Wire holder for directly cooling three-phase copper bar, power assembly and vehicle

Abstract

The utility model provides a wire holder for directly cooling a three-phase copper bar. The wire holder comprises a cooling inlet, three cooling outlets and three fixing structures which are integrally formed. And the three fixing structures are respectively used for fixing three-phase copper bars of the motor controller or the motor. The cooling inlet is communicated with the three cooling outlets through an internal flow channel communicated with the wire holder, and each cooling outlet is used for containing and fixing one fixing structure.

Description

Technical Field

[0001] The present application relates to the field of vehicles, and in particular to a terminal block for directly cooling a three-phase copper busbar, a powertrain, and a vehicle. Background Art

[0002] The connection between the three-phase AC output copper busbar of the motor controller of new energy vehicles and the three-phase AC input copper busbar of the motor is usually achieved by overlapping the ends of the copper busbar and fastening them to the terminal block with screws. Since the working current of the three-phase copper busbar is large and there is a large contact resistance on the copper busbar overlap surface, the heat generated in the copper busbar overlap surface area is large. The current terminal blocks cannot solve the heat dissipation problem in the copper busbar overlap surface area well, resulting in the risk of over-temperature aging failure of the copper busbar, which is easy to cause powertrain failure.

[0003] Therefore, a terminal block that can effectively solve the contact heating of the three-phase copper busbar between the motor controller and the motor without affecting reliable installation and good insulation is exactly what the industry needs. Utility Model Content

[0004] The present application provides a terminal block, a powertrain and a vehicle for directly cooling a three-phase copper busbar.

[0005] In a first aspect, the present application provides a terminal block for directly cooling a three-phase copper busbar, the terminal block comprising an integrally formed cooling inlet, three cooling outlets and three fixing structures. The three fixing structures are respectively used to fix the three-phase copper busbar of the motor controller or the motor. The cooling inlet is connected to the three cooling outlets through an internal flow channel connected to the terminal block. Each cooling outlet is used to accommodate and fix a fixing structure.

[0006] Correspondingly, the terminal block provided in the first aspect integrates a cooling inlet, a cooling outlet, an internal flow channel and a fixing structure, which can not only effectively solve the contact heat generation between the motor controller and the three-phase copper busbar of the motor, but also does not affect the fixing of the three-phase copper busbar of the motor controller or the motor to the terminal block.

[0007] The first aspect provides a terminal block, wherein a fixing structure of the terminal block includes a ring nut, each ring nut is used to fix and accommodate a screw. A screw is used to sequentially pass through a copper bar of a motor controller, a copper bar of a motor, and the ring nut, or a screw is used to sequentially pass through a copper bar of a motor, a copper bar of a motor controller, and the ring nut.

[0008] Correspondingly, the fixing structure included in the terminal block provided in the first aspect utilizes annular nuts and screws to reliably fix the three-phase copper busbars of the motor controller and the three-phase copper busbars of the motor on the terminal block.

[0009] In the wiring socket provided in the first aspect, the screw of the wiring socket includes a through hole, and the through hole is used to penetrate the screw along the length direction of the screw.

[0010] Correspondingly, the through-hole screws included in the terminal block provided in the first aspect can guide the cooling oil to flow out of the hole, which is beneficial to the contact and heat dissipation between the motor controller and the three-phase copper busbar of the motor.

[0011] In the first aspect, the cross-sectional shape of the cooling outlet of the terminal holder is polygonal, and the outer peripheral surface of each ring nut contacts the inner wall of the cooling outlet.

[0012] Correspondingly, the cross-sectional shape of the cooling outlet of the terminal block provided in the first aspect is a polygon, which can form a cooling oil circulation gap with the annular nut respectively and prevent the annular nut from sliding in the corresponding cooling outlet.

[0013] In the terminal block provided in the first aspect, the outer wall of the terminal block ring nut also includes a plurality of grooves, the cross-sectional shape of the grooves is "U"-shaped or "V"-shaped, and the notches of the grooves face the inner wall of the cooling outlet.

[0014] Correspondingly, the outer wall of the terminal block ring nut is designed with multiple "U"-shaped or "V"-shaped grooves, which increases the flow of cooling oil and is beneficial to the contact and heat dissipation between the motor controller and the three-phase copper busbar of the motor.

[0015] The terminal block provided in the first aspect, each cooling outlet of the terminal block further includes a first part and a second part, the distance between the first part and the internal flow channel is greater than the distance between the second part and the internal flow channel, and the inner diameter of the first part is smaller than the inner diameter of the second part.

[0016] Correspondingly, the two parts of each cooling outlet of the terminal block close to the cooling channel form a funnel shape, so that the pressure of the cooling oil is relatively high when it flows out, which can speed up the flow of the cooling oil to the motor controller and the three-phase copper busbar of the motor, which is beneficial to speed up the heat dissipation.

[0017] The terminal block provided in the first aspect, the terminal block cooling inlet also includes a third part and a fourth part, the distance between the third part and the internal flow channel is greater than the distance between the fourth part and the internal flow channel, and the inner diameter of the third part is smaller than the inner diameter of the fourth part.

[0018] Accordingly, the cooling inlet of the terminal block is in a conical shape, so that the cooling inlet is easier to install into the cooling channel of the motor, and leakage of the cooling oil when flowing into the cooling inlet can also be prevented.

[0019] The first aspect provides a wiring socket, wherein the wiring socket includes two side surfaces, the two side surfaces are opposite to each other along a first direction. One side surface includes three cooling outlets arranged in sequence along a second direction. The other side surface includes a cooling inlet, the direction of the cooling inlet is opposite to the direction of the three cooling outlets along the first direction.

[0020] Accordingly, the cooling inlet of the terminal block and the three cooling outlets are not designed on the same side, which is conducive to the coordinated installation of the terminal block and the motor cooling channel, and also provides more flexible space for the arrangement of the three-phase copper busbars of the motor controller and the motor.

