, with fewer wire ends and clear wiring. Resistance welding is used with the busbar assembly, a mature process with high assembly efficiency.

[0032] In other embodiments, such as Figure 1 , Figure 5 and Figure 6 As shown, the motor housing includes a housing body 22, which is a cylindrical structure with one end open, and both the open end and the bottom are sealed with an O-ring radial seal structure.

[0033] Specifically, the open end of the housing body 22 is used to mate with the hydraulic valve block (not shown in the figure) of the EHB system. An annular first sealing groove 23 is machined on the open end face. The first sealing groove 23 has a rectangular cross-section and has a first bottom wall and a first and a second side wall extending from the first bottom wall. The first side wall is the inner ring side wall, close to the central axis of the housing body 22, and the second side wall is the outer ring side wall, away from the central axis of the housing body 22. The height of the first side wall is greater than the height of the second side wall, forming an asymmetrical structure. This design facilitates demolding during die casting and optimizes the compression deformation behavior of the O-ring. Furthermore, this structure replaces the cylindrical shape required by the prior art where the valve block must protrude due to radial sealing requirements, greatly simplifying the valve block structure and reducing material and machining costs. During assembly, the O-ring is placed in the first sealing groove 23. When the valve body and the open end of the housing body 22 are tightened by bolts, the O-ring is axially compressed, achieving a reliable axial static seal between the housing body 22 and the valve body. In the specific implementation process, three mounting ears 29 are provided at equal intervals along the circumference at the open end of the housing body 22 to realize the bolt connection between the motor housing and the valve body.

[0034] A cylindrical protrusion 25 extends outward from the center of the closed end of the housing body 22. This cylindrical protrusion 25 has a through hole 26 along its axis (i.e., at its center). Simultaneously, a second sealing groove 27 is formed on the end face of the cylindrical protrusion 25. An O-ring is placed within the second sealing groove 27 to achieve axial sealing. More specifically, the second sealing groove 27 has a second bottom wall and third and fourth side walls extending from the second bottom wall. The third side wall is an inner ring side wall, close to the central axis of the housing body 22 and surrounding the through hole 26. The fourth side wall is an outer ring side wall, away from the central axis of the housing body 22. When the through hole 26 is connected to an external component, and an O-ring is placed within the second sealing groove 27, an axial seal is achieved between the housing body 22 and the external component (such as an external end cap or connector). That is, the external sealing end cap or connector covers the end face of the cylindrical protrusion 25, and an axial seal is achieved through the O-ring placed within the second sealing groove 27.

[0035] In some specific embodiments, at least one sidewall (such as the fourth sidewall) of the second sealing groove 27 is plastically deformed inward by a riveting process to form a constricted structure for clamping the external connector. This constricted structure presses the external connector tightly against the O-ring seal inside the second sealing groove 27, achieving screwless fixing, simplifying assembly, making assembly quick, and reducing costs.

[0036] To achieve an extremely compact overall motor structure, the motor rotor and stator 28 are tightly packed within the inner cavity of the housing body 22 without any gaps, maximizing the use of internal space and achieving miniaturization of the housing. Furthermore, the outer contour of the motor stator 28 is adapted to the shape of the inner wall of the housing body 22, and the gap between them is less than a preset threshold to ensure good heat conduction and mechanical stability. That is, the outer circle of the motor stator 28 and the inner wall of the housing body 22 adopt an interference fit or a small clearance transition fit to ensure a compact structure and good heat dissipation.

[0037] In other specific embodiments, a plurality of reinforcing ribs 24 are provided at the bottom of the inner cavity of the housing body 22 to compensate for the possible decrease in rigidity due to structural compactness and to enhance the rigidity of the bottom of the housing. Furthermore, the reinforcing ribs 24 are arranged radially, and each reinforcing rib 24 is connected at both ends to the inner wall of the housing body 22 and the through hole 26, respectively, forming an efficient force transmission path. In specific implementations, the number of reinforcing ribs 24 is 6 to 8, achieving an optimal balance between ensuring structural strength and casting processability.

