Wheel hub motor cable

Abstract

The utility model discloses a wheel hub motor cable, which relates to the technical field of cables and comprises a brake control line, a motor temperature sensor line, a support layer, a power line core, a shielding layer and an outer sheath, the support layer, the power line core, the shielding layer and the outer sheath are sequentially distributed from inside to outside, and the brake control line, the motor temperature sensor line and the power line core are respectively wrapped by an insulating layer. The brake control line and the motor temperature sensor line are located in the shielding layer, and the brake control line and the motor temperature sensor line are hinged to each other; the brake control wire, the motor temperature sensor wire and the power wire core are distributed on the outer circumference of the supporting layer; and the bending resistance is better.

Description

Technical Field

[0001] The utility model relates to the technical field of cables, in particular to a hub motor cable. Background Art

[0002] The wheel hub motor is a motor designed by integrating the vehicle's power system, transmission system, brake system, etc. It is used in automobiles as an electric drive device integrated on the wheel axle. The wheel hub motor converts electrical energy into mechanical energy and directly drives the vehicle forward.

[0003] The hub motor cable is a cable used in the hub motor system of electric vehicles or hybrid vehicles. The hub motor cable plays an important role in transmitting power signals to the hub motor and receiving feedback signals from the hub motor. Since the hub motor cable needs to pass through the area where the wheel rotates, it needs to have good anti-bending properties to adapt to the bending stress caused by the rotation of the wheel while maintaining the connection performance and reliability of the cable. Utility Model Content

[0004] In view of the deficiencies in the prior art, the utility model provides a hub motor cable with better anti-bending performance.

[0005] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0006] A hub motor cable comprises: a brake control line, a motor temperature sensor line, and a support layer, a power line core, a shielding layer and an outer sheath which are sequentially distributed from the inside to the outside, wherein the brake control line, the motor temperature sensor line and the power line core are respectively wrapped by an insulating layer, the brake control line and the motor temperature sensor line are located in the shielding layer, and the brake control line and the motor temperature sensor line are respectively hinged; the brake control line, the motor temperature sensor line and the power line core are distributed on the outer circumference of the support layer.

[0007] Compared with the prior art, the utility model has the following beneficial effects:

[0008] On the one hand, the brake control line and motor temperature sensor line are integrated into the cable to meet the requirements of control and signal transmission; on the other hand, the cable has a buffer space when bending, which reduces damage to the wire and insulation layer and improves the service life; in addition, a support layer is designed at the center position where stress is most likely to be applied, and other functional core wires are wrapped around the periphery of the support layer. When the cable is bent as a whole, the support layer bears the tensile force, and the peripheral functional core wires are subjected to less stress, thereby improving the service life.

[0009] As a preferred solution, the pitch diameter ratio of the brake control line and the motor temperature sensor line is 20 to 25.

[0010] As a preferred solution, the support layer is a hollow tube, and its inner cavity is used to fill the refrigerant.

[0011] As a preferred solution, the brake control line, the motor temperature sensor line and the power line core are wound together by a film, and the film is located inside the shielding layer.

[0012] As a preferred solution, the inner layer of the shielding layer includes tinned copper wire and bulletproof wire, and the outer layer of the shielding layer includes an aluminum-plastic composite tape.

[0013] As a preferred solution, the weaving density of the tinned copper wire is 85%, and the aluminum-plastic composite belt adopts an aluminum layer with a thickness of 0.04 mm.

[0014] As a preferred solution, the power line cores include three groups, and each of the power line cores, the brake control line and the motor temperature sensor line is surrounded by the circumference of the support layer.

[0015] As a preferred solution, the power core includes oxygen-free copper wires and copper foil wires which are first bundled and then re-twisted. In different bundles of twisted wires, the number of copper foil wires is positively correlated with the magnitude of the stress borne by the bundle of twisted wires when the hub motor is twisted.

[0016] As a preferred solution, the pitch diameter ratio of the bundled wire strands should be no greater than 20, and the pitch diameter ratios of the inner and outer layers of the strands should be no greater than 14 and 16 respectively. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Schematic diagram of the structure of the cable in the embodiment.

