Busbar assembly suitable for motor stator and base thereof

Abstract

The utility model provides a busbar assembly suitable for a motor stator and a pedestal thereof. The motor stator comprises a stator core, a plurality of flat wire windings, a plurality of first outgoing wires and a plurality of second outgoing wires. The busbar assembly is arranged at one end of the motor stator and comprises a base and a plurality of second copper bars. The base comprises a first side, a second side, at least one first copper bar and an insulating part, the first side and the second side are opposite, and the second side is adjacent to the end of the motor stator. The at least one first copper bar is disposed between the first side and the second side, and is configured to abut against a plurality of first outgoing lines of the motor stator. The insulating part at least partially wraps the at least one first copper bar, so that the base is of an integrated single-piece structure. The plurality of second copper bars are arranged on the first side of the base and correspondingly abut against a plurality of second outgoing lines of the motor stator respectively.

Description

Technical Field

[0001] The utility model relates to a busbar component, in particular to a busbar component suitable for a motor stator and a base thereof. Background Art

[0002] With the booming development of the electric vehicle industry, the demand for power density of its drive system has also increased. Compared with the known motors, the flat wire motor increases the slot fill rate by configuring the hairpin flat wire winding in the corresponding wire slot of the stator core, so it has higher power density and operating efficiency, and has become the mainstream choice of electric vehicle motors.

[0003] In a flat wire motor, the outgoing wires of different phases in the winding are integrated through a bus assembly set at one end of the motor stator, so as to be electrically connected to the inverter and the battery through the bus assembly to drive the motor. However, the number of components in the existing bus assembly is large and the shape is complex. The components are not properly arranged in space, which not only increases the overall volume of the motor and reduces efficiency, but is also not conducive to manufacturing and assembly, resulting in increased production costs.

[0004] In view of this, it is necessary to provide a busbar assembly and a base thereof suitable for a motor stator to solve the defects of the existing technology. Utility Model Content

[0005] The utility model aims to provide a busbar assembly and a base suitable for a motor stator. The busbar assembly includes a base and a plurality of second copper bars, wherein the base includes at least one first copper bar and an insulating portion. By, for example but not limited to, coating injection molding or ultrasonic welding, the insulating portion is at least partially coated on at least one first copper bar, thereby making the base an integrated single-piece structure, thereby simplifying the structure and assembly process of the busbar assembly to improve assembly efficiency and reduce the generation of manual errors during installation. In addition, the plurality of second copper bars have the same structure and profile, and can be compactly arranged when arranged on the base, thereby saving manufacturing costs and facilitating maintenance and replacement, and optimizing the spatial configuration of the busbar assembly to improve space utilization. Furthermore, the base can assist in positioning the plurality of second copper bars in the busbar assembly, and can insulate and isolate the first copper bar from the second copper bar to improve electrical safety. Furthermore, the base of the busbar assembly can assist in setting a temperature sensor to facilitate accurate monitoring of the motor temperature.

[0006] To achieve the above-mentioned purpose, the utility model provides a busbar assembly suitable for a motor stator. The motor stator includes a stator core and a plurality of flat wire windings, wherein the stator core includes a plurality of wire slots, and the plurality of flat wire windings are wound in corresponding wire slots, wherein the plurality of flat wire windings include a plurality of first outgoing wires and a plurality of second outgoing wires. The busbar assembly is arranged at one end of the motor stator, and includes a base and a plurality of second copper bars. The base includes a first side, a second side, at least one first copper bar and an insulating portion, wherein the first side and the second side are opposite sides, and the second side is adjacent to the end of the motor stator. At least one first copper bar is arranged between the first side and the second side, and is structured to abut against the plurality of first outgoing wires of the motor stator. The insulating portion at least partially covers the at least one first copper bar, so that the base is an integrated single-piece structure. A plurality of second copper bars are arranged on the first side of the base, and are respectively structured to abut against the plurality of second outgoing wires of the motor stator.

[0007] In one embodiment, the base is an arc-shaped rectangular parallelepiped and is disposed at the end of the motor stator along a circumferential direction of the motor stator, and a plurality of second copper bars are disposed on a first side of the base along the circumferential direction of the motor stator.

