Flat wire stator assembly and busbar thereof
By using busbars made of flexible copper strips and insulating materials in the stator assembly of flat wire card issuing motors, the assembly difficulties and shear stress problems of traditional hard copper strips are solved, and assembly quality and safety and reliability are improved.
Patent Information
- Application Number
- CN202422149219.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-03
- Publication Date
- 2025-06-17
- Estimated Expiration
- 2034-09-03
AI Technical Summary
The traditional hard copper busbar is difficult to assemble in the stator assembly of the flat wire issuing motor, and it is easy to apply shear stress to the flat wire, resulting in damage to the flat wire under vibration or mechanical impact, and poor safety and reliability.
U-phase copper strips, V-phase copper strips, W-phase copper strips, span-layer copper strips and zero-point copper strips are used, combined with busbar brackets made of insulating material injection molding, forming a flexible busbar, which can adapt to the distance changes between the flat wires of the zipper, be compatible with assembly errors, and avoid applying shear stress to the flat wires of the zipper.
It reduces assembly difficulty, improves assembly quality and efficiency, enhances the safety and reliability of flat wire stator components, and avoids damage to the flat wire caused by vibration or mechanical impact.
Smart Images
Figure CN222996324U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of permanent magnet synchronous motors, in particular to a flat wire stator assembly and a bus bar thereof. Background Art
[0002] With the development of new energy vehicles, the performance requirements for vehicle motors are also getting higher and higher. Due to its high slot fill factor, high power density, good heat dissipation performance and NVH performance, the flat wire hairpin motor can greatly reduce the height of the motor winding end, reduce the copper consumption, reduce the copper loss of the winding, and improve the efficiency of the vehicle motor. Therefore, it has gradually become the new favorite of motor enterprises.
[0003] With the increase in the number of parallel branches and layers of the stator assembly of the flat wire hairpin motor, its lead wires become more and more complex. To reduce the process difficulty, reduce the frequency of welding errors and improve the manufacturability of the stator assembly, the flat wire hairpin motor mostly uses a bus bar to organize its lead wires, thereby reducing the manufacturing of the special-shaped wire of the winding. The traditional bus bar is a hard copper bar. The hard copper bar not only cannot fully accommodate the assembly error, increasing the assembly difficulty of the bus bar on the stator assembly, but also the hard copper bar can apply shear stress to the hairpin flat wire, and it is extremely easy to cause damage to the hairpin flat wire under vibration and mechanical shock, and the safety and reliability are poor. Summary of the Utility Model
[0004] Aiming at the above-mentioned defects existing in the prior art, the utility model aims to provide a flat wire stator assembly and a bus bar thereof. The flat wire stator assembly and the bus bar can accommodate the assembly error, reduce the assembly difficulty, improve the assembly quality and efficiency, and have high safety and reliability.
[0005] To solve the above technical problems, the technical solution adopted by the utility model is:
[0006] A bus bar includes a bus bar bracket, and a flexible U-phase copper bar, a V-phase copper bar, a W-phase copper bar, a cross-layer copper bar and a zero-point copper bar arranged on the bus bar bracket; the U-phase copper bar, the V-phase copper bar and the W-phase copper bar are respectively used for connecting with the branch lead wires of the corresponding parallel branches of the flat wire winding; the flat wire winding includes multiple layers of hairpin flat wires arranged inside and outside, and the cross-layer copper bar is used for cross-layer bridging of the two hairpin flat wires of the same branch; the zero-point copper bar is used for connecting with the zero-line lead wire of the flat wire winding.
[0007] Wherein, the U-phase copper bar, the V-phase copper bar, the W-phase copper bar, the cross-layer copper bar and the zero-point copper bar are all formed by stacking multiple layers of flexible copper foils.
[0008] Wherein, the bus bar bracket is injection molded from an insulating material, and the U-phase copper bar, the V-phase copper bar, the W-phase copper bar, the cross-layer copper bar and the zero-point copper bar are all embedded in the bus bar bracket.
[0009] Among them, lead wire through holes are reserved on the busbar support, and the U-phase copper bar, the V-phase copper bar, the W-phase copper bar, the cross-layer copper bar, and the neutral point copper bar all extend out through the corresponding lead wire through holes.
[0010] Among them, the insulating material is epoxy resin.
