Motor power supply connection structure and assembly method

Abstract

The application discloses a motor power supply connecting structure and an assembling method, which comprise a stator winding, a plastic bus plate is arranged on the stator winding, three-phase terminals are connected on the plastic bus plate, a plurality of enameled wires extending outward are arranged on the stator winding, the enameled wires are embedded on the inner side of the plastic bus plate, and one end of each enameled wire is connected with the three-phase terminals. A plurality of wire grooves and metal buckles are arranged on the plastic bus plate to replace the plastic-coated bus bar, the connection between the motor stator windings is realized through the metal buckles, and the plastic bus plate is connected with the three-phase terminals through the wire outlet, so that the volume is small, the transmission path is high in flexibility, the product is small in size and light in weight, the copper bar is removed, the enameled wires are directly connected, the copper consumption can be effectively reduced, and the cost can be effectively reduced.

Description

Technical Field

[0001] This invention relates to the field of automotive motors, and more particularly to a motor power supply connection structure and assembly method. Background Technology

[0002] Existing automotive motors typically use plastic-coated busbars for connections between stator windings and between stator windings and the motor's three-phase terminals. Plastic-coated busbars consist of several copper busbars integrated circumferentially inside for connection, with the outer side integrally molded. During manufacturing, different sizes require different copper busbar stamping dies and injection molding dies, resulting in high die costs, large busbar size, poor overall transmission path flexibility, hindering product miniaturization and weight reduction, and offering limited compatibility with power supply connections. Summary of the Invention

[0003] The purpose of this invention is to address the shortcomings of existing technologies by proposing a motor power supply connection structure and assembly method.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a motor power supply connection structure, comprising: Stator windings; A plastic busbar is provided on the stator winding, and three-phase terminals are connected to the plastic busbar; The stator winding is provided with a plurality of enameled wires extending outward, the enameled wires being embedded in the inner side of the plastic busbar, and one end being connected to the three-phase terminals.

[0005] As a further description of the above technical solution: the plastic busbar has a through hole in the middle and an axial positioning block and a radial positioning block on the outside, which are engaged and positioned with the outside of the stator winding by the axial positioning block and the radial positioning block.

[0006] As a further description of the above technical solution: the plastic manifold is provided with a plurality of wire grooves, and the plurality of wire grooves are arranged circumferentially in sequence along the radial direction.

[0007] As a further description of the above technical solution: for the same circumferential diameter, anti-reverse ribs are provided between adjacent grooves.

[0008] As a further description of the above technical solution: a positioning buckle is provided on the inner side of the wire groove to limit the enameled wire.

[0009] As a further description of the above technical solution: the plastic manifold is provided with an installation groove, and a metal buckle is provided in the installation groove.

[0010] As a further description of the above technical solution: the metal buckle has several slots on both sides corresponding to the positions of the wire grooves, so that the several wire grooves are connected to the metal buckle.

[0011] As a further description of the above technical solution: the ends of several enameled wires pass through the slots and are connected to the inside of the metal buckle.

[0012] As a further description of the above technical solution: On the plastic busbar, a cable outlet is provided on the opposite side of the same end face as the mounting groove, and several enameled wires pass through the cable outlet and are connected to the three-phase terminals.

[0013] It also includes an assembly method for a motor power supply connection structure, the assembly method being applicable to the connection structure described in any one of the above technical solutions, comprising: The metal clips are pressed into the mounting slots of the plastic busbar; Pass the enameled wire extending from the stator winding through the plastic busbar and snap the plastic busbar into position with the stator winding; The enameled wires are collected through the wire grooves on the plastic busbar and respectively to the metal buckle and the wire outlet. The connection between the motor windings is achieved by pressing the metal buckle together, and the connection to the three-phase terminals is achieved by the wire outlet. The stator winding and the plastic busbar are placed inside the motor housing and assembled with the motor components to obtain the motor.

[0014] The above technical solution has the following advantages or beneficial effects: By setting several wire grooves and metal clips on the plastic busbar to replace the plastic-coated busbar, the connection between the motor stator windings is realized through the metal clips, and the connection to the three-phase terminals is achieved through the outlet of the plastic busbar. It is small in size, has high flexibility in transmission path, and facilitates product miniaturization and weight reduction. Removing the copper busbar and using enameled wire for direct connection can effectively reduce the amount of copper used and reduce costs. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a perspective view of the connection structure proposed in this invention; Figure 2 This is a schematic diagram of the structure of the plastic busbar in this invention; Figure 3This is a schematic diagram of the stator winding structure in this invention; Figure 4 This is a schematic diagram of the installation structure of the plastic busbar and stator winding in this invention; Figure 5 This is a schematic diagram of the structure of the enameled wire and the wire groove in this invention; Figure 6 This is a schematic diagram of the connection structure between the plastic busbar and the three-phase terminals in this invention; Figure 7 This is a schematic diagram of the structure in which the enameled wire and the metal buckle are joined in this invention; Figure 8 This is a schematic diagram of the structure assembled into a motor in this invention; Figure 9 This is a flowchart of the assembly method proposed in this invention.