[0008] In one embodiment, each first copper bar includes a plurality of first conductive portions, and each second copper bar includes a plurality of second conductive portions. The base also includes a third side and a fourth side, which are respectively connected between the first side and the second side, and the third side and the fourth side are opposite sides, wherein the plurality of first conductive portions of the first copper bar are exposed from the third side and the fourth side of the base, and respectively abut against the plurality of first outgoing wires along the radial direction of the motor stator. The plurality of second conductive portions of the plurality of second copper bars respectively abut against the plurality of second outgoing wires along the radial direction of the motor stator.

[0009] In one embodiment, the plurality of second conductive portions of each second copper bar include an inner second conductive portion and an outer second conductive portion, and the inner second conductive portion or the outer second conductive portion of each second copper bar at least partially overlaps with the outer second conductive portion or the inner second conductive portion of an adjacent second copper bar in a visual direction along the radial direction of the motor stator.

[0010] In one embodiment, each second copper bar further includes a connecting portion and an extending portion. The connecting portion is connected between the inner second conductive portion and the outer second conductive portion and has a bending section, wherein the bending section enables the inner second conductive portion and the outer second conductive portion to form a mutually displaced structure. The extending portion extends outward from one side of the connecting portion and is bent toward a direction adjacent to the inner second conductive portion, wherein the extending portion has a screw hole.

[0011] In one embodiment, the insulating portion includes a plurality of positioning holes disposed on the first side of the base and spaced apart from each other. Each second copper bar includes a positioning post, and the plurality of positioning posts of the plurality of second copper bars are respectively inserted into the plurality of positioning holes of the insulating portion.

[0012] In one embodiment, the insulating portion includes at least one supporting wall protruding outward from the first side of the base and extending to support the plurality of second copper bars.

[0013] In one embodiment, the at least one first copper bar includes an upper first copper bar and a lower first copper bar, which are spaced apart in a first direction, wherein the first direction is a direction from the first side toward the second side.

[0014] In one embodiment, the insulating portion is at least partially coated on at least one first copper bar by coating injection molding or ultrasonic welding, so that the base is an integrated single-piece structure.

[0015] In one embodiment, the insulating portion includes a bearing element disposed on a first side of the base and having a receiving groove. The busbar assembly includes a temperature sensor received in the receiving groove and disposed adjacent to the first copper busbar.

[0016] In one embodiment, the base includes a fastener disposed in the receiving groove and configured to fix the temperature sensor.

[0017] To achieve the above-mentioned purpose, the utility model provides a base for a busbar assembly of a motor stator, wherein the motor stator includes a stator core and a plurality of flat wire windings, the plurality of flat wire windings are wound on the stator core and include a plurality of first outgoing wires and a plurality of second outgoing wires, the busbar assembly is arranged at one end of the motor stator and includes a plurality of second copper bars, the plurality of second copper bars include a plurality of second conductive portions correspondingly abutting against the plurality of second outgoing wires. The base includes a first side, a second side, at least one first copper bar and an insulating portion. The first side is structured to arrange the plurality of second copper bars. The first side and the second side are opposite sides, and the second side is adjacent to the end of the motor stator. At least one first copper bar is arranged between the first side and the second side, and includes a plurality of first conductive portions exposed to the base, wherein the plurality of first conductive portions are structured to abut against the plurality of first outgoing wires of the plurality of flat wire windings. The insulating portion at least partially covers at least one first copper bar, so that the base is an integrated single-piece structure.

[0018] The utility model has the beneficial effect that the utility model provides a busbar assembly suitable for a motor stator. The busbar assembly includes a base and a plurality of second copper bars, wherein the base includes at least one first copper bar and an insulating portion. The insulating portion is at least partially coated on the first copper bar by, for example but not limited to, coating injection molding or ultrasonic welding, so that the base is an integrated single-piece structure, thereby simplifying the structure and assembly process to improve assembly efficiency and reduce the generation of manual errors during assembly operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1A It is a structural schematic diagram of a motor stator and a busbar assembly according to an embodiment of the utility model.

[0020] Figure 1B A schematic structural diagram of a motor stator and a busbar assembly according to an embodiment of the present invention at another angle.

[0021] Figure 2A It is a structural schematic diagram of a busbar assembly according to an embodiment of the utility model.

[0022] Figure 2B It is a schematic structural diagram of a busbar assembly according to an embodiment of the present invention at another angle.

