Double-layer wiring structure of high-power commercial vehicle oil-cooled motor

Abstract

The utility model discloses a double-layer wiring structure of a high-power commercial vehicle oil-cooled motor, which comprises a motor rear end cover, a lower-layer wiring box, an upper-layer wiring box and a waterproof lock nut, the motor rear end cover and the lower-layer wiring box are integrally cast, a lower-layer wiring seat is arranged in the lower-layer wiring box, a wiring copper column and an O-shaped ring are arranged in the lower-layer wiring seat, and the waterproof lock nut is arranged in the lower-layer wiring seat. An upper-layer junction box is installed above the lower-layer junction box, an upper-layer wire holder is arranged in the upper-layer junction box, a connecting copper bar is connected between the upper-layer wire holder and the lower-layer wire holder, the top of the upper-layer junction box is connected with a junction box cover, and waterproof lock nuts are installed in an upper layer and a lower layer. The compact double-layer wiring structure is staggered for a certain distance in the axial direction, the purpose of reducing the wiring box is achieved, the wiring box supporting problem caused by occupying the whole vehicle space and vibration is avoided, and the wiring box supporting effect is improved by shortening the support cantilever distance and the double-layer wiring harness fixing frame structure. And the cable bracket can meet the use requirements of a commercial vehicle under a vibration impact working condition.

Description

Technical Field

[0001] The utility model belongs to the technical field of oil-cooled motors, and particularly relates to a double-layer wiring structure of a high-power commercial vehicle oil-cooled motor. Background Technique

[0002] With the continuous increase in the penetration rate of new energy commercial vehicles and the urgent market demand for high load capacity and high voltage, the motors of new energy commercial vehicles are continuously innovated and upgraded in the direction of high power and high voltage. However, the pursuit of high power also brings a series of challenges. The rated current of the motor increases, and the cross-sectional area of the copper wire of the motor also needs to be increased correspondingly to more than 120 square millimeters. However, due to the limitation of the controller and the fact that some vehicle manufacturers do not accept wiring harnesses with a cross-sectional area of more than 95 square millimeters, for high-power commercial vehicle motors, usually two cable wires need to be led out for each phase to match the motor controller for application. The arrangement of a larger number of cable wires and the limit of the motor safety regulations conditions make the wiring box of the motor need to be increased by nearly twice in volume. Under the limitation of the vehicle space and the vibration conditions of the complex working conditions of commercial vehicles, the too-large wiring box is generally not acceptable.

[0003] At present, the wiring boxes of high-power main drive motors for mining trucks on the market are almost as wide as the end covers. Such high-power motors have the following problems:

[0004] 1. The wiring box of the existing high-power motor wiring scheme is too large in volume, and many vehicle models cannot match it, resulting in limited application space. At the same time, when wiring, the vehicle manufacturer needs to disassemble and assemble too many bolts, causing production waste;

[0005] 2. In the existing high-power motor wiring scheme, because the wiring box protrudes too much from the motor body and is too wide, it is difficult for the motor to match the corresponding cable bracket. It can only be fixed by the vehicle manufacturer for the high-voltage wiring harness during vehicle layout. However, the distance between the fixing point and the motor waterproof lock nut is too far, and for the complex vibration conditions of mining trucks, the risk of the waterproof lock nut loosening is relatively high;

[0006] 3. The structural compatibility of the existing high-power motors is not strong. The existing high-power motors generally have a large wiring box with 6 outgoing wires connected to the rear end cover of the motor. For the mainstream market demand (3 outgoing wire methods), they cannot be directly compatible, and the entire outgoing wire structure needs to be replaced, resulting in relatively large cost waste;

[0007] 4. In the existing high-power motor wiring scheme, the wiring box is not sealed with the motor cavity, resulting in the oil and gas generated by the internal cooling oil of the oil-cooled motor at high temperature entering the wiring box and condensing into liquid, affecting the contact resistance of the cable connection. Content of the Utility Model

[0008] The main purpose of the present utility model is to provide a double - layer wiring structure for a high - power commercial vehicle oil - cooled motor, which solves the problems of the too - large junction box of the existing high - power commercial vehicle oil - cooled motor, the inability of the cable bracket to support, and the low - cost compatibility of high - power and low - power motors.

