A terminal box for a low-voltage high-power water-cooled motor

Abstract

The application relates to the field of motor junction boxes, in particular to a junction box for a low-voltage high-power water-cooled motor. The junction box for the low-voltage high-power water-cooled motor comprises a junction box and a motor shell, and the junction box is installed on the motor shell through a neck cylinder; the junction box comprises a shell body, a top maintenance opening, a side wire inlet and a bottom wire outlet are arranged on the shell body; a junction module is installed inside the shell body, the junction module comprises a flat plate-shaped junction plate body and a plurality of junction terminals arranged on the junction plate body; a waterproof wire bundling structure is installed at the wire inlet of the shell body; the bottom wire outlet is communicated with the motor shell through the neck cylinder, and the flow area of the neck cylinder is smaller than that of the shell body. In the junction box for the low-voltage high-power water-cooled motor, the plate-shaped junction plate is convenient to process and install, and the junction seat part between the junction box and the motor is designed as a "thin waist", so that the temperature difference area is reduced.

Description

Technical Field

[0001] This invention relates to the field of motor junction boxes, and more particularly to a junction box for a low-voltage, high-power water-cooled motor. Background Technology

[0002] In the field of industrial drives, the motor is the core power source, and the reliability of its auxiliary electrical components is crucial to ensuring the long-term stable operation of the entire system. Among them, the junction box, as the hub for electrical connection between the motor and external power supply and control circuits, directly affects the motor's service life, operational safety, and maintenance costs.

[0003] Currently, the wiring structure of a traditional junction box is as follows: Figure 1 and below Figure 2 As shown (a, the junction box for a low-voltage, high-power water-cooled motor; c, the corresponding structure), these components typically use non-standard shaped terminal blocks such as L-shaped or C-shaped ones. These parts have complex manufacturing processes and high costs. Furthermore, when assembling multiple layers within a narrow box, the installation sequence is strictly controlled. Incorrect sequence or component interference often necessitates complete disassembly and rework, significantly impacting production and maintenance efficiency. Simultaneously, the wiring channel between the junction box and the motor housing is usually a straight-through design. During installation or subsequent maintenance wiring, there is a risk of small metal foreign objects such as screws and nuts falling into the motor. If this occurs, the motor must be disassembled to remove them, with serious consequences.

[0004] Secondly, the anti-condensation capabilities are generally insufficient. Motor operation generates heat, while the external ambient temperature may be low, causing condensation to easily form inside the junction box due to the temperature difference. Existing designs mostly focus on sealing and waterproofing, but lack effective prevention and drainage mechanisms for internal condensation. Simply sealing can lead to moisture accumulation, exacerbating condensation and potentially causing electrical short circuits, terminal corrosion, and other safety hazards. While some designs include drainage holes, they often lack a systematic approach, failing to simultaneously address dust prevention, insect control, and effective drainage.

[0005] Therefore, it is necessary to provide a new junction box for low-voltage, high-power water-cooled motors to solve the above-mentioned technical problems. Summary of the Invention

[0006] To solve the above-mentioned technical problems, the present invention provides a junction box for a low-voltage, high-power water-cooled motor.

[0007] The present invention provides a junction box for a low-voltage, high-power water-cooled motor, comprising a junction box and a motor housing, wherein the junction box is mounted on the motor housing via a neck sleeve; The junction box includes: The housing has a top inspection port, a side cable inlet, and a bottom cable outlet. A wiring module, which is installed inside the housing, includes a flat wiring board body and multiple wiring terminals disposed thereon; A waterproof cable bundle structure is installed at the cable inlet of the housing; The top inspection port is equipped with a removable cover plate, and the area of ​​the inspection port is adapted to the cross-sectional area of ​​the housing at that location, so as to facilitate overall internal maintenance; the bottom cable outlet is connected to the motor housing through a neck tube, and the flow cross-sectional area of ​​the neck tube is smaller than the cross-sectional area of ​​the housing.

[0008] Preferably, the wiring module further includes a mounting plate and support terminals. The mounting plate is horizontally fixed to the inner wall of the housing, and the wiring block body is mounted above the mounting plate via multiple support terminals. The upper end of the terminal block body has two rows of terminals, and each terminal is equipped with a wiring terminal.