[0023] Figure 3A It is a structural exploded view of a busbar assembly according to an embodiment of the present invention.

[0024] Figure 3B It is a structural exploded view of a busbar assembly according to an embodiment of the present invention at another angle.

[0025] Figure 4 It is a schematic structural diagram of a second copper busbar according to an embodiment of the utility model.

[0026] Figure 5A This is a structural exploded view of a base according to an embodiment of the present invention.

[0027] Figure 5B This is a structural exploded view of a base according to an embodiment of the present invention at another angle.

[0028] The reference numerals are as follows:

[0029] 1: Busbar assembly

[0030] 10: Base

[0031] 11: First side

[0032] 12: Second side

[0033] 13: The first copper bar

[0034] 13a: The first copper bar on the upper side

[0035] 13b: The first copper bar on the lower side

[0036] 131: First connecting portion

[0037] 131a: Inner first conductive portion

[0038] 131b: first outer conductive portion

[0039] 132: Heat transfer part

[0040] 14: Insulation

[0041] 141: Positioning hole

[0042] 142: Support wall

[0043] 143: Load-bearing components

[0044] 143a: Receiving groove

[0045] 144: Perforation

[0046] 15: Third side

[0047] 16: Fourth side

[0048] 20: The second copper bar

[0049] 21: Second connecting part

[0050] 21a: Inner second guide portion

[0051] 21b: Outer second connecting portion

[0052] 22: Positioning column

[0053] 23: Connection

[0054] 24: Extension

[0055] 24a: Screw hole

[0056] 40: Temperature sensor

[0057] 50: Fasteners

[0058] 9: Motor stator

[0059] 91: Stator core

[0060] 911: Hollow

[0061] 92: Flat wire winding

[0062] 93: Wire Trough

[0063] 94: First End

[0064] 95: Second End

[0065] 96: First qualifying

[0066] 97: Second place

[0067] A: Center axis

[0068] D1: First direction

[0069] X, Y, Z: Axis DETAILED DESCRIPTION

[0070] Some typical embodiments that embody the features and advantages of the utility model will be described in detail in the following description. It should be understood that the utility model can have various changes in different ways, all of which do not depart from the scope of the utility model, and the description and drawings therein are essentially used for illustrative purposes rather than for limiting the utility model. For example, if the following content of the utility model describes that a first feature is set on or above a second feature, it means that it includes an embodiment in which the first feature and the second feature are directly in contact, and also includes an embodiment in which the additional feature can be set between the first feature and the second feature, so that the first feature and the second feature may not be in direct contact. In addition to the orientation shown in the drawings, spatially related terms are used to cover different orientations of the device in use or operation. The device may also be positioned in other ways (for example, rotated 90 degrees or located in other orientations), and the description of the spatially related terms used is interpreted accordingly. In addition, when a component is referred to as "connected to" or "coupled to" another component, it may be directly connected to or coupled to another component, or there may be an intervening component. In addition, it is understood that although the terms "first", "second", etc. may be used in the claims to describe different components, these components should not be limited by these terms, and these components described in the embodiments are represented by different component symbols. These terms are used to distinguish different components. For example, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component without departing from the scope of the embodiments.

[0071] Please refer to Figure 1A and Figure 1B . Figure 1A It is a structural schematic diagram of a motor stator and a busbar assembly according to an embodiment of the utility model. Figure 1B A schematic diagram of the structure of a motor stator and a busbar assembly of an embodiment of the utility model at another angle. In this embodiment, the motor stator 9 includes a stator core 91 and a plurality of flat wire windings 92. The stator core 91 includes a plurality of wire slots 93, which are arranged separately from each other. The plurality of flat wire windings 92 are respectively arranged in the corresponding plurality of wire slots 93 of the stator core 91, and are wound around the stator core 91. The motor stator 9 includes a first end 94 and a second end 95, and the plurality of flat wire windings 92 include a plurality of first outgoing wires 96 and a plurality of second outgoing wires 97, wherein the first end 94 and the second end 95 are two opposite ends of the motor stator 9. The stator core 91 includes a hollow portion 911 and a central axis A, wherein the central axis A passes through the hollow portion 911. The stator core 91 of the motor stator 9 is, for example, arranged in an annular shape along the axial direction (Z-axis direction) of the central axis A, and the busbar assembly 1 is arranged at the first end 94 of the motor stator 9. In one embodiment, the motor stator 9 is a flat wire motor stator, and the flat wire winding 92 is a hairpin flat wire winding, but the present invention is not limited thereto.