[0011] Among them, the U-phase copper bar, the V-phase copper bar, and the W-phase copper bar all have one wiring terminal and two welding parts. The wiring terminal is used to connect with the corresponding busbar of the inverter, and the two welding parts are respectively used to weld with the corresponding branch lead wire.
[0012] Among them, wiring waist holes are provided on the wiring terminal.
[0013] Among them, the cross-layer copper bar has two welding arms. The two welding arms are located on the same side of the cross-layer copper bar and are used to weld with the corresponding hairpin flat wire.
[0014] Among them, the neutral point copper bar has three welding ends, and the welding ends are used to connect with the neutral line lead wire.
[0015] A flat wire stator assembly includes a stator core, a flat wire winding arranged in the stator core, and also includes the busbar in the above technical solution. The busbar is welded to the flat wire winding.
[0016] Adopting the above technical solution, the beneficial effect of the present utility model is:
[0017] For the flat wire stator assembly and its busbar provided by the present utility model, since the U-phase copper bar, V-phase copper bar, W-phase copper bar, cross-layer copper bar, and neutral point copper bar of the busbar are all flexible, therefore, each copper bar can not only well adapt to the distance change between the hairpin flat wires, be compatible with the assembly error, but also avoid applying shear stress to the hairpin flat wires, play a role in buffering and shock absorption, and avoid the problem of damage to the hairpin flat wires caused by vibration and mechanical shock. In summary, compared with the prior art, the flat wire stator assembly and its busbar of the present utility model reduce the assembly difficulty, improve the assembly quality and efficiency, and have high safety and reliability. Description of the Drawings
[0018] Figure 1 is a partial structural schematic diagram of the flat wire stator assembly of the present utility model;
[0019] Figure 2 is Figure 1 the structural schematic diagram of the busbar in
[0020] Figure 3 is Figure 1Schematic diagram of the connection between the middle busbar and the flat wire winding;
[0021] Figure 4 is Figure 3 Schematic diagram of the structure of the U-phase copper bar in the middle;
[0022] Figure 5 is Figure 3 Schematic diagram of the structure of the V-phase copper bar in the middle;
[0023] Figure 6 is Figure 3 Schematic diagram of the structure of the W-phase copper bar in the middle;
[0024] Figure 7 is Figure 3 Schematic diagram of the structure of the cross-layer copper bar in the middle;
[0025] Figure 8 is Figure 3 Schematic diagram of the structure of the neutral point copper bar in the middle;
[0026] Figure 9 is Figure 3 Schematic diagram of the details of the U-phase copper bar, V-phase copper bar, W-phase copper bar, cross-layer copper bar and neutral point copper bar in the middle;
[0027] In the figure: 1. Stator core; 2. Flat wire winding; 3. Busbar; 31. Busbar support; 310. Through hole for U-phase winding lead wire; 311. Through hole for V-phase winding lead wire; 312. Through hole for W-phase winding lead wire; 313. Through hole for cross-layer hairpin flat wire lead wire; 314. Through hole for neutral wire lead wire; 32. U-phase copper bar; 321. Terminal; 322. Welding part; 323. Wiring waist hole; 33. V-phase copper bar; 34. W-phase copper bar; 35. Cross-layer copper bar; 351. Welding arm; 36. Neutral point copper bar; 361. Welding end; 100. Copper foil. Specific implementation manner
[0028] In order to make the objectives, technical solutions and advantages of the present utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present utility model and are not used to limit the present utility model.
[0029] As Figures 1 to 9 shown, this embodiment discloses a flat wire stator assembly, including a stator core 1 and a flat wire winding 2 disposed within the stator core 1. It further includes a busbar 3, and the busbar 3 is welded to the flat wire winding 2. Using the busbar 3 to organize the lead wires of the flat wire winding 2 reduces the manufacturing of the special-shaped wires of the winding, lowers the process difficulty, reduces the frequency of welding errors, and improves the manufacturability of the stator assembly.
[0030] The busbar 3 in this embodiment includes a busbar bracket 31, and a flexible U-phase copper bar 32, V-phase copper bar 33, W-phase copper bar 34, cross-layer copper bar 35 and neutral copper bar 36 arranged on the busbar bracket 31; the U-phase copper bar 32, V-phase copper bar 33 and W-phase copper bar 34 are respectively connected to the branch lead-out wires of the parallel branches of the corresponding windings in the flat wire winding 2; the flat wire winding 2 includes multiple layers of hairpin flat wires arranged inside and outside, and the cross-layer copper bar 35 bridges two hairpin flat wires of the same branch across layers; the neutral copper bar 36 is correspondingly connected to the neutral lead-out wire of the flat wire winding 2.