[0017] Legend: 1. Stator winding; 11. Enameled wire; 2. Plastic busbar; 21. Axial positioning block; 22. Radial positioning block; 23. Wire groove; 24. Anti-reverse rib; 25. Positioning buckle; 26. Mounting groove; 27. Outlet; 3. Three-phase terminal; 4. Metal buckle; 41. Slot. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Reference Figures 1-8 An embodiment of the present invention provides a motor power supply connection structure, comprising: a stator winding 1; a plastic busbar 2 is provided on the stator winding 1, and three-phase terminals 3 are connected to the plastic busbar 2; a plurality of enameled wires 11 extending outward are provided on the stator winding 1, the enameled wires 11 are embedded in the inner side of the plastic busbar 2, and one end is connected to the three-phase terminals 3.

[0020] In this embodiment, a plastic busbar 2 is mounted on the stator winding 1, and three-phase terminals 3 are installed on the plastic busbar 2. Several enameled wires 11 are pre-installed on the stator winding 1. The enameled wires 11 pass through the holes below the plastic busbar 2 and are embedded in the inner wire grooves 23 of the plastic busbar 2. A portion of the enameled wires 11 are interconnected by metal clips 4, and the other portion is connected to the three-phase terminals 3 at its end. The plastic busbar 2 serves as the main body for carrying insulated wiring, replacing the existing plastic-coated busbar. The enameled wires 11 serve as the conductive carrier, replacing the existing copper busbar. The connection structure is small in size and has high flexibility in transmission path, which is conducive to product miniaturization and weight reduction. Removing the copper busbar and using enameled wires 11 for direct connection can effectively reduce the amount of copper used and effectively reduce costs.

[0021] The plastic busbar 2 has a through hole in the middle and an axial positioning block 21 and a radial positioning block 22 on the outside. The axial positioning block 21 and the radial positioning block 22 are engaged with the outside of the stator winding 1 for positioning.

[0022] In this embodiment, the plastic busbar 2 has a through hole in the middle, forming an annular structure, which can be directly fitted onto the outside of the stator winding 1 from the axial direction, avoiding motor components such as the motor rotor. During assembly, it can be directly fitted from top to bottom. The axial positioning block 21 is locked onto the protrusion on the outside of the stator winding 1, preventing the plastic busbar 2 from moving axially after installation and falling off. The radial positioning block 22 is locked onto the outer circumferential side of the stator winding 1, restricting the radial displacement of the plastic busbar 2. The axial positioning block 21 and the radial positioning block 22 ensure that the plastic busbar 2 is positioned and installed, aligned with the lead-out position of the enameled wire 11.

[0023] The plastic manifold 2 is provided with several wire grooves 23, which are arranged circumferentially in the radial direction.

[0024] In this embodiment, the wire grooves 23 are arranged circumferentially in the radial direction, forming a number of annular grooves on the plastic busbar 2 for routing the enameled wire 11 and isolating and insulating each other.

[0025] Within the same circumferential diameter, anti-reverse ribs 24 are provided between adjacent wire grooves 23.

[0026] In this embodiment, by setting anti-reverse ribs 24 between adjacent wire grooves 23, the enameled wire 11 is prevented from being misaligned across grooves, and the enameled wire 11 can only be laid from the corresponding wire groove 23, thus avoiding wiring errors.

[0027] A positioning buckle 25 is provided on the inner side of the wire groove 23 to limit the enameled wire 11.

[0028] In this embodiment, the positioning buckle 25 is disposed on the inner wall of the wire groove 23 and is integrally formed with the wire groove 23. After the enameled wire 11 is embedded in the wire groove 23, the positioning buckle 25 presses the enameled wire 11 from above or the side to limit the enameled wire 11, so that the enameled wire 11 is constrained inside the wire groove 23 and prevents the enameled wire 11 from coming out.

[0029] The plastic manifold 2 has a mounting groove 26, and a metal clip 4 is installed in the mounting groove 26. Several slots 41 corresponding to the positions of the wire grooves 23 are provided on both sides of the metal clip 4, so that the wire grooves 23 are connected to the metal clip 4.

[0030] In this embodiment, an installation groove 26 is provided on the plastic busbar 2, and the metal buckle 4 is directly embedded inside the installation groove 26. Multiple slots 41 are provided on the left and right sides of the metal buckle 4. The number and position of the slots 41 correspond to the slot openings of the wire groove 23 on the plastic busbar 2, so that the enameled wire 1 can enter the inside of the metal buckle 4 through the slots 41 along the wire groove 23.

[0031] Several enameled wires 11 have slots 41 at their ends and are connected inside the metal buckle 4.

[0032] In this embodiment, the enameled wire 11 runs along the wire groove 23 and its end extends into the corresponding slot 41 of the metal buckle 4. It is positioned by the slot 41 and the enameled wire 11 is interference-fitted with the slot 41. The enameled wire 11 in the metal buckle 4 can be connected by soldering, laser welding or argon arc welding to realize the electrical connection between the motor windings.