[0072] Figure 2A It is a structural schematic diagram of a busbar assembly according to an embodiment of the utility model. Figure 2B It is a schematic structural diagram of a busbar assembly according to an embodiment of the present invention at another angle. Figure 3A It is a structural exploded view of a busbar assembly according to an embodiment of the present invention. Figure 3B It is a structural exploded view of a busbar assembly according to an embodiment of the present invention at another angle. Figure 4 It is a schematic structural diagram of a second copper busbar according to an embodiment of the utility model. Figure 5A This is a structural exploded view of a base according to an embodiment of the present invention. Figure 5B This is a structural exploded view of the base of an embodiment of the utility model from another angle. Figures 1A to 5B As shown, the busbar assembly 1 includes a base 10 and a plurality of second copper bars 20. The base 10 includes a first side 11, a second side 12, at least one first copper bar 13 and an insulating portion 14, wherein the first side 11 and the second side 12 are opposite sides, and the second side 12 is adjacent to the first end 94 of the motor stator 9. At least one first copper bar 13 is disposed between the first side 11 and the second side 12, and is structured to abut against a plurality of first outgoing wires 96 of the motor stator 9. The insulating portion 14 at least partially covers the first copper bar 13, so that the base 10 is an integrated single-piece structure. The plurality of second copper bars 20 are disposed on the first side 11 of the base 10, and are respectively structured to abut against a plurality of second outgoing wires 97 of the motor stator 9. The base 10 of an integrated single-piece structure is formed by covering the first copper bar 13 with the insulating portion 14, which can not only reduce the number of components of the busbar assembly 1 during assembly, simplify the assembly process, but also improve the assembly efficiency and reduce the generation of manual errors during assembly. In this embodiment, the plurality of second copper bars 20 have the same structure and profile, which facilitates manufacturing and replacement, and reduces costs. In this embodiment, the insulating portion 14 can be coated on the first copper bar 13 by coating injection molding or ultrasonic welding. It should be emphasized that the insulating portion 14 is not limited to the aforementioned embodiment, and can be adjusted according to actual application requirements.

[0073] In this embodiment, the base 10 is an arc-shaped rectangular parallelepiped, which can be arranged at the first end 94 of the motor stator 9 along the circumference of the motor stator 9. A plurality of second copper bars 20 are arranged at the first side 11 of the base 10 along the circumference of the motor stator 9. The outer contour of the busbar assembly 1 matches and corresponds to the outer contour of the first end 94 of the motor stator 9, thereby optimizing the spatial configuration and reducing the overall volume of the motor. In this embodiment, the first copper bar 13 includes a plurality of first conductive portions 131, and each second copper bar 20 includes a plurality of second conductive portions 21. The plurality of first conductive portions 131 of the first copper bar 13 protrude outward from the side wall surface of the insulating portion 14 and are exposed to the insulating portion 14, thereby the plurality of first conductive portions 131 can be respectively abutted with the plurality of first outgoing wires 96 along the radial direction of the motor stator 9. The plurality of second conductive portions 21 of the plurality of second copper bars 20 are respectively abutted with the plurality of second outgoing wires 97 along the radial direction of the motor stator 9. Since most of the first copper bar 13 is embedded in the insulating portion 14 and is only exposed outside the insulating portion 14 through the first conductive portions 131 , the first copper bar 13 can be electrically isolated from the second copper bars 20 or other peripheral components.