[0018] In the above drawings:

[0019] 1. Power line core; 2. Line core insulation layer; 3. Inner sheath; 4. Shielding layer; 5. Outer sheath; 6. Brake control line; 7. Control line insulation layer; 8. Temperature sensor line; 9. Sensor insulation layer; 10. Support layer. DETAILED DESCRIPTION

[0020] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments; the structures described in the various embodiments can be freely combined without any conflict in structure or principle.

[0021] In the present invention, unless otherwise clearly specified and limited, the terms "install", "connect", "connect", "fix" and the like should be understood in a broad sense, for example, it 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 the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0022] In the description of the present utility model, it should be noted that the terms "center", "upper", "lower", "left", "right", "inner", "outer", etc. indicate the orientation or position relationship based on the orientation or position relationship shown in the drawings, or the orientation or position relationship in which the utility model product is usually placed when in use, which is only for the convenience of describing the utility model and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present utility model. In addition, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0023] The following is a description of some embodiments of the present invention in conjunction with the accompanying drawings:

[0024] like Figure 1 As shown, the utility model proposes a hub motor cable, comprising: a brake control line 6, a motor temperature sensor line 8, and a support layer 10, a power core 1, a shielding layer 4 and an outer sheath 5 distributed from the inside to the outside; wherein the brake control line 6, the motor temperature sensor line 8 and the power core 1 are respectively wrapped by an insulating layer, specifically, the power core 1 is wrapped with a core insulation layer 2, the brake control line 6 is wrapped with a control line insulation layer 7, and the temperature sensor line 8 is wrapped with a sensor insulation layer 9. The brake control line 6 and the motor temperature sensor line 8 are located in the shielding layer 4, and the brake control line 6 and the motor temperature sensor line 8 are respectively hinged. As a preferred embodiment, the pitch ratio of the brake control line 6 and the motor temperature sensor line 8 is designed to be 20 to 25. The brake control line 6, the motor temperature sensor line 8 and the power core 1 are distributed on the outer circumference of the support layer 10; exemplarily, the power core 1 includes three groups, and the brake control line 6, the motor temperature sensor line 8 and each power core 1 are surrounded by the circumference of the support layer 10.

[0025] By adopting the above solution, on the one hand, the brake control line 6 and the motor temperature sensor line 8 are integrated into the cable to meet the requirements of control and signal transmission; on the other hand, the cable has a buffer space when it is bent, which reduces the damage to the wire and the insulation layer and improves the service life. In addition, the support layer 10 is designed at the center position that is most susceptible to stress, and other functional core wires are wound around the periphery of the support layer 10. When the cable is bent as a whole, the support layer 10 is subjected to tension, and the peripheral functional core wires are subjected to less stress, thereby improving the service life.

[0026] As a preferred solution, an inner sheath 3 is designed in the shielding layer 4, and the inner sheath 3 can be made of PVC or other conventional fillers, etc. The outer sheath 5 and the inner sheath 3 play a waterproof, dustproof and protective role on the cable.

[0027] As a preferred solution, the support layer 10 is designed as a hollow tube, and the inner cavity of the hollow tube is filled / transmitted with a refrigerant to reduce the internal heating temperature of the cable.

[0028] As a preferred solution, the brake control line 6, the motor temperature sensor line 8 and the power core 1 are wound together through a film, and the film is located inside the shielding layer 4. Exemplarily, the film is provided with two layers and is wrapped around the brake control line 6, the motor temperature sensor line 8 and the power core 1 in a directional manner to isolate the shielding layer 4 and the functional core wire, and reduce the wear of the shielding layer 4 (especially the braided layer therein) on the insulation layer when bending.

[0029] As a preferred solution, due to the back and forth twisting of the hub motor, the braided shielding layer 4 of the cable must withstand high-intensity mechanical stress, which can easily lead to the breakage of the braided layer and cause the electromagnetic interference shielding to fail. In order to avoid deformation or breakage of the braided layer, the cable is designed as a double-layer shielding structure, and reinforcing elements are added to the braided layer to improve the mechanical strength and tensile properties. Taking the bulletproof wire as an example, the inner layer of the shielding layer 4 includes a braided layer of tinned copper wire and bulletproof wire, and the outer layer of the shielding layer 4 includes an aluminum-plastic composite tape. For example, the braiding density of the tinned copper wire is designed to be 85%, and the aluminum-plastic composite tape uses an aluminum layer with a thickness of 0.04 mm.