[0033] On the plastic busbar 2, on the opposite side of the same end face as the mounting groove 26, there is a cable outlet 27, and several enameled wires 11 pass through the cable outlet 27 and are connected to the three-phase terminal 3.

[0034] In this embodiment, the outlet 27 and the mounting groove 26 of the metal buckle 4 are located on opposite sides of the same end face of the plastic busbar 2, forming a winding busbar on one side and an outlet on the other side. The three-phase enameled wires of the stator winding 1 are routed along the wire groove 23 and then pass through the outlet 27 and are directly connected to the three-phase terminal 3 to realize the external output of the motor power.

[0035] Reference Figure 9 It also includes an assembly method for a motor power supply connection structure, the assembly method being applicable to the connection structure of any of the above technical solutions, including: S1. Press the metal clips into the mounting slots of the plastic busbar; S2. Pass the enameled wire extending from the stator winding through the plastic busbar and snap the plastic busbar into place with the stator winding. S3. The enameled wires are collected through the wire grooves on the plastic busbar to the metal buckle and the wire outlet respectively. The connection between the motor windings is achieved by pressing the metal buckle together, and the connection with the three-phase terminals is achieved through the wire outlet. S4. Place the stator winding and plastic busbar inside the motor housing and assemble them with the motor components to obtain the motor.

[0036] In this embodiment, the metal clip 4 is press-fitted into the mounting groove 26 of the plastic busbar 2; the enameled wire 11 led out from the stator winding 1 is first passed through the plastic busbar 2, and then snapped onto the outside of the stator winding 1 through the axial positioning block 21 and the radial positioning block 22 to complete the positioning installation; the enameled wire 11 is divided into a neutral wire and three-phase wires, which are run along their respective wire grooves 23. The stator winding neutral wires are gathered at the metal clip 4 through the corresponding wire grooves 23 to realize the connection between the motor windings. The three-phase wires are gathered at the three-phase terminals 3 through the corresponding wire grooves 23 and welded together with the three-phase terminals 3 to realize the connection between the stator winding 1 and the motor three-phase terminals 3. The assembled plastic busbar 2 and stator winding 1 are placed into the motor housing as a whole, and then assembled with the motor rotor, end cover and other motor components to form a complete motor.

[0037] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0038] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A motor power supply connection structure, characterized in that, include: Stator winding (1); A plastic busbar (2) is provided on the stator winding (1), and three-phase terminals (3) are connected to the plastic busbar (2). The stator winding (1) is provided with a plurality of enameled wires (11) extending outward. The enameled wires (11) are embedded in the inner side of the plastic busbar (2) and one end is connected to the three-phase terminal (3).

2. The connection structure according to claim 1, characterized in that: The plastic busbar (2) has a through hole in the middle and an axial positioning block (21) and a radial positioning block (22) on the outside. The axial positioning block (21) and the radial positioning block (22) are engaged with the outside of the stator winding (1) for positioning.

3. The connection structure according to claim 1, characterized by: The plastic manifold (2) is provided with a number of wire grooves (23), and the number of wire grooves (23) are arranged circumferentially in the radial direction.

4. The connection structure according to claim 3, characterized in that: Under the same circumferential diameter, anti-reverse ribs (24) are provided between adjacent grooves (23).

5. The connection structure according to claim 3, characterized in that: The inner side of the wire groove (23) is provided with a positioning buckle (25) to limit the enameled wire (11).

6. The connection structure according to claim 3, characterized in that: The plastic manifold (2) is provided with an installation groove (26), and a metal buckle (4) is provided in the installation groove (26).

7. The connection structure according to claim 6, characterized in that: The metal buckle (4) has several slots (41) on both sides corresponding to the positions of the wire grooves (23), so that the wire grooves (23) are connected to the metal buckle (4).

8. The connection structure according to claim 7, characterized in that: The ends of several of the enameled wires (11) pass through the slots (41) and are connected to the inside of the metal buckle (4).

9. The connection structure according to claim 6, characterized in that: On the plastic busbar (2), a cable outlet (27) is provided on the opposite side of the same end face as the mounting groove (26), and a plurality of enameled wires (11) pass through the cable outlet (27) and are connected to the three-phase terminal (3).

10. An assembly method for a motor power supply connection structure, characterized in that, The assembly method is applicable to the connection structure described in any one of claims 1-9, and includes: The metal clips are pressed into the mounting slots of the plastic busbar; Pass the enameled wire extending from the stator winding through the plastic busbar and snap the plastic busbar into position with the stator winding; The enameled wires are collected through the wire grooves on the plastic busbar and respectively to the metal buckle and the wire outlet. The connection between the motor windings is achieved by pressing the metal buckle together, and the connection to the three-phase terminals is achieved by the wire outlet. The stator winding and the plastic busbar are placed inside the motor housing and assembled with the motor components to obtain the motor.

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