[0038] In a specific implementation process, the housing body 22 is die-cast from aluminum alloy material, and the reinforcing rib 24 is integrally die-cast with the housing body 22. Its inner end is connected to the outer wall of the through hole 26, and its outer end is connected to the inner side wall of the housing body 22, forming an efficient reinforcing structure, which significantly improves the deformation resistance of the bottom of the housing and ensures the overall structural strength and production efficiency.

[0039] The EHB motor housing in this application features a gapless filling layout internally, coupled with radially integrated reinforcing ribs at the bottom, achieving both compactness and lightweight design while maintaining the housing's rigidity and strength. This housing is particularly suitable for space- and cost-sensitive automotive brake-by-wire systems.

[0040] In this embodiment, the EHB motor housing employs a dual axial seal. Axial sealing structures are used between the motor housing and the valve block, as well as at the bottom of the housing. This avoids the need for complex cylindrical protrusions on the valve block, greatly simplifying the valve block structure and reducing material and machining costs. Furthermore, the bottom seal eliminates the need for additional end caps and screws, further reducing costs and increasing efficiency. The "gap-free filling" internal layout significantly reduces the internal reserved space of the housing, lowering its overall height and volume, resulting in a compact structure that saves material while reducing weight. Additionally, the sealing structure at the bottom of the housing can be plastically deformed to form a narrowing, achieving a screwless connection. This not only ensures reliable connection but also simplifies the assembly process and improves production efficiency. Despite its compact structure, the radially integrated reinforcing ribs at the bottom of the housing cavity effectively enhance the overall rigidity and strength of the housing, reliably withstanding various stresses during operation and ensuring long-term stable motor operation. The overall structure of the motor housing in this application is suitable for die casting, with the reinforcing ribs cast integrally with the body, resulting in high production efficiency and material utilization, exhibiting excellent processability and economic benefits.

[0041] In summary, this application discloses a motor for an electro-hydraulic braking system. Its busbar assembly and power connector adopt a separate structure and standard terminal connection, resulting in simple molds, low cost, and reliable connection. Furthermore, all its coils are connected in series, reducing the number of wire ends and simplifying wiring, thus improving insulation and withstand voltage performance. This application optimizes the housing structure, reduces material usage, and simplifies the sealing structure, further lowering costs. Simultaneously, the simplified rotor structure increases processing efficiency, improves dynamic balance, and significantly enhances NVH performance. The motor has a compact overall structure and is lightweight, making it suitable for compact braking systems such as one-box systems.

[0042] It will be understood by those skilled in the art that the accompanying drawings are merely schematic diagrams of one embodiment, and the components shown in the drawings are not necessarily essential for implementing the invention. It should also be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0043] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Furthermore, in the description of the embodiments of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0044] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. Their protection scope is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be determined by the protection scope described in the claims.

Claims

1. A motor for an electro-hydraulic braking system, characterized in that, include: Stator assembly, including motor housing, stator core, stator frame, excitation coil, busbar assembly, power connector, bearing and bearing race; The stator core is fixedly disposed on the inner circumference of the motor housing; the stator frame is installed on the axial end of the stator core; the excitation coil is wound on the stator frame; the busbar assembly is electrically connected to the excitation coil and fixed on the stator frame; the power connector is disposed inside the motor housing and electrically connected to the busbar assembly; the bearing ring is fixed to the axial end inside the motor housing, and the bearing is installed inside the bearing ring; wherein, the busbar assembly includes stacked U-phase conductive busbars, V-phase conductive busbars and W-phase conductive busbars, and the U-phase conductive busbars, the V-phase conductive busbars and the W-phase conductive busbars are all one-sixth annular copper plates, and are fixed and insulated by separate plastic parts; the power connector includes three power terminals, which are fixed and insulated by insert injection molding parts respectively, and connect to the U-phase conductive busbars, the V-phase conductive busbars and the W-phase conductive busbars; The rotor assembly includes a hollow shaft, a magnetic tile, a magnetic tile support, a rotor steel sleeve, and a yoke. The magnetic tile support is fixedly sleeved on the outer periphery of the hollow shaft, the yoke is fixedly installed on the outside of the magnetic tile support, the magnetic tile is fixedly attached to the outer surface of the yoke, and the rotor steel sleeve is fixedly sleeved on the outer periphery of the magnetic tile for fixing and protecting the magnetic tile.