[0009] Preferably, the terminal block body is provided with a plurality of plug slots along its length, and an insulating plate can be detachably plugged into each plug slot to divide the wiring area on the terminal block body into a plurality of mutually isolated intervals.

[0010] Preferably, the waterproof cable bundle structure includes a second mounting plate and a cable threading tube; The mounting plate 2 is fixed to the outside of the wire inlet of the housing, and has multiple through holes. The wire threading tube is coaxially installed in the through holes.

[0011] Preferably, the outer wall of the threading tube is provided with an annular groove, and an O-ring is embedded in the annular groove to achieve radial sealing between the threading tube and the mounting plate.

[0012] Preferably, the second mounting plate is detachable, so that mounting plates with different through holes can be replaced to accommodate cables of different diameters.

[0013] Preferably, the inner bottom of the housing is an inclined surface, and a hexagonal water-permeable valve is installed at its lowest point to automatically drain the condensate formed inside the housing.

[0014] Preferably, a filter screen is also installed at the drain outlet at the lower end of the housing.

[0015] Preferably, the connection area between the interior of the housing and the neck cylinder is filled with heat-insulating foam to reduce heat conduction between the internal cavity of the housing and the interior of the motor.

[0016] Compared with related technologies, the junction box for low-voltage high-power water-cooled motors provided by the present invention has the following advantages: By adopting a flat terminal block body, combined with a modular mounting plate and plug-in insulation plate design, the traditional complex irregular structural components are replaced. This makes the manufacturing process of the terminal block body much easier, and its simple shape allows for quick assembly and disassembly within the confined space of a junction box.

[0017] By designing the connection channel between the junction box and the motor body into a "narrow waist" shape and filling it with high-efficiency heat insulation material, the direct heat conduction path from the high temperature inside the motor to the junction box is blocked, significantly reducing the temperature difference between the inside and outside of the box and limiting the generation of condensate. Furthermore, the filling material also seals off the internal space of the neck cylinder to prevent parts from falling into the motor through this channel during disassembly and assembly. Attached Figure Description

[0018] Figure 1 A schematic diagram of the internal structure of a conventional junction box provided by the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the internal structure of a conventional junction box as shown in this invention. Figure 2 ; Figure 3 This is a schematic diagram of a preferred embodiment of the junction box for a low-voltage, high-power water-cooled motor provided by the present invention. Figure 4 As shown in this invention Figure 3 A structural diagram of the other side; Figure 5 This is a schematic diagram of the internal structure of the junction box shown in this invention; Figure 6 This is a schematic diagram of the wiring module shown in the present invention; Figure 7 This is a schematic diagram of the waterproof wire harness structure shown in this invention; Figure 8 This is a schematic diagram of the connection between the junction box and the motor as shown in this invention.

[0019] The following are the labels in the diagram: 1. Housing; 2. Cover plate; 3. Mounting plate one; 4. Support terminal; 5. Terminal block body; 6. Terminal post; 7. Terminal block; 8. Insulating plate; 9. Mounting plate two; 10. Cable reel; 11. O-ring seal; 12. Neck; 13. Hexagonal permeable valve; 14. Thermal insulation foam; 15. Motor housing. Detailed Implementation

[0020] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," 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 this invention and simplifying the description, and do not indicate or imply that the device or element 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 this invention.

[0021] In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0022] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0024] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0025] Please see Figures 3 to 8 The present invention provides a junction box for a low-voltage high-power water-cooled motor. The junction box for the low-voltage high-power water-cooled motor includes a motor housing 15 and a junction box installed outside the motor housing 15.

[0026] The junction box includes a rectangular housing 1. The housing 1 has three openings: a top access port for internal inspection and maintenance; a side access port for introducing external cables; and a bottom access port for guiding wires into the motor.

[0027] The inspection port is secured with a removable cover plate 2 via screws for easy opening and closing and sealing. A waterproof cable tie structure is installed at the cable inlet to seal and secure externally introduced cables. A neck sleeve 12 is fixedly connected to the cable outlet, with its other end fixed to the motor housing 15, thereby stably mounting the entire junction box on the motor and forming a conductive path to the motor's internal cavity.

[0028] The access panel at the top of housing 1 has a net opening area that matches the effective internal flow area of ​​housing 1 at that cross-section. That is, the access panel completely covers the entire cross-sectional space of housing 1 at that height. This ensures that after opening the cover plate 2, operators can more comprehensively inspect, repair, clean, and replace all electrical components (including wires, wiring structures, and support structures) inside housing 1, greatly improving maintenance convenience.