[0074] In one embodiment, the plurality of second conductive portions 21 of each second copper bar 20 include an inner second conductive portion 21a and an outer second conductive portion 21b, wherein the inner second conductive portion 21a is closer to the central axis A of the stator core 91 than the outer second conductive portion 21b. The inner second conductive portion 21a or the outer second conductive portion 21b of each second copper bar 20 at least partially overlaps with the outer second conductive portion 21b or the inner second conductive portion 21a of the adjacent second copper bar 20 in a visual direction along the radial direction of the motor stator 9. In one embodiment, the inner second conductive portion 21a is, for example, disposed along the inner periphery of the motor stator 9, and the outer second conductive portion 21b is disposed along the outer periphery of the motor stator 9, and the inner second conductive portion 21a or the outer second conductive portion 21b of the adjacent second copper bar 20 overlaps in a visual direction along the radial direction of the motor stator 9 corresponding to the inner second conductive portion 21a or the outer second conductive portion 21b. Specifically, when a plurality of second copper bars 20 are disposed on the first side 11 of the base 10 and arranged in sequence, except for the second copper bars 20 located at the head and tail ends, the inner second conductive portion 21a of each of the remaining second copper bars 20 corresponds to the outer second conductive portion 21b of the adjacent second copper bar 20, and the outer second conductive portion 21b corresponds to the inner second conductive portion 21a of the adjacent second copper bar 20. Adjacent second copper bars 20 can be closely arranged by staggering the corresponding second conductive portions 21, thereby optimizing the spatial configuration of the busbar assembly 1 and improving the space utilization. In this embodiment, each second copper bar 20 further includes a connecting portion 23, which is connected between the plurality of second conductive portions 21, that is, connected between the inner second conductive portion 21a and the outer second conductive portion 21b. The connecting portion 23 is disposed between the inner periphery and the outer periphery of the motor stator 9, and has a bending section, thereby forming a structure in which the inner second conducting portion 21a and the outer second conducting portion 21b are displaced from each other. In one embodiment, each second copper bar 20 includes an extension portion 24, which extends outward from one side of the connecting portion 23 and is bent toward the direction adjacent to the inner second conducting portion 21a, wherein the extension portion 24 has a screw hole 24a. Through the screw hole 24a of the extension portion 24, it can be assembled and fixed with the corresponding external wire by screw locking. In other embodiments, the second copper bar 20 can also be assembled with the corresponding external wire, for example, by welding. It should be emphasized that the structure and method of assembling the second copper bar 20 with the corresponding external wire are not limited to the aforementioned embodiments, and can be adjusted according to actual application requirements.

[0075] In one embodiment, at least one first copper bar 13 of the busbar assembly 1 includes two first copper bars 13, which are neutral copper bars. The number of the plurality of second copper bars 20 is 3n (where n is an integer greater than or equal to 1), for example, the plurality of second copper bars 20 includes three second copper bars 20, which are respectively a U-phase copper bar, a V-phase copper bar and a W-phase copper bar. The base 10 also includes a third side 15 and a fourth side 16, which are respectively connected between the first side 11 and the second side 12, wherein the third side 15 and the fourth side 16 are opposite sides, and the third side 15 is closer to the central axis A of the stator core 91 than the fourth side 16. The plurality of first conductive portions 131 of the first copper bar 13, for example, include an inner first conductive portion 131a and an outer first conductive portion 131b. The inner first conductive portion 131a is exposed from the third side 15 of the base 10 and is disposed along the inner periphery of the motor stator 9, and the outer first conductive portion 131b is exposed from the fourth side 16 of the base 10 and is disposed along the outer periphery of the motor stator 9. The inner second conductive portion 21a of the second copper bar 20, which is the U-phase / V-phase / W-phase copper bar, is adjacent to the third side 15 of the base 10 and is disposed along the inner periphery of the motor stator 9, and the outer second conductive portion 21b is adjacent to the fourth side 16 of the base 10 and is disposed along the outer periphery of the motor stator 9.

[0076] In one embodiment, the plurality of first outgoing wires 96 of the motor stator 9 are neutral outgoing wires, and the plurality of second outgoing wires 97 of the motor stator 9 are respectively a plurality of U-phase outgoing wires, a plurality of V-phase outgoing wires, and a plurality of W-phase outgoing wires. In some embodiments, the plurality of first outgoing wires 96 of the motor stator 9 include, for example, twelve neutral outgoing wires, and the twelve neutral outgoing wires correspond to the neutral copper bar. The motor stator 9 includes, for example, twelve second outgoing wires 97, including four U-phase outgoing wires, four V-phase outgoing wires, and four W-phase outgoing wires. The four U-phase outgoing wires correspond to the U-phase copper bar, the four V-phase outgoing wires correspond to the V-phase copper bar, and the four W-phase outgoing wires correspond to the W-phase copper bar. Through the configuration of the aforementioned outgoing wires and copper bars, the motor forms a three-phase circuit through the busbar assembly 1 of the utility model.