[0031] Since the U-phase copper bar 32, V-phase copper bar 33, W-phase copper bar 34, cross-layer copper bar 35 and neutral copper bar 36 of the busbar 3 are all flexible, each copper bar can not only well adapt to the distance change between the hairpin flat wires, be compatible with the assembly error, thereby reducing the assembly difficulty, improving the assembly quality and efficiency, but also avoid applying shear stress to the hairpin flat wires, play a role in buffering and shock absorption, avoid the problem of damage to the hairpin flat wires caused by vibration and mechanical impact, and improve the safety and reliability.
[0032] Specifically, the flat wire winding 2 in this embodiment includes a U-phase winding, a V-phase winding and a W-phase winding. The U-phase winding, V-phase winding and W-phase winding each have two parallel branches. The U-phase copper bar 32 is correspondingly connected to the branch lead-out wires of the two parallel branches of the U-phase winding; the V-phase copper bar 33 is correspondingly connected to the branch lead-out wires of the two parallel branches of the V-phase winding; the W-phase copper bar 34 is correspondingly connected to the branch lead-out wires of the two parallel branches of the W-phase winding; the cross-layer copper bar 35 bridges two hairpin flat wires of the same branch of the U-phase winding, V-phase winding or W-phase winding across layers; the neutral copper bar 36 is correspondingly connected to the neutral lead-out wires of the U-phase winding, V-phase winding and W-phase winding.
[0033] Since the copper foil 100 is a conductive part with high conductivity, fast heat dissipation and easy bending, and has the characteristics of large current carrying capacity, small resistance value and durability, etc., the U-phase copper bar 32, V-phase copper bar 33, W-phase copper bar 34, cross-layer copper bar 35 and neutral copper bar 36 in this embodiment are all preferably formed by stacking multiple layers of flexible copper foil 100. Of course, the copper foil 100 can also be replaced by aluminum foil, and the specific selection is based on actual needs, and this embodiment does not limit this.
[0034] The busbar bracket 31 in this embodiment is injection molded from an insulating material, and the U-phase copper bar 32, V-phase copper bar 33, W-phase copper bar 34, cross-layer copper bar 35 and neutral copper bar 36 are all embedded in the busbar bracket 31. Using an insulating material improves the insulation and voltage withstand performance of the busbar bracket 31, and embedding each copper bar in the busbar bracket 31 in the form of inserts improves the connection strength between the various components of the busbar 3.
[0035] Since epoxy resin is an excellent insulating material and has a strong adhesion to metals, the insulating material in this embodiment is preferably epoxy resin.
[0036] For the convenience of welding, lead-out holes are reserved on the busbar bracket 31 in this embodiment. The U-phase copper bar 32, V-phase copper bar 33, W-phase copper bar 34, cross-layer copper bar 35 and neutral copper bar 36 all extend out through the corresponding lead-out holes.
[0037] In this embodiment, there is one U-phase copper bar 32, one V-phase copper bar 33 and one W-phase copper bar 34 respectively. The U-phase copper bar 32, V-phase copper bar 33 and W-phase copper bar 34 all have one wiring terminal 321 and two welding parts 322. The wiring terminal 321 is used to connect with the corresponding busbar of the inverter, and the two welding parts 322 are respectively used to weld with the corresponding branch lead-out wires; there are multiple cross-layer copper bars 35, and each cross-layer copper bar 35 has two welding arms 351. The two welding arms 351 are located on the same side of the cross-layer copper bar 35 and are used to weld with the corresponding hairpin flat wire; there are two neutral copper bars 36, and each neutral copper bar 36 has three welding ends 361, and the welding ends 361 are used to connect with the neutral lead-out wires of the corresponding branches.