[0021] The terminal block provided in the first aspect comprises a plurality of grooves on one side of the terminal block, each groove is used to connect to at least one cooling outlet, the cross-sectional shape of each groove is "U"-shaped or "V"-shaped, and the notch direction of each groove is the same as the direction of the cooling outlet.

[0022] Correspondingly, there are multiple "U"-shaped or "V"-shaped grooves on one side of the terminal block. After the grooves are connected to the cooling outlet, the cooling oil will flow into the grooves and then contact the three-phase copper busbar of the motor controller or the motor, which is beneficial to heat dissipation.

[0023] In the wiring socket provided in the first aspect, at least one groove among the plurality of grooves on one side of the wiring socket is used to connect to another groove among the plurality of grooves.

[0024] Correspondingly, the grooves on one side of the terminal block are connected to adjacent grooves, which can accelerate the flow of cooling oil and promote heat dissipation.

[0025] The terminal block provided in the first aspect has one side surface of the terminal block including two interphase insulating ribs, the two interphase insulating ribs are arranged at intervals along the second direction, the interval between the two interphase insulating ribs is used to accommodate a single-phase copper bar of the motor controller and a single-phase copper bar of the motor, and the height of each interphase insulating rib is greater than the sum of the thickness of the single-phase copper bar of the motor controller and the thickness of the single-phase copper bar of the motor.

[0026] Correspondingly, the height of the interphase insulating ribs on one side of the terminal block is higher than that of the two copper bars stacked together, which can better achieve isolation and insulation between the three-phase copper bars.

[0027] The first aspect provides a terminal block, wherein one side of the terminal block includes two edge insulating ribs, the two edge insulating ribs are arranged at intervals on both sides of the three fixed structures along the second direction, the two edge insulating ribs are arranged at intervals on both sides of the interphase insulating ribs along the second direction, and the interval between each edge insulating rib and an adjacent interphase insulating rib is used to accommodate another phase copper bar of the motor controller and another phase copper bar of the motor, and the height of each edge insulating rib is greater than the sum of the thickness of the other phase copper bar of the motor controller and the thickness of the other phase copper bar of the motor.

[0028] Correspondingly, the height of the edge insulating rib on one side of the terminal block is higher than that of the two copper bars stacked together, which can better achieve isolation and insulation between the three-phase copper bar and the motor housing.

[0029] The first aspect provides a terminal block, wherein at least one of the two phase-to-phase insulating ribs or the two edge insulating ribs of the terminal block includes a first section of insulating ribs and a second section of insulating ribs that are integrally formed, wherein the angle between the first section of insulating ribs and the second section of insulating ribs is less than 180 degrees, and the direction of the angle between the first section of insulating ribs and the second section of insulating ribs is toward a fixed structure.

[0030] Correspondingly, the two interphase insulating ribs or two edge insulating ribs on one side of the terminal block have a curved structure and the angle between them is toward the fixed structure. The curved structure can gather the cooling oil, allowing the three-phase copper busbar to fully contact the cooling oil, which is beneficial to heat dissipation.

[0031] The first aspect provides a terminal block, wherein the internal flow channel of the terminal block further includes an oil storage cavity, and the sum of the inner diameters of the three cooling outlets and the inner diameter of the cooling inlet along the radial direction of the cooling outlet or the cooling inlet is smaller than the width of the oil storage cavity.

[0032] Correspondingly, the width of the oil storage cavity of the internal flow channel of the terminal block is greater than the sum of the inner diameters of the three cooling outlets and the inner diameters of the cooling inlet, which can not only ensure that the cooling oil can be stored in the oil storage cavity, but also ensure that the cooling oil in the oil storage cavity can fully flow out to the three-phase copper busbar.

[0033] The wiring socket provided in the first aspect comprises two fastening holes, the two fastening holes are arranged at an interval, and a line connecting the two fastening holes passes through a cooling inlet.

[0034] Accordingly, the fastening hole connection line of the terminal block passing through the cooling inlet can better fasten the cooling inlet and press it into the cooling channel of the housing.

[0035] In the terminal block provided in the first aspect, the angle between the arrangement direction of the two fastening holes of the terminal block and the arrangement direction of the three cooling outlets is less than 30 degrees.

[0036] Accordingly, the angle between the arrangement direction of the terminal block fastening holes and the arrangement direction of the three cooling outlets is less than 30 degrees, which can save more installation space.

[0037] In a second aspect, the present application provides a powertrain, the powertrain comprising a housing, a motor controller, a motor, and a terminal block according to the first aspect. The motor controller is used to control the motor. The housing is used to accommodate the motor, the housing comprises a housing cooling channel and a housing cooling outlet, the housing cooling channel is used to connect to the housing cooling outlet, and the housing cooling outlet is used to connect to a cooling inlet.

[0038] Correspondingly, the powertrain of the second aspect connects the housing oil channel and the terminal block cooling inlet to supply oil, and the cooling system of the three-phase copper busbar is integrated into the powertrain cooling system, so that the cooling system of the powertrain can fully function.

[0039] In the power assembly provided in the second aspect, after the terminal block of the power assembly is fixed to the housing, the cooling inlet is inserted into the housing cooling channel of the motor.

[0040] Correspondingly, the power assembly of the second aspect takes into account the coordination between the cooling inlet and the cooling channel of the motor housing when using the terminal block, making the production, maintenance and installation of the terminal block more convenient.

[0041] In a third aspect, the present application provides a vehicle, comprising a frame, a power battery and a power assembly as in the second aspect, wherein a motor controller is used to receive power from the power battery, and the frame is used to fix the power battery and the power assembly.

[0042] Correspondingly, the vehicle of the third aspect uses the powertrain of the second aspect, so that the three-phase copper busbar of the powertrain operates at a suitable temperature, which can improve the power performance of the vehicle.

[0043] A third aspect provides a vehicle, wherein after the power assembly of the vehicle is fixed to the frame, the angle between the arrangement direction of the three cooling outlets of the vehicle terminal block and the gravity direction is greater than 10 degrees.