[0077] In one embodiment, a portion of the twelve neutral line outlets are arranged along the inner periphery of the motor stator 9, and the rest are arranged along the outer periphery of the motor stator 9, for example, six neutral line outlets are arranged along the inner periphery of the motor stator 9, and six neutral line outlets are arranged along the outer periphery of the motor stator 9. A portion of the four U-phase / V-phase / W-phase outlets are arranged along the inner periphery of the motor stator 9, and the rest are arranged along the outer periphery of the motor stator 9, for example, two U-phase / V-phase / W-phase outlets are arranged along the inner periphery of the motor stator 9, and two U-phase / V-phase / W-phase outlets are arranged along the outer periphery of the motor stator 9. The inner first conductive portion 131a of the first copper bar 13 is arranged along the inner periphery of the motor stator 9 and respectively abuts against the neutral line outlets arranged along the inner periphery of the motor stator 9, and the outer first conductive portion 131b of the first copper bar 13 is arranged along the outer periphery of the motor stator 9 and respectively abuts against the neutral line outlets arranged along the outer periphery of the motor stator 9. The inner second conductive portion 21a of the second copper bar 20, which is a U-phase / V-phase / W-phase copper bar, is arranged along the inner periphery of the motor stator 9 and respectively abuts against the U-phase / V-phase / W-phase outlets arranged along the inner periphery of the motor stator 9, and the outer second conductive portion 21b of the second copper bar 20 is arranged along the outer periphery of the motor stator 9 and respectively abuts against the U-phase / V-phase / W-phase outlets arranged along the outer periphery of the motor stator 9. It should be noted that the number and configuration of the first outlet wire 96, the second outlet wire 97, the first copper bar 13, the second copper bar 20, the first conductive portion 131, and the second conductive portion 21 of the utility model are not limited to the above-mentioned embodiment, and can be adjusted according to actual applications, and will not be described in detail here. By arranging multiple outlet wires and copper bars along the inner periphery and the outer periphery of the motor stator 9, the space configuration can be optimized to reduce the overall volume of the motor.

[0078] In the present embodiment, the insulating portion 14 includes a plurality of positioning holes 141, which are disposed on the first side 11 of the base 10 and are arranged at intervals from each other. The number of the plurality of positioning holes 141 matches the number of the plurality of second copper bars 20, but is not limited thereto. Each second copper bar 20 includes a positioning column 22, which protrudes outward along the lower edge of the connecting portion 23. The positioning column 22 of the second copper bar 20 can be inserted into the corresponding positioning hole 141 of the base 10 along the Z-axis direction, thereby positioning and fixing the second copper bar 20 to the first side 11 of the base 10. In addition, since the positioning column 22 is disposed at the lower edge of the connecting portion 23, that is, disposed between the two second conductive portions 21, the second copper bar 20 can achieve the function of balancing the weight when it is configured on the first side 11 of the base 10.

[0079] In this embodiment, the insulating portion 14 includes at least one supporting wall 142, which protrudes outward from the first side 11 of the base 10 and is extended on the first side 11. At least one supporting wall 142 of the insulating portion 14 is structured to abut the corresponding second copper bar 20, so as to provide support in the vertical direction (i.e., the Z-axis direction) and assist the second copper bar 20 to be positioned on the base 10. In one embodiment, the insulating portion 14 has a single supporting wall 142, and the single supporting wall 142 is structured to abut three second copper bars 20 separated from each other, thereby assisting the aforementioned three second copper bars 20 to be positioned on the base 10. It should be emphasized that the number of supporting walls 142 of the insulating portion 14 is not limited to the above-mentioned embodiment, and can be adjusted according to actual application requirements, for example, the insulating portion 14 has three supporting walls 142 separated from each other. In some embodiments, the aforementioned positioning hole 141 can be set in the wall surface of the supporting wall 142, but is not limited thereto.