[0029] The neck cylinder 12, which connects to the motor housing 15 at the bottom, has a smaller cross-sectional area than the housing 1. This reduces the direct heat transfer area between the internal cavity of the junction box and the high-temperature area inside the motor, thereby reducing the risk of condensation inside the junction box due to temperature differences. Furthermore, to further enhance the insulation effect, a dedicated heat-insulating foam 14 material is filled in the transition area between the inner wall of the housing 1 and the neck cylinder 12 to block thermal bridges and reduce internal air convection.

[0030] The insulating foam 14 is applied after the cable has been guided from the junction box into the motor. This does not affect the cable routing and also seals the internal passages of the neck cylinder 12. Therefore, during subsequent maintenance or disassembly of the junction box, dirt or components can be prevented from falling into the motor through the neck cylinder 12, further enhancing its safety.

[0031] A wiring module is installed inside the housing 1. The wiring module includes a horizontally mounted mounting plate 3, which is fixed to the inner wall of the housing 1 with screws. Above the mounting plate 3, a long, flat terminal block body 5 is mounted parallel to it. The terminal block body 5 is fixedly connected to the mounting plate 3 below through multiple insulated support terminals 4 to ensure the stability of the terminal block body 5 and to provide electrical insulation, thereby further improving its safety. On the upper surface of the terminal block body 5, two rows of terminals 6 are arranged along its length. Each terminal 6 is equipped with a terminal block 7 for connecting and fixing wires to achieve circuit connection.

[0032] The junction box body 5 adopts a simplified flat design. Compared with the complex L-shaped or C-shaped structure that requires multiple bends in traditional junction boxes, this design not only greatly simplifies the stamping or casting process and reduces manufacturing costs, but also makes the installation and positioning inside the housing 1 simpler and more direct.

[0033] On the surface of the terminal block body 5, multiple parallel strip-shaped grooves are machined along its length. An independent insulating plate 8 can be inserted and installed in each groove. These insulating plates 8 divide the upper surface of the terminal block body 5 into multiple independent wiring sections that are insulated from each other, thereby separating the wire connection points of different phase sequences or functions.

[0034] For the waterproof cable harness structure, the structure includes a mounting plate 2 9 fixed to the outer wall of the housing 1 by screws. The mounting plate 2 9 has multiple through holes of different sizes for passing cables of different diameters. A cable guide spool 10 made of metal or high-strength plastic is coaxially mounted in each through hole. An annular groove is provided in the center of the outer wall of the cable guide spool 10, and an O-ring seal 11 is embedded and fixed inside this groove. When the cable guide spool 10 is installed in the through hole, the O-ring seal 11 is radially compressed, thereby better filling all microscopic gaps between the outer wall of the cable guide spool 10 and the inner wall of the through hole of the mounting plate 2 9, forming a more effective radial seal and preventing external moisture or water droplets from seeping into the housing 1 along the cable surface.

[0035] When the motor is used in an environment with large temperature variations, condensation may occur inside the junction box. To address this, the bottom of the housing 1 is designed with an inclined guide slope. At the lowest point of this slope, a hexagonal water-permeable valve 13 with a filter function is installed. That is, when a small amount of condensation occurs inside the housing 1 due to environmental changes, the water droplets will collect along the slope under gravity to the lowest point and be automatically discharged outside the box through the hexagonal water-permeable valve 13, thereby preventing condensation from accumulating inside the box and providing good protection for all internal structures of the junction box.

[0036] The specific working and maintenance procedures for this junction box are as follows: First step: Secure the housing 1 with neck 12 to the predetermined position on the motor housing 15 through the interface at the end of neck 12, and fill the connection area between neck 12 and housing 1 with heat-insulating foam 14. Then, install and secure the internal wiring assembly (mounting plate 1 3, support terminal 4, wiring plate body 5, terminal block 6, and terminal block 7) into housing 1. Finally, install the waterproof wiring structure (mounting plate 2 9, wire guide 10, and O-ring 11) and the hexagonal water-permeable valve 13 at the bottom.