[0044] Correspondingly, after the powertrain of the vehicle of the third aspect is installed and fixed to the whole vehicle, the cooling oil from the three cooling outlets can flow more to the three copper bars to take away the heat. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is a schematic diagram of a vehicle provided in an embodiment of the present application;

[0046] Figure 2 is a schematic diagram of a powertrain provided in an embodiment of the present application;

[0047] Figure 3 This is a schematic diagram of a wiring socket fixing a three-phase copper busbar provided in an embodiment of the present application;

[0048] Figure 4 This is a schematic diagram of a wiring socket provided in an embodiment of the present application;

[0049] Figure 5 is another schematic diagram of the wiring socket provided in the embodiment of the present application;

[0050] Figure 6 It is a cross-sectional schematic diagram of a fixed structure of a wiring socket provided in an embodiment of the present application;

[0051] Figure 7 is another schematic diagram of the wiring socket provided in the embodiment of the present application;

[0052] Figure 8 This is another schematic diagram of the terminal block provided in the embodiment of the present application. DETAILED DESCRIPTION

[0053] This section will describe the technical solutions in the embodiments of the present application in conjunction with the drawings in the embodiments of the present application. It should be noted that the embodiments described in this section are only part of the embodiments of the present application, not all of the embodiments.

[0054] The present application provides a vehicle, which includes a frame, a power battery and a power assembly as in the second aspect, wherein a motor controller is used to receive power from the power battery, and the frame is used to fix the power battery and the power assembly.

[0055] In the vehicle provided in the present application, after the powertrain is fixed to the vehicle frame, the angle between the arrangement direction of the three cooling outlets and the direction of gravity is greater than 10 degrees.

[0056] Figure 1 is a schematic diagram of a vehicle provided in an embodiment of the present application, Figure 2 is a schematic diagram of a powertrain provided in an embodiment of the present application, Figure 3 This is a schematic diagram of a wiring socket fixing a three-phase copper busbar provided in an embodiment of the present application. Figure 4 This is a schematic diagram of a wiring socket provided in an embodiment of the present application.

[0057] Figure 1 As shown, the vehicle 1 includes a power battery 2, a power assembly 3, a motor controller 4 and a frame 5. The motor controller 4 is used to receive power from the power battery 2, and the frame 5 is used to fix the power battery 2 and the power assembly 3. Figure 3 The wiring socket 32 ​​shown is located in the power assembly 3. After the power assembly 3 is fixed to the vehicle frame 5, the angle between the arrangement direction of the three cooling outlets (325, 326, 327) and the gravity direction is greater than 10 degrees.

[0058] Vehicle 1 uses powertrain 3, the motor controller 31 of powertrain 3 contains UVW three-phase copper bars (311, 312, 313), and the motor 33 contains UVW three-phase copper bars (331, 332, 333). The three-phase copper bars (311, 312, 313) of the motor controller 31 of powertrain 3 and the three-phase copper bars (331, 332, 333) of the motor 33 work at a suitable temperature, which can improve the power performance of vehicle 1. After powertrain 2 is installed and fixed to vehicle 1, the cooling oil of the three cooling outlets (325, 326, 327) can flow more to the three-phase copper bars (311, 312, 313) of the motor controller 31 and the three-phase copper bars (331, 332, 333) of the motor 33 to take away heat.

[0059] The present application provides a powertrain, which includes a housing, a motor controller, a motor, and a terminal block of the first aspect. The motor controller is used to control the motor. The housing is used to accommodate the motor, and the housing includes a housing cooling channel and a housing cooling outlet, the housing cooling channel is used to connect to the housing cooling outlet, and the housing cooling outlet is used to connect to a cooling inlet.

[0060] In the power assembly provided in the present application, after the terminal block of the power assembly is fixed to the housing, the cooling inlet is inserted into the housing cooling channel of the motor.

[0061] Figure 2 is a schematic diagram of a powertrain provided in an embodiment of the present application, Figure 3 This is a schematic diagram of a wiring socket fixing a three-phase copper busbar provided in an embodiment of the present application. Figure 4 is a schematic diagram of a wiring socket provided in an embodiment of the present application, Figure 5 This is another schematic diagram of the terminal block provided in the embodiment of the present application.

[0062] Figure 2 , Figure 3 , Figure 4 , Figure 5 As shown, the power assembly 3 includes a housing 30, a motor controller 31, a motor 33, a terminal block 32, a housing cooling channel 34, a housing cooling outlet 35, an oil return channel 36 and a heat exchanger 37. The motor controller 31 is used to control the motor 33. The housing 30 is used to accommodate the motor 33, and the housing 30 includes a housing cooling channel 34 and a housing cooling outlet 35. The housing cooling channel 34 is used to connect to the housing cooling outlet 35, and the housing cooling outlet 35 is used to connect to a cooling inlet 321 of the terminal block 32. The cooling oil flows out through the heat exchanger 37, flows into a cooling inlet 321 of the terminal block 32 from the casing cooling outlet 35 through the casing cooling channel 34, and then flows through the three cooling outlets (325, 326, 327) of the terminal block 32 to the three-phase copper busbars (311, 312, 313) of the motor controller 31 and the three-phase copper busbars (331, 332, 333) of the motor 33 to take away the heat, and finally flows into the heat exchanger 37 through the oil return channel 36 for heat dissipation, thereby completing a cycle.

[0063] The cooperation between the cooling inlet 321 of the terminal block 32 in the power assembly 3 and the shell cooling channel 34 of the motor 33 makes the production, maintenance and installation of the terminal block 32 more convenient. The shell cooling channel 34 and the terminal block cooling inlet 321 in the power assembly 3 are connected to supply oil together, and the cooling system of the three-phase copper busbar (311, 312, 313) of the motor controller 31 and the three-phase copper busbar (331, 332, 333) of the motor 33 are integrated into the cooling system of the power assembly 3, so that the cooling system of the power assembly 3 can fully function.