[0080] In this embodiment, if Figure 5A and Figure 5B As shown, at least one first copper bar 13 includes two first copper bars 13, such as an upper first copper bar 13a and a lower first copper bar 13b, wherein the upper first copper bar 13a and the lower first copper bar 13b are spaced apart in the first direction D1 (Z-axis direction). The first direction D1 is, for example, the direction from the first side 11 to the second side 12, and is parallel to the axial direction of the central axis A. The upper first copper bar 13a and the lower first copper bar 13b are respectively covered by the insulating portion 14 and separated to serve as neutral copper bars in different circuits. By spacing the upper first copper bar 13a and the lower first copper bar 13b in the first direction D1, a current shunting effect can be achieved, reducing the current carrying capacity required for a single copper bar, thereby reducing the volume required for the copper bar. It should be emphasized that the number of first copper bars 13 is not limited to the above-mentioned embodiments, and can be adjusted according to actual application requirements.

[0081] In the present embodiment, the insulating portion 14 includes a bearing element 143, which is disposed on the first side 11 of the base 10 and has a receiving groove 143a. The busbar assembly 1 includes a temperature sensor 40, which is accommodated in the receiving groove 143a of the bearing element 143 and is adjacent to the first copper bar 13 to monitor the temperature of the motor. In the present embodiment, the first copper bar 13 also includes a heat-conducting portion 132, and the insulating portion 14 includes a through hole 144, which is connected to the receiving groove 143a of the bearing element 143 and is correspondingly arranged with the heat-conducting portion 132 of the first copper bar 13. The heat-conducting portion 132 of the first copper bar 13 is, for example, partially arranged in the receiving groove 143a by penetrating the insulating portion 14 through the corresponding through hole 144 along the Z-axis direction, and is adjacent to or attached to the temperature sensor 40, thereby improving the accuracy of the motor temperature monitoring. In some embodiments, the base 10 includes a fastener 50, which is disposed in the receiving groove 143a and is structured to fix the temperature sensor 40. The fastener 50 is, for example, a metal clip, which clamps and fixes the temperature sensor 40 through the elastic force of metal deformation. In some embodiments, the fastener 50 can also be a clamp, which fixes the temperature sensor 40 by locking. In other embodiments, the temperature sensor 40 can also be fixed in the receiving groove 143a by means of, for example, glue. It should be emphasized that the way the temperature sensor 40 is fixed to the receiving groove 143a and the type or material of the fastener are not limited to the aforementioned embodiments, and can be adjusted according to actual application requirements.

[0082] In summary, the utility model provides a busbar assembly suitable for a motor stator. The busbar assembly includes a base and a plurality of second copper bars, wherein the base includes at least one first copper bar and an insulating portion. The insulating portion is at least partially coated on the first copper bar by, for example but not limited to, coating injection molding or ultrasonic welding, so that the base is an integrated single-piece structure, thereby simplifying the structure and assembly process to improve assembly efficiency and reduce the generation of manual errors during assembly operations. In addition, the second copper bar includes an inner second conductive portion and an outer second conductive portion, and the inner / outer second conductive portion of the second copper bar overlaps with the outer / inner second conductive portion of the adjacent second copper bar in the radial direction of the motor stator, that is, the adjacent second copper bars are closely arranged by the staggered arrangement of the second conductive portions, thereby optimizing the spatial configuration of the busbar assembly and improving space utilization. Furthermore, the second copper bar includes a positioning column, and the insulating portion of the base has a positioning hole. The second copper bar can achieve positioning effect and provide horizontal support by inserting the positioning column into the corresponding positioning hole. In addition, the base also has at least one supporting wall, which can provide vertical support by supporting the second copper bar. In addition, the base includes an upper first copper bar and a lower first copper bar spaced apart in the vertical direction, thereby shunting the current in different circuits, reducing the current carrying capacity required for a single copper bar, and thus reducing the volume required for the copper bar. Furthermore, the base of the busbar assembly includes a bearing element, which can carry and accommodate a temperature sensor, thereby realizing accurate monitoring of the motor temperature.

[0083] The present invention can be modified in various ways by those skilled in the art, but all of them are within the protection scope of the appended claims.

Claims

1. A busbar assembly for a motor stator, characterized in that: The motor stator comprises a stator core and a plurality of flat wire windings, wherein the plurality of flat wire windings are wound on the stator core and comprise a plurality of first outgoing wires and a plurality of second outgoing wires, wherein the busbar assembly is disposed at one end of the motor stator and comprises: A base, comprising: a first side; a second side, wherein the first side and the second side are opposite sides, and the second side is adjacent to the end of the motor stator; At least one first copper bar is disposed between the first side and the second side and is structured to abut against the first outgoing wires of the flat wire windings; and an insulating portion, at least partially covering the at least one first copper bar, so that the base is an integrated single-piece structure; and A plurality of second copper bars are disposed on the first side of the base and are respectively structured to abut against the plurality of second outgoing wires of the plurality of flat wire windings.