[0030] As a preferred solution, copper foil wire is used to strengthen the power core 1 to meet its high voltage and high current capabilities. Specifically, the power core 1 is made of oxygen-free copper wire and copper foil wire "first bundled and then re-twisted", and the strand stranding machine adopts an active wire-releasing device to prevent the copper wire from being pulled. The number of copper foil wires is different in different bundled strands. Copper foil acts as a buffer when stress is released, but its DC resistance is much greater than that of oxygen-free copper wire of the same specification. According to the stress that the bundled strands are subjected to when the hub motor is twisted, multiple copper foil wires are added to the strands that are mainly subjected to stress, and one copper foil wire is added to the strands that are subjected to less stress on the conductor, so as to balance the contradiction between the tensile strength of the conductor and the DC resistance.

[0031] As a preferred solution, the "back-twisting" regular twisting process is adopted when the strands are twisted again. The strands of adjacent layers are twisted in opposite directions so that the sum of the torsional moments of each layer is zero, in order to ensure the softness and roundness of the conductor. The pitch diameter ratio of the bundled strands should not be greater than 20, and the pitch diameter ratios of the inner and outer layers of the strands should not be greater than 14 and 16, respectively. Taking into account the vertical torsion of special cables for hub motors, the twisting pitch of the bundled strands should not be too large or too small. A pitch that is too large will increase the bending radius of the cable, and a pitch that is too small will cause the cable to suffer excessive stress when twisted vertically.

[0032] As a preferred solution, the insulation layer is made of high-temperature resistant silicone rubber with a temperature resistance level of up to 200°C. The insulation layer is made of high-strength silicone rubber, which not only has the softness of polyurethane, but also has good tensile strength and wear resistance.

Claims

1. A hub motor cable, characterized in that: include: A brake control line (6), a motor temperature sensor line (8), and a support layer (10), a power line core (1), a shielding layer (4), and an outer sheath (5) are sequentially arranged from the inside to the outside. The brake control line (6), the motor temperature sensor line (8), and the power line core (1) are respectively wrapped by an insulating layer. The brake control line (6) and the motor temperature sensor line (8) are located in the shielding layer (4). The brake control line (6) and the motor temperature sensor line (8) are respectively hinged. The brake control line (6), the motor temperature sensor line (8), and the power line core (1) are arranged on the outer circumference of the support layer (10).

2. A hub motor cable according to claim 1, characterized in that: The pitch-to-diameter ratio of the brake control line (6) and the motor temperature sensor line (8) is 20 to 25.

3. A hub motor cable according to claim 1 or 2, characterized in that: The support layer (10) is a hollow tube, and its inner cavity is used to fill with refrigerant.

4. The hub motor cable according to claim 1, characterized in that: The brake control line (6), the motor temperature sensor line (8) and the power line core (1) are wound together by a film, and the film is located inside the shielding layer (4).

5. The hub motor cable according to claim 4, characterized in that: The inner layer of the shielding layer (4) comprises tinned copper wires and bulletproof wires, and the outer layer of the shielding layer (4) comprises an aluminum-plastic composite tape.

6. The hub motor cable according to claim 5, characterized in that: The braiding density of the tinned copper wire is 85%, and the aluminum-plastic composite belt adopts an aluminum layer with a thickness of 0.04 mm.

7. A hub motor cable according to any one of claims 2, 4, 5 and 6, characterized in that: The power line core (1) includes three groups, and each of the power line cores (1), the brake control line (6), and the motor temperature sensor line (8) are wrapped around the circumference of the support layer (10).

8. The hub motor cable according to claim 7, characterized in that: The power line core (1) comprises oxygen-free copper wires and copper foil wires which are first bundled and twisted and then re-twisted. In different bundles of twisted strands, the number of the copper foil wires is positively correlated with the magnitude of the stress borne by the bundle of twisted strands when the wheel hub motor is twisted.

9. The hub motor cable according to claim 8, characterized in that: The pitch diameter ratio of the bundled wire strands should not be greater than 20, and the pitch diameter ratios of the inner and outer layers of the strands should not be greater than 14 and 16 respectively.

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