[0064] In one embodiment provided by the present application, a wiring socket for directly cooling a three-phase copper busbar includes an integrally formed cooling inlet, three cooling outlets, and three fixing structures. The three fixing structures are respectively used to fix the three-phase copper busbar of the motor controller or the motor. The cooling inlet is connected to the three cooling outlets through an internal flow channel connected to the wiring socket. Each cooling outlet is used to accommodate and fix a fixing structure.

[0065] Figure 3 , Figure 5 As shown, the terminal block 32 for directly cooling the three-phase copper busbar includes an integrally formed cooling inlet 321, three cooling outlets 325, 326, 327) and three fixed structures (322, 323, 324). The three fixed structures (322, 323, 324) are respectively used to fix the three-phase copper busbar (311, 312, 313) of the motor controller 31 or the three-phase copper busbar (331, 332, 333) of the motor 33. The cooling inlet 321 is connected to the three cooling outlets (325, 326, 327) through the internal flow channel 328 of the terminal block. The cooling outlet 325 is used to accommodate and fix a fixed structure 322, the cooling outlet 326 is used to accommodate and fix a fixed structure 323, and the cooling outlet 327 is used to accommodate and fix a fixed structure 324.

[0066] The terminal block 32 of the present embodiment integrates a cooling inlet 321, a cooling outlet (325, 326, 327), an internal flow channel 328 and a fixing structure (322, 323, 324), which can well solve the contact heating of the three-phase copper busbar (311, 312, 313) of the motor controller 31 and the three-phase copper busbar (331, 332, 333) of the motor 33, and does not affect the three-phase copper busbar (311, 312, 313) of the motor controller 31 and the three-phase copper busbar (331, 332, 333) of the motor 33 being fixed to the terminal block 32 respectively.

[0067] In one embodiment provided by the present application, a fixing structure of the terminal block includes a ring nut, each ring nut is used to fix and accommodate a screw. A screw is used to sequentially pass through a copper busbar of a motor controller, a copper busbar of a motor, and the ring nut, or a screw is used to sequentially pass through a copper busbar of a motor, a copper busbar of a motor controller, and the ring nut.

[0068] Figure 3 , Figure 4 , Figure 5As shown, in an embodiment provided by the present application, a fixing structure 322 of the terminal block 32 includes a ring nut 32d, a fixing structure 323 includes a ring nut 32e, and a fixing structure 324 includes a ring nut 32f. The ring nut 32d is used to fix and accommodate a screw 32a, the ring nut 32e is used to fix and accommodate a screw 32b, and the ring nut 32f is used to fix and accommodate a screw 32c. A screw 32a is used to sequentially pass through a single-phase copper bar 311 of a motor controller, a single-phase copper bar 331 of a motor, and the ring nut 32d, or a screw 32a is used to sequentially pass through a single-phase copper bar 331 of a motor, a single-phase copper bar 311 of a motor controller, and the ring nut 32d, and the placement positions of the single-phase copper bar 331 of a motor and the single-phase copper bar 311 of a motor controller can be interchanged. One screw 32b is used to sequentially pass through the single-phase copper bar 312 of the motor controller, the single-phase copper bar 332 of the motor and the ring nut 32e, or one screw 32b is used to sequentially pass through the single-phase copper bar 332 of the motor, the single-phase copper bar 312 of the motor controller and the ring nut 32e, and the single-phase copper bar 332 of the motor and the single-phase copper bar 312 of the motor controller can be placed in an interchangeable position. One screw 32c is used to sequentially pass through the single-phase copper bar 313 of the motor controller, the single-phase copper bar 333 of the motor and the ring nut 32f, or one screw 32c is used to sequentially pass through the single-phase copper bar 333 of the motor, the single-phase copper bar 313 of the motor controller and the ring nut 32f, and the single-phase copper bar 333 of the motor and the single-phase copper bar 313 of the motor controller can be placed in an interchangeable position.

[0069] The fixing structures (322, 323, 324) included in the wiring base 32 of the present embodiment respectively utilize ring nuts (32d, 32e, 32f) and their paired screws (32a, 32b, 32c) to reliably fix the corresponding three-phase copper busbars (311, 312, 313) of the motor controller and the three-phase copper busbars (331, 332, 333) of the motor on the wiring base 32.

[0070] In an embodiment provided in the present application, the screw of the terminal block includes a through hole, and the through hole is used to penetrate the screw along the length direction of the screw.

[0071] Figure 6 It is a schematic cross-sectional view of a fixed structure of a wiring socket provided in an embodiment of the present application.

[0072] Figure 4 , Figure 5 , Figure 6As shown, in one embodiment provided by the present application, the screw 32a of the wiring base 32 includes a through hole 32g, the screw 32b includes a through hole 32h, and the screw 32c includes a through hole 32k. A through hole 32g is used to penetrate the screw 32a along the length direction of the screw 32a, a through hole 32h is used to penetrate the screw 32b along the length direction of the screw 32b, and a through hole 32i is used to penetrate the screw 32c along the length direction of the screw 32c.

[0073] The screws (32a, 32b, 32c) included in the terminal block 32 provided in this embodiment can guide the cooling oil to flow out from the through holes in the middle of each of them, thereby taking away the contact heat of the three-phase copper busbars (311, 312, 313) of the motor controller and the three-phase copper busbars (331, 332, 333) of the motor, which is beneficial to cooling.

[0074] In an embodiment provided in the present application, the cross-sectional shape of the cooling outlet of the terminal block is polygonal, and the outer peripheral surface of each annular nut contacts the inner wall of the cooling outlet.