[0038] Specifically, the lead-out holes include a U-phase winding lead-out hole 310, a V-phase winding lead-out hole 311, a W-phase winding lead-out hole 312, a cross-layer hairpin flat wire lead-out hole 313 and a neutral lead-out hole 314. The welding part 322 of the U-phase copper bar 32 extends out through the U-phase winding lead-out hole 310 and welds with the branch lead-out wire of the U-phase winding in this hole; the welding part 322 of the V-phase copper bar 33 extends out through the V-phase winding lead-out hole 311 and welds with the branch lead-out wire of the V-phase winding in this hole; the welding part 322 of the W-phase copper bar 34 extends out through the W-phase winding lead-out hole 312 and welds with the branch lead-out wire of the W-phase winding in this hole; the welding arm 351 of the cross-layer copper bar 35 extends out through the cross-layer hairpin flat wire lead-out hole 313 and welds with the hairpin flat wire in this hole; the welding end 361 of the neutral copper bar 36 extends out through the neutral lead-out hole 314 and welds with the neutral lead-out wire in this hole.
[0039] In this embodiment, wiring waist holes 323 are provided on the wiring terminals 321 of the U-phase copper bar 32, V-phase copper bar 33 and W-phase copper bar 34. By providing the wiring waist holes 323, it can be directly connected to the busbar of the inverter through bolts, improving the assembly efficiency.
[0040] The above details a preferred embodiment of the hairpin stator assembly and its busbar of the present utility model, and there are more embodiments not elaborated here. In summary, the hairpin stator assembly and its busbar of the present utility model can be compatible with assembly errors, reduce the assembly difficulty, improve the assembly quality and efficiency, and have high safety and reliability.
[0041] The present utility model is not limited to the above specific embodiments. Various changes made by those of ordinary skill in the art starting from the above concepts without creative efforts fall within the protection scope of the present utility model.
Claims
1. A busbar, characterized in that: It comprises a busbar support (31), and a U-phase copper bar (32), a V-phase copper bar (33), a W-phase copper bar (34), a cross-layer copper bar (35), and a zero-point copper bar (36) which are arranged on the busbar support (31) and are flexible; The U-phase copper bar (32), the V-phase copper bar (33) and the W-phase copper bar (34) are respectively used to connect to the branch lead wires of the parallel branches of the corresponding windings in the flat wire winding (2); the flat wire winding (2) comprises multiple layers of hairpin flat wires arranged inside and outside, and the cross-layer copper bar (35) is used to cross-layer bridge the two hairpin flat wires of the same branch; the zero-point copper bar (36) is used to connect to the zero-line lead wire of the flat wire winding (2).
2. The busbar according to claim 1, characterized in that: The U-phase copper busbar (32), the V-phase copper busbar (33), the W-phase copper busbar (34), the cross-layer copper busbar (35) and the zero-point copper busbar (36) are all formed by stacking multiple layers of flexible copper foil (100).
3. The busbar according to claim 1, characterized in that: The busbar support (31) is formed by injection molding of insulating material, and the U-phase copper bar (32), the V-phase copper bar (33), the W-phase copper bar (34), the cross-layer copper bar (35) and the zero-point copper bar (36) are all embedded in the busbar support (31).
4. The busbar according to claim 3, characterized in that: The busbar support (31) is provided with lead-out wire through holes, and the U-phase copper bar (32), the V-phase copper bar (33), the W-phase copper bar (34), the cross-layer copper bar (35) and the zero-point copper bar (36) all extend out from the corresponding lead-out wire through holes.
5. The busbar according to claim 3, characterized in that: The insulating material is epoxy resin.
6. The busbar according to claim 1, characterized in that: The U-phase copper bar (32), the V-phase copper bar (33) and the W-phase copper bar (34) each have a connection terminal (321) and two welding portions (322); the connection terminal (321) is used to be connected to a corresponding busbar of the inverter, and the two welding portions (322) are respectively used to be welded to the corresponding branch lead wires.
7. The busbar according to claim 6, characterized in that: The wiring terminal (321) is provided with a wiring waist hole (323).
8. The busbar according to claim 1, characterized in that: The cross-layer copper busbar (35) has two welding arms (351), the two welding arms (351) are located on the same side of the cross-layer copper busbar (35), and the two welding arms (351) are used to be welded with the corresponding hairpin flat wires.
9. The busbar according to claim 1, characterized in that: The zero-point copper bar (36) has three welding ends (361), and the welding ends (361) are used to be connected to the zero-line lead-out wires.
10. A flat wire stator assembly, comprising a stator core (1), and a flat wire winding (2) arranged in the stator core (1), characterized in that: It also comprises a busbar (3) as claimed in any one of claims 1 to 9, wherein the busbar (3) is welded to the flat wire winding (2).