2. The busbar assembly according to claim 1, wherein: The base is an arc-shaped rectangular parallelepiped and is arranged at the end of the motor stator along a circumferential direction of the motor stator. The plurality of second copper bars are arranged at the first side of the base along the circumferential direction of the motor stator.

3. The busbar assembly according to claim 1, wherein: Each of the first copper bars includes a plurality of first conductive connection portions, and each of the second copper bars includes a plurality of second conductive connection portions, wherein the base further includes a third side and a fourth side, respectively connected between the first side and the second side, and the third side and the fourth side are opposite sides, wherein the plurality of first conductive connection portions are exposed from the third side and the fourth side of the base, and respectively abut against the plurality of first outgoing wires along a radial direction of the motor stator, wherein the plurality of second conductive connection portions of the plurality of second copper bars respectively abut against the plurality of second outgoing wires along the radial direction of the motor stator.

4. The busbar assembly according to claim 3, characterized in that: The plurality of second conductive portions of each second copper bar include an inner second conductive portion and an outer second conductive portion, and the inner second conductive portion or the outer second conductive portion of each second copper bar at least partially overlaps with the outer second conductive portion or the inner second conductive portion of an adjacent second copper bar in a visual direction along the radial direction of the motor stator.

5. The busbar assembly according to claim 4, characterized in that: Each of the second copper bars further comprises: a connecting portion connected between the inner second conductive portion and the outer second conductive portion and having a bending section, wherein the bending section enables the inner second conductive portion and the outer second conductive portion to form a structure that is offset from each other; and An extension portion extends outward from a side edge of the connecting portion and is bent toward a direction adjacent to the inner second conductive portion, wherein the extension portion has a screw hole.

6. The busbar assembly according to claim 1, wherein: The insulating part includes a plurality of positioning holes, which are arranged on the first side of the base and spaced apart from each other, wherein each of the second copper bars includes a positioning column, and the plurality of positioning columns of the plurality of second copper bars are respectively inserted into the plurality of positioning holes of the insulating part.

7. The busbar assembly according to claim 1, wherein: The insulating portion includes at least one supporting wall, which protrudes outward from the first side of the base and is extended to be structured to support and support the plurality of second copper bars.

8. The busbar assembly according to claim 1, wherein: The at least one first copper bar includes an upper first copper bar and a lower first copper bar, which are arranged at intervals in a first direction, and the first direction is the direction from the first side to the second side.

9. The busbar assembly according to claim 1, wherein: The insulating part is at least partially coated on the at least one first copper bar by coating injection molding or ultrasonic welding, so that the base is an integrated single-piece structure.

10. The busbar assembly according to claim 1, wherein: The insulating part includes a bearing element, which is arranged on the first side of the base and has a receiving groove, wherein the busbar assembly includes a temperature sensor, which is received in the receiving groove and adjacent to the first copper busbar.

11. The busbar assembly according to claim 10, wherein: The base includes a fastener which is arranged in the accommodating groove and is structured to fix and engage the temperature sensor.

12. A base for a busbar assembly of a motor stator, characterized in that: The motor stator comprises a stator core and a plurality of flat wire windings, the plurality of flat wire windings are wound on the stator core and comprise a plurality of first outgoing wires and a plurality of second outgoing wires, the busbar assembly is arranged at one end of the motor stator and comprises a plurality of second copper bars, the plurality of second copper bars comprise a plurality of second conductive portions correspondingly abutting against the plurality of second outgoing wires, wherein the base comprises: A first side, configured to dispose the plurality of second copper bars; a second side, wherein the first side and the second side are opposite sides, and the second side is adjacent to the end of the motor stator; At least one first copper bar is disposed between the first side and the second side and includes a plurality of first conductive portions exposed to the base, wherein the plurality of first conductive portions are arranged to abut against the plurality of first outgoing wires of the plurality of flat wire windings; and An insulating portion at least partially covers the at least one first copper bar, so that the base is an integrated single-piece structure.

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