[0075] Figure 5 , Figure 6 As shown, in one embodiment provided by the present application, the cross-sectional shape of the cooling outlet (325, 326, 327) of the terminal block 32 is a polygon, and the outer peripheral surface of the ring nut 32d contacts the inner wall of the cooling outlet 325, thereby fixing the ring nut 32d in the fixing seat 322. The outer peripheral surface of the ring nut 32e contacts the inner wall of the cooling outlet 326, thereby fixing the ring nut 32e in the fixing seat 323. The outer peripheral surface of the ring nut 32f contacts the inner wall of the cooling outlet 327, thereby fixing the ring nut 32f in the fixing seat 324. The polygonal inner angle of the cooling outlet 325 and the outer peripheral surface of the ring nut 32d form a cooling oil circulation gap, the polygonal inner angle of the cooling outlet 326 and the outer peripheral surface of the ring nut 32e form a cooling oil circulation gap, and the polygonal inner angle of the cooling outlet 327 and the outer peripheral surface of the ring nut 32f form a cooling oil circulation gap.

[0076] In this embodiment, the cross-sectional shape of the cooling outlet (325, 326, 327) of the terminal block 32 is a polygon, which can form a cooling oil circulation gap with the annular nuts (32d, 32e, 32f) respectively, and also prevent the annular nuts (32d, 32e, 32f) from sliding in the corresponding cooling outlets (325, 326, 327).

[0077] In an embodiment provided in the present application, the outer wall of the annular nut of the terminal block further includes a plurality of grooves, the cross-sectional shape of the grooves is "U"-shaped or "V"-shaped, and the notches of the grooves face the inner wall of the cooling outlet.

[0078] Figure 5 , Figure 6 As shown, in one embodiment provided by the present application, as Figure 6 As shown, the outer wall of the annular nut 32f of the terminal block 32 further includes a plurality of grooves 32j, the cross-sectional shape of the groove 32j is “U”-shaped or “V”-shaped, and the notch of the groove 32j faces the inner wall of the cooling outlet 327 . Figure 6 The figure shows a cross-sectional schematic diagram of the cooling outlet 327 and the ring nut 32f. Similarly, it can be seen that the outer wall of the ring nut 32d also has multiple "U"-shaped or "V"-shaped grooves facing the inner wall of the cooling outlet 325, and the outer wall of the ring nut 32e also has multiple "U"-shaped or "V"-shaped grooves facing the inner wall of the cooling outlet 326.

[0079] In the embodiment of the present application, the outer walls of the annular nuts (32d, 32e, 32f) of the terminal block 32 are respectively designed with a plurality of "U"-shaped or "V"-shaped grooves, which increases the flow rate of cooling oil, thereby taking away the contact heat of the three-phase copper busbars (311, 312, 313) of the motor controller and the three-phase copper busbars (331, 332, 333) of the motor, which is beneficial to cooling.

[0080] In an embodiment provided in the present application, each cooling outlet of the terminal block further includes a first part and a second part, the distance between the first part and the internal flow channel is greater than the distance between the second part and the internal flow channel, and the inner diameter of the first part is smaller than the inner diameter of the second part.

[0081] Figure 5 , Figure 6 As shown, in one embodiment provided by the present application, as Figure 6 As shown, the cooling outlet 327 of the terminal block 32 also includes a first portion 32m and a second portion 32n, the distance between the first portion 32m and the internal flow channel 328 is greater than the distance between the second portion 32n and the internal flow channel 328, and the inner diameter of the first portion 32m is smaller than the inner diameter of the second portion 32n. The first portion 32m and the second portion 32n of the cooling outlet 327 and the inner wall therebetween form a funnel shape, so that the outlet pressure and flow rate of the cooling oil are both relatively large. Figure 6 The first portion 32m and the second portion 32n of the cooling outlet 327 are shown. Similarly, it can be understood that the first portion and the second portion of the cooling outlet 325 or 326 also have similar situations.

[0082] In the embodiment of the present application, the cooling outlet (325, 326, 327) of the terminal block 32 is formed into a funnel shape at two parts close to the cooling flow channel, so that the pressure of the cooling oil is relatively high when it flows out, which can speed up the cooling oil to take away the contact heat of the three-phase copper busbar (311, 312, 313) of the motor controller 31 and the three-phase copper busbar (331, 332, 333) of the motor 33, thereby facilitating cooling.

[0083] In an embodiment provided in the present application, the cooling inlet of the terminal block further includes a third part and a fourth part, the distance between the third part and the internal flow channel is greater than the distance between the fourth part and the internal flow channel, and the inner diameter of the third part is smaller than the inner diameter of the fourth part.

[0084] Figure 7 This is another schematic diagram of the terminal block provided in the embodiment of the present application.

[0085] Figure 6 , Figure 7 As shown, in one embodiment provided by the present application, as Figure 7 As shown, the cooling inlet 321 of the terminal block 32 further includes a third portion 32p and a fourth portion 32q, the distance between the third portion 32p and the internal flow channel 328 is greater than the distance between the fourth portion 32q and the internal flow channel 328, and the inner diameter of the third portion 32p is smaller than the inner diameter of the fourth portion 32q. The third portion 32p and the fourth portion 32q of the cooling inlet 321 and the portion therebetween form a cone, so that the cooling inlet 321 is easier to install into the cooling channel 34 of the motor 33.

[0086] In this embodiment, the cooling inlet 321 of the terminal block 32 is conical, so that the cooling inlet 321 is easier to install into the cooling channel of the motor, and also prevents leakage of cooling oil when it flows into the cooling inlet 321 .

[0087] In one embodiment provided by the present application, the terminal block includes two side surfaces, the two side surfaces are opposite to each other along a first direction. One side surface includes three cooling outlets arranged in sequence along a second direction. The other side surface includes a cooling inlet, the direction of the cooling inlet is opposite to the direction of the three cooling outlets along the first direction.

[0088] Figure 4 As shown, in one embodiment provided by the present application, the terminal block 32 includes two side surfaces A and B, and the two side surfaces A and B are opposite to each other along the first direction X. One side surface A includes three cooling outlets (325, 326, 327) arranged in sequence along the second direction Y. The other side surface B includes a cooling inlet 321, and the direction of the cooling inlet 321 is opposite to the direction of the three cooling outlets (325, 326, 327) along the first direction X.