[0037] Step 2: Open the top cover 2, and thread the external cables through the corresponding cable reels 10 and into the housing 1. With the access port open, operators can easily crimp the cable conductors to the corresponding terminals 7, ensuring uniform isolation using the insulating plate 8. After wiring, tidy the cable bundle, close the cover 2, and tighten the screws.

[0038] Step 3: During motor operation, a small amount of moisture may be generated inside the junction box due to temperature differences. Thanks to the "narrow waist" design of the neck 12 and the presence of the insulating foam 14, heat exchange and air convection between the neck and the motor body are significantly reduced, thus minimizing condensation. Even if a small amount of condensation is generated, it will collect along the sloping surface at the bottom and eventually be automatically discharged outside the box through the hexagonal permeable valve 13.

[0039] Step 4: When inspection or maintenance is required, simply unscrew the screws on the top cover 2 and remove the cover 2 to obtain an operating window the same size as the cross-section of the housing 1. All electrical connection points, insulation status, and internal structure are clearly visible, providing greater operating space for maintenance and cleaning. There is no need to disassemble the entire junction box or disturb the neck 12 section connected to the motor.

[0040] The circuits and controls involved in this invention are all existing technologies and will not be described in detail here.

[0041] The above are merely embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A junction box for a low-voltage, high-power water-cooled motor, comprising a junction box and a motor housing (15), wherein the junction box is mounted on the motor housing (15) via a neck (12), characterized in that: The junction box includes: The housing (1) is provided with a top inspection port, a side cable inlet and a bottom cable outlet; Wiring module, which is installed inside the housing (1), includes a flat wiring board body (5) and multiple wiring terminals (7) disposed thereon. A waterproof cable bundle structure is installed at the cable inlet of the housing (1); The top inspection port is provided with a detachable cover plate (2), and the area of ​​the inspection port is adapted to the cross-sectional area of ​​the housing (1) at that position, so as to carry out overall maintenance of the interior; the bottom outlet is connected to the motor housing (15) through the neck cylinder (12), and the flow cross-sectional area of ​​the neck cylinder (12) is smaller than the cross-sectional area of ​​the housing (1).

2. The junction box for a low-voltage, high-power water-cooled motor according to claim 1, characterized in that, The wiring module also includes a mounting plate (3) and support terminals (4). The mounting plate (3) is horizontally fixed to the inner wall of the housing (1). The wiring board body (5) is mounted above the mounting plate (3) through multiple support terminals (4). The upper end of the terminal block body (5) has two rows of terminals (6), and each terminal (6) is equipped with a terminal block (7).

3. The junction box for a low-voltage, high-power water-cooled motor according to claim 2, characterized in that, The terminal block body (5) is provided with multiple plug slots along its length, and an insulating plate (8) can be detachably plugged into each plug slot to divide the wiring area on the terminal block body (5) into multiple isolated intervals.

4. The junction box for a low-voltage, high-power water-cooled motor according to claim 1, characterized in that, The waterproof cable tie structure includes mounting plate two (9) and cable threading tube (10). The mounting plate 2 (9) is fixed to the outside of the wire inlet of the housing (1), and has multiple through holes. The wire tube (10) is coaxially installed in the through holes.

5. The junction box for a low-voltage, high-power water-cooled motor according to claim 4, characterized in that, The outer wall of the threading tube (10) is provided with an annular groove, and an O-ring (11) is embedded in the annular groove to achieve radial sealing between the threading tube (10) and the mounting plate (9).

6. The junction box for a low-voltage, high-power water-cooled motor according to claim 5, characterized in that, The second mounting plate (9) is detachable, so that the second mounting plate (9) with different through holes can be replaced to adapt to cables of different diameters.

7. The junction box for a low-voltage, high-power water-cooled motor according to claim 1, characterized in that, The bottom of the shell (1) is an inclined surface, and a drain outlet is installed at its lowest point. A hexagonal water valve (13) is also installed to automatically drain the condensate formed inside the shell (1).

8. The junction box for a low-voltage, high-power water-cooled motor according to claim 7, characterized in that, A filter screen is also installed at the drain outlet at the lower end of the housing (1).

9. The junction box for a low-voltage, high-power water-cooled motor according to claim 1, characterized in that, The connection area between the interior of the housing (1) and the neck cylinder (12) is filled with heat-insulating foam (14) to reduce heat conduction between the internal cavity of the housing (1) and the interior of the motor.

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