2. The motor for an electro-hydraulic braking system according to claim 1, characterized in that, The stator assembly also includes three wire-to-plate connection terminals. The first end of each of the three wire-to-plate connection terminals is fixed to the U-phase busbar, the V-phase busbar, and the W-phase busbar respectively by resistance welding, and the second end is connected to the three power terminals respectively to form a plug-in fit. The wire-to-plate connection terminals are standard 250 series female terminals.

3. The motor for an electro-hydraulic braking system according to claim 1, characterized in that, The Busbar assembly is interference-fitted with the motor stator frame, and the U-phase conductor bus, the V-phase conductor bus, and the W-phase conductor bus are all provided with slots. The motor stator frame is provided with a barb structure that engages with the three slots.

4. The motor for an electro-hydraulic braking system according to claim 1, characterized in that, An O-ring is provided at the interface between the power connector and the valve block, and an annular groove is provided on the outer wall of the insert injection molded part, and the O-ring is embedded in the annular groove.

5. The motor for an electro-hydraulic braking system according to claim 1, characterized in that, The connection between the U-phase busbar, the V-phase busbar, the W-phase busbar and the motor stator coil adopts a delta connection. Each phase winding of the motor stator coil consists of 4 coils connected in series, and each phase winding has two wire ends, which are connected to the corresponding U-phase busbar, V-phase busbar or W-phase busbar.

6. The motor for an electro-hydraulic braking system according to claim 5, characterized in that, The two wire ends connected to the V-phase busbar are located in the first stator slot, and the stator slots where the two wire ends connected to the other two phase busbars are located are no more than 3 slot pitches apart from the first stator slot.

7. The motor for an electro-hydraulic braking system according to claim 2, characterized in that, The split plastic component includes an upper support frame, a lower support frame, and an insulating plate. The Busbar assembly is fixed on the lower support frame, and the insulating plate is used to insulate each phase conductor from each other. The upper support frame is installed on the lower support frame, together forming three fixing slots. The power terminal, which is encapsulated in the insert injection molded part, is fixed in the fixing slot.

8. The motor for an electro-hydraulic braking system according to claim 7, characterized in that, The lower support frame includes a first horizontal part and a first vertical part connected to each other. The first horizontal part is provided with a first mounting groove for fixing the U-phase conductive busbar, the V-phase conductive busbar, the W-phase conductive busbar, and the insulating plate. The first vertical part is provided with three open slots. The first horizontal part is provided with a second mounting groove connecting the open slots and the first mounting groove. The wire-to-plate connection terminal is disposed in the second mounting groove. A locking groove is provided at each end of the first horizontal part. The upper support frame includes a second horizontal part and a second vertical part connected to each other. The second vertical part includes three locking plates. A hook is provided at each end of the second horizontal part. The two hooks are respectively locked into the corresponding locking grooves. The upper support frame is installed on the lower support frame, and the three locking plates abut against the corresponding open slots to form three fixing grooves.

9. The motor for an electro-hydraulic braking system according to claim 1, characterized in that, The motor housing and the valve block are sealed with a radial O-ring, and the bottom of the motor housing is sealed with a radial O-ring. The stator assembly and the rotor assembly are filled into the inner cavity of the motor housing in a gapless manner. The outer contour of the stator assembly is adapted to the shape of the inner wall of the motor housing, and the gap between them is less than a preset threshold.

10. The motor for an electro-hydraulic braking system according to claim 1, characterized in that, The stator core is T-shaped and there are 12 of them; the number of magnetic tiles is 10.

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