[0089] In this embodiment, the cooling inlet 321 and the three cooling outlets (325, 326, 327) of the terminal block 32 are not designed on the same side, which is conducive to the coordinated installation of the terminal block 32 and the cooling channel 34 of the motor 33, and also provides more flexible space for the arrangement of the three-phase copper busbars (311, 312, 313) of the motor controller 31 and the three-phase copper busbars (331, 332, 333) of the motor 33.

[0090] In an embodiment provided in the present application, one side of the terminal block includes a plurality of grooves, each groove is used to connect to at least one cooling outlet, the cross-sectional shape of each groove is "U"-shaped or "V"-shaped, and the notch direction of each groove is the same as the direction of the cooling outlet.

[0091] In an embodiment provided in the present application, at least one groove among the plurality of grooves on a side surface of the wiring seat is used to connect to another groove among the plurality of grooves.

[0092] Figure 4 As shown, in one embodiment provided by the present application, a side surface A of the terminal block 32 includes a plurality of grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2). The groove 32r1 or 32r2 is used to connect a cooling outlet 325, the groove 32s1 or 32s2 is used to connect a cooling outlet 326, and the groove 32t1 or 32t2 is used to connect a cooling outlet 327. The cross-sectional shape of the grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2) is "U"-shaped or "V"-shaped, and the notch direction of the grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2) is the same as the direction of the cooling outlets (325, 326, 327).

[0093] In an embodiment provided by the present application, among the multiple grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2) on one side A of the terminal block, one groove 32r1 is used to connect to another groove 32r2 among the multiple grooves, one groove 32s1 is used to connect to another groove 32s2 among the multiple grooves, and one groove 32t1 is used to connect to another groove 32t2 among the multiple grooves.

[0094] In the present embodiment, a plurality of "U"-shaped or "V"-shaped grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2) are provided on one side surface A of the terminal block 32. After the grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2) are respectively connected with the corresponding cooling outlets (325, 326, 327), the cooling oil will flow into the grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2), and then contact the three-phase copper busbars (311, 312, 313) of the motor controller or the three-phase copper busbars (331, 332, 333) of the motor, which is beneficial to heat dissipation. The grooves on one side A of the wiring seat 32 are connected to adjacent grooves (32r1, 32r2, 32s1, 32s2, 32t1, 32t2), which can accelerate the flow of cooling oil and promote heat dissipation.

[0095] In an embodiment provided in the present application, one side of the terminal block includes two interphase insulating ribs, and the two interphase insulating ribs are arranged at intervals along a second direction. The interval between the two interphase insulating ribs is used to accommodate a single-phase copper bar of a motor controller and a single-phase copper bar of a motor, and the height of each interphase insulating rib is greater than the sum of the thickness of a single-phase copper bar of a motor controller and the thickness of a single-phase copper bar of a motor.

[0096] Figure 8 This is another schematic diagram of the terminal block provided in the embodiment of the present application.

[0097] Figure 8 As shown, in one embodiment provided by the present application, one side A of the terminal block 32 includes two interphase insulating ribs 32v and 32w, and the two interphase insulating ribs 32v and 32w are arranged at intervals along the second direction Y, and the interval between the two interphase insulating ribs 32v and 32w is used to accommodate the one-phase copper bar 312 of the motor controller 31 and the one-phase copper bar 332 of the motor 33. The height of the interphase insulating ribs 32v or the interphase insulating ribs 32w is greater than the sum of the thickness of the one-phase copper bar 312 of the motor controller 31 and the thickness of the one-phase copper bar 332 of the motor 33, the height of the interphase insulating ribs 32v or the interphase insulating ribs 32w is greater than the sum of the thickness of the one-phase copper bar 311 of the motor controller 31 and the thickness of the one-phase copper bar 331 of the motor 33, and the height of the interphase insulating ribs 32v or the interphase insulating ribs 32w is greater than the sum of the thickness of the one-phase copper bar 313 of the motor controller 31 and the thickness of the one-phase copper bar 333 of the motor 33.

[0098] In this embodiment, the height of the phase-to-phase insulating rib 32v or 32w on one side A of the terminal block 32 is higher than the sum of the thickness of the single-phase copper bar 312 of the motor controller 31 and the thickness of the single-phase copper bar 332 of the motor 33, the height of the phase-to-phase insulating rib 32v or 32w is higher than the sum of the thickness of the single-phase copper bar 311 of the motor controller 31 and the thickness of the single-phase copper bar 331 of the motor 33, and the height of the phase-to-phase insulating rib 32v or 32w is higher than the sum of the thickness of the single-phase copper bar 313 of the motor controller 31 and the thickness of the single-phase copper bar 333 of the motor 33, which can better achieve isolation and insulation between the three-phase copper bars (311, 312, 313) of the motor controller 31 or the three-phase copper bars (331, 332, 333) of the motor 33.

[0099] In an embodiment provided in the present application, one side of the terminal block includes two edge insulating ribs, the two edge insulating ribs are arranged at intervals on both sides of the three fixed structures along the second direction, the two edge insulating ribs are arranged at intervals on both sides of the interphase insulating ribs along the second direction, and the interval between each edge insulating rib and an adjacent interphase insulating rib is used to accommodate another phase copper bar of the motor controller and another phase copper bar of the motor, and the height of each edge insulating rib is greater than the sum of the thickness of the other phase copper bar of the motor controller and the thickness of the other phase copper bar of the motor.

[0100] Figure 5 , Figure 8 As shown, in an embodiment provided by the present application, one side A of the terminal block 32 includes two edge insulating ribs 32u and 32k, and the two edge insulating ribs 32u and 32k are arranged at intervals on both sides of the three fixed structures (322, 323, 324) along the second direction Y, and the two edge insulating ribs 32u and 32k are arranged at intervals on both sides of the interphase insulating ribs 32v and 32w along the second direction Y, and the interval between the edge insulating rib 32u and an adjacent interphase insulating rib 32v is used to accommodate another phase copper busbar 313 of the motor controller 31 and another phase copper busbar 333 of the motor 33, and the interval between the edge insulating rib 32k and an adjacent interphase insulating rib 32w is used to accommodate another phase copper busbar 311 of the motor controller 31 and another phase copper busbar 331 of the motor 33. The height of the edge insulating rib 32u is greater than the sum of the thickness of the other phase copper bar 313 of the motor controller 31 and the thickness of the other phase copper bar 333 of the motor 33, and the height of the edge insulating rib 32k is greater than the sum of the thickness of the other phase copper bar 311 of the motor controller 31 and the thickness of the other phase copper bar 331 of the motor 33.

[0101] In this embodiment, the edge insulating rib 32u or 32k on one side A of the terminal block 32 has a height greater than the sum of the thickness of the other phase copper bar 313 of the motor controller 31 and the thickness of the other phase copper bar 333 of the motor 33, and a height greater than the thickness of the other phase copper bar 311 of the motor controller 31 and the thickness of the other phase copper bar 331 of the motor 33, which can better achieve the isolation and insulation between the other phase copper bar 313 of the motor controller 31 or the other phase copper bar 333 of the motor 33 and the motor housing, and can better achieve the isolation and insulation between the other phase copper bar 311 of the motor controller 31 or the other phase copper bar 331 of the motor 33 and the motor housing.

[0102] In an embodiment provided in the present application, at least one of the two interphase insulating ribs or the two edge insulating ribs of the terminal block includes a first section of insulating ribs and a second section of insulating ribs formed integrally, the angle between the first section of insulating ribs and the second section of insulating ribs is less than 180 degrees, and the direction of the angle between the first section of insulating ribs and the second section of insulating ribs is toward a fixed structure.

[0103] Figure 5 , Figure 8As shown, in one embodiment provided by the present application, among the two interphase insulating ribs 32v, 32w or the two edge insulating ribs 32u, 32k of the terminal block 32, the interphase insulating rib 32v includes an integrally formed first section insulating rib 32v1 and a second section insulating rib 32v2, the angle between the first section insulating rib 32v1 and the second section insulating rib 32v2 is less than 180 degrees, and the angle between the first section insulating rib 32v1 and the second section insulating rib 32v2 is oriented toward a fixed structure 324. The interphase insulating rib 32w includes an integrally formed first section insulating rib 32w1 and a second section insulating rib 32w2, the angle between the first section insulating rib 32w1 and the second section insulating rib 32w2 is less than 180 degrees, and the angle between the first section insulating rib 32w1 and the second section insulating rib 32w2 is oriented toward a fixed structure 323. The edge insulating rib 32u includes an integrally formed first section insulating rib 32u1 and a second section insulating rib 32u2, wherein the angle between the first section insulating rib 32u1 and the second section insulating rib 32u2 is less than 180 degrees, and the angle between the first section insulating rib 32u1 and the second section insulating rib 32u2 is directed toward a fixed structure 322.

[0104] In this embodiment, at least one of the two interphase insulating ribs 32v and 32w or the two edge insulating ribs 32u and 32k on a side surface A of the terminal block 32 has a curved structure and the angle is toward the fixed structure 322 or 323 or 324. The curved structure can gather cooling oil, allowing the three-phase copper busbar (311, 312, 313) of the motor controller 31 or the three-phase copper busbar (331, 332, 333) of the motor 33 to more fully contact the cooling oil, which is beneficial to heat dissipation.

[0105] In an embodiment provided in the present application, the internal flow channel of the terminal block also includes an oil storage cavity, and the sum of the inner diameters of the three cooling outlets and the inner diameter of the cooling inlet along the radial direction of the cooling outlet or cooling inlet is less than the width of the oil storage cavity.

[0106] Figure 6 , Figure 7 As shown, in an embodiment provided by the present application, the internal flow channel 328 of the terminal block 32 also includes an oil storage cavity 328q. In the second direction Y, along the radial direction of the cooling outlet (325, 326, 327) or the cooling inlet 321, the sum of the inner diameters of the three cooling outlets (325, 326, 327) and the inner diameter of the cooling inlet 321 is less than the width of the oil storage cavity 328q.

[0107] In this embodiment, the width of the oil storage cavity 328q of the internal flow channel 328 of the terminal block 32 is greater than the sum of the inner diameters of the three cooling outlets (325, 326, 327) and the inner diameter of the cooling inlet 321, which can not only ensure that the cooling oil can be stored in the oil storage cavity 328q, but also ensure that the cooling oil in the oil storage cavity 328q can fully flow out to the three-phase copper busbar (311, 312, 313) of the motor controller 31 or the three-phase copper busbar (331, 332, 333) of the motor 33.

[0108] In an embodiment provided in the present application, the terminal block includes two fastening holes, the two fastening holes are arranged at intervals, and a line connecting the two fastening holes passes through a cooling inlet.

[0109] Figure 7 As shown, in one embodiment provided by the present application, the terminal block 32 includes two fastening holes K1 and K2 or K1 and K3, the two fastening holes K1 and K2 or the fastening holes K1 and K3 are arranged at intervals, and the line connecting the two fastening holes K1 and K2 or the fastening holes K1 and K3 passes through a cooling inlet 321. The terminal block 32 may also include three fastening holes (K1, K2, K3), the fastening hole K1 is arranged at intervals with the two fastening holes K2 and K3, and the line connecting the fastening holes K1 and K2 or the fastening holes K1 and K3 passes through a cooling inlet 321.

[0110] In this embodiment, the connecting line of the fastening holes K1 and K2 or the fastening holes K1 and K3 of the terminal block 32 passes through the cooling inlet 321 , which can better fasten the cooling inlet 321 and press it into the housing cooling channel 34 .

[0111] In an embodiment provided in the present application, an angle between an arrangement direction of the two fastening holes of the terminal block and an arrangement direction of the three cooling outlets is less than 30 degrees.

[0112] Figure 6 , Figure 7 As shown, in an embodiment provided by the present application, the angle between the arrangement direction of the connecting line of the fastening holes K1 and K2 or the fastening holes K1 and K3 of the terminal block 32 and the arrangement direction of the three cooling outlets (325, 326, 327) along the Y direction is less than 30 degrees, which can save more installation space.

Claims

1. A terminal block for directly cooling a three-phase copper busbar, characterized in that: The terminal block includes an integrally formed cooling inlet, three cooling outlets and three fixing structures, wherein: The three fixing structures are used to fix the three-phase copper busbars of the motor controller or the motor respectively; The cooling inlet is connected to the three cooling outlets via an internal flow channel connected to the wiring seat, and each cooling outlet is used to accommodate and fix one of the fixing structures.

2. The terminal block according to claim 1, characterized in that: One of the fixing structures comprises a ring nut, each of which is used to fix and accommodate a screw, wherein the screw is used to: Passing through the copper bar of one phase of the motor controller, the copper bar of one phase of the motor and the ring nut in sequence; or, Pass through the copper bar of one phase of the motor, the copper bar of one phase of the motor controller and the ring nut in sequence.

3. The terminal block according to claim 2, characterized in that: The screw comprises a through hole, and the through hole is used to penetrate the screw along the length direction of the screw.

4. The terminal block according to claim 2 or 3, characterized in that: The cross-sectional shape of the cooling outlet is polygonal, and the outer peripheral surface of each of the ring nuts contacts the inner wall of the cooling outlet.

5. The terminal block according to claim 2 or 3, characterized in that: The outer wall of the annular nut further includes a plurality of grooves, the cross-sectional shape of the grooves is "U"-shaped or "V"-shaped, and the notches of the grooves face the inner wall of the cooling outlet.

6. The terminal block according to claim 1, characterized in that: Each of the cooling outlets further includes a first portion and a second portion, wherein the distance between the first portion and the internal flow passage is greater than the distance between the second portion and the internal flow passage, and the inner diameter of the first portion is smaller than the inner diameter of the second portion.

7. The terminal block according to claim 1, characterized in that: The cooling inlet further includes a third portion and a fourth portion, the distance between the third portion and the internal flow channel is greater than the distance between the fourth portion and the internal flow channel, and the inner diameter of the third portion is smaller than the inner diameter of the fourth portion.

8. The terminal block according to claim 1, characterized in that: The wiring seat includes two side surfaces, and the two side surfaces are opposite to each other along a first direction, wherein: One of the side surfaces includes the three cooling outlets arranged in sequence along the second direction, and the other side surface includes the one cooling inlet, wherein the orientation of the one cooling inlet is opposite to the orientation of the three cooling outlets along the first direction.

9. The terminal block according to claim 8, characterized in that: The one side surface includes a plurality of grooves, each of the grooves is used to connect to at least one of the cooling outlets, the cross-sectional shape of each of the grooves is "U"-shaped or "V"-shaped, and the notch direction of each of the grooves is the same as the direction of the cooling outlet.

10. The wiring socket according to claim 9, characterized in that: At least one of the plurality of grooves is used to communicate with another of the plurality of grooves.

11. The terminal block according to claim 8, characterized in that: One side surface includes two interphase insulating ribs, and the two interphase insulating ribs are arranged at intervals along the second direction. The interval between the two interphase insulating ribs is used to accommodate the copper bar of one phase of the motor controller and the copper bar of one phase of the motor. The height of each of the interphase insulating ribs is greater than the sum of the thickness of the copper bar of one phase of the motor controller and the thickness of the copper bar of one phase of the motor.

12. The terminal block according to claim 11, characterized in that: One side surface includes two edge insulating ribs, and the two edge insulating ribs are arranged at intervals on both sides of the three fixed structures along the second direction, and the two edge insulating ribs are arranged at intervals on both sides of the interphase insulating ribs along the second direction, and the interval between each edge insulating rib and an adjacent interphase insulating rib is used to accommodate the copper bar of another phase of the motor controller and the copper bar of another phase of the motor, and the height of each edge insulating rib is greater than the sum of the thickness of the copper bar of another phase of the motor controller and the thickness of the copper bar of another phase of the motor.

13. The terminal block according to claim 12, characterized in that: At least one of the two interphase insulating ribs or the two edge insulating ribs includes a first section of insulating ribs and a second section of insulating ribs formed integrally, the angle between the first section of insulating ribs and the second section of insulating ribs is less than 180 degrees, and the direction of the angle between the first section of insulating ribs and the second section of insulating ribs is toward one of the fixed structures.

14. The terminal block according to claim 1, characterized in that: The internal flow channel also includes an oil storage cavity, and the sum of the inner diameters of the three cooling outlets and the inner diameter of the cooling inlet along the radial direction of the cooling outlet or the cooling inlet is smaller than the width of the oil storage cavity.

15. The terminal block according to claim 1, characterized in that: The wiring seat includes two fastening holes, the two fastening holes are arranged at intervals, and a connecting line of the two fastening holes passes through the one cooling inlet.

16. The terminal block according to claim 15, characterized in that: The angle between the arrangement direction of the two fastening holes and the arrangement direction of the three cooling outlets is less than 30 degrees.

17. A powertrain, characterized in that: The power assembly comprises a housing, a motor controller, a motor and a terminal block according to any one of claims 1 to 16, wherein the motor controller is used to control the motor, wherein: The housing is used to accommodate the motor, and the housing includes a housing cooling channel and a housing cooling outlet. The housing cooling channel is used to communicate with the housing cooling outlet, and the housing cooling outlet is used to communicate with the one cooling inlet.

18. The powertrain according to claim 17, characterized in that: After the terminal block is fixed to the housing, the cooling inlet is inserted into the housing cooling channel of the motor.

19. A vehicle, characterized in that: The vehicle comprises a vehicle frame, a power battery and a power assembly as described in claim 17 or 18, the motor controller is used to receive power from the power battery, and the vehicle frame is used to fix the power battery and the power assembly.

20. The vehicle according to claim 19, characterized in that After the power assembly is fixed to the vehicle frame, the angle between the arrangement direction of the three cooling outlets and the gravity direction is greater than 10 degrees.

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