[0009] To achieve the above object, the technical solution adopted by the present utility model is as follows: A double - layer wiring structure for a high - power commercial vehicle oil - cooled motor, including a motor rear end cover, a lower - layer junction box, an upper - layer junction box, and a waterproof lock nut. The motor rear end cover and the lower - layer junction box are integrally cast. A lower - layer wiring seat is installed in the lower - layer junction box. A wiring copper column and an O - ring are arranged in the lower - layer wiring seat. The upper - layer junction box is installed above the lower - layer junction box. An upper - layer wiring seat is arranged in the upper - layer junction box. A connecting copper row is connected between the upper - layer wiring seat and the lower - layer wiring seat. A junction box cover is connected to the top of the upper - layer junction box. The waterproof lock nut is installed in two layers.

[0010] The motor rear end cover is further connected with a wire harness bracket. A wire harness fixing frame is arranged on the wire harness bracket. A wire harness pressing plate is further arranged on the wire harness fixing frame.

[0011] Furthermore, a sealing gasket is arranged between the upper - layer junction box and the lower - layer junction box, and a wiring seat gasket is arranged between the lower - layer wiring seat and the lower - layer junction box.

[0012] Furthermore, the upper - layer junction box is installed above the lower - layer junction box by bolts, the upper - layer wiring seat is assembled on the upper - layer junction box by bolts, the junction box cover is fixed on the upper - layer junction box by bolts, and the wire harness bracket is installed on the motor rear end cover by bolts.

[0013] Furthermore, the upper - layer wiring seat and the connecting copper row are pre - assembled into one body. A groove is arranged on the connecting copper row, and a protrusion is arranged on the upper - layer wiring seat. The connecting copper row and the upper - layer wiring seat are stably combined together through the groove on the connecting copper row and the protrusion on the upper - layer wiring seat.

[0014] Furthermore, the connecting copper row is in a "Z" shape. One end of the connecting copper row is fixed in the upper - layer wiring seat through a wiring bolt, and the other end of the connecting copper row is fixed in the lower - layer wiring seat through a wiring bolt.

[0015] Furthermore, the wire harness fixing frame is in a double - layer fixed structure. The wire harness fixing frame includes a first fixing block. The bottom of the first fixing block is fixed to the side of the wire harness bracket by bolts. The first fixing block is in an "L" shape. The straight section of the first fixing block is connected with a second fixing block by bolts, and the top of the vertical section of the first fixing block is connected with a wire harness pressing plate by bolts.

[0016] Furthermore, a sealing rubber strip is arranged between the junction box cover and the upper - layer junction box.

[0017] Compared with the prior art, the utility model has the following beneficial effects:

[0018] 1. Through a compact double-layer wiring structure with a certain axial offset distance, the utility model achieves the purpose of reducing the size of the junction box. Compared with the ordinary wiring structure, the new double-layer wiring structure has basically the same volume, avoiding the problems of occupying the vehicle space and the support of the junction box caused by vibration;

[0019] 2. By shortening the distance of the bracket cantilever and adopting a double-layer wire harness fixing frame structure, the cable bracket of the utility model can meet the use requirements of the vibration and shock conditions of commercial vehicles. At the same time, when assembling the cable, it is not necessary to disassemble the wire harness bracket and the wire harness fixing frame, improving the manufacturability;

[0020] 3. The new double-layer wiring structure can be quickly switched with the 3-outlet motor for heavy trucks, improving the compatibility of the platform product molds and production lines, and greatly reducing the production and development costs;

[0021] 4. The lower part of the double-layer wiring structure and the motor cavity are absolutely sealed, preventing the oil and gas inside the oil-cooled motor from entering the junction box and causing poor contact problems, and also avoiding the insulation failure caused by the water vapor inside the motor cavity entering the junction box and forming condensed water. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic structural diagram of the double-layer wiring structure of a high-power oil-cooled motor for commercial vehicles according to the utility model;

[0023] Figure 2 It is an exploded structural diagram of the double-layer wiring structure of a high-power oil-cooled motor for commercial vehicles according to the utility model.

[0024] In the figure: 1. Junction box cover; 2. Sealing strip; 3. Connecting copper bar; 4. Upper wiring seat; 5. Upper junction box; 6. Lower wiring seat; 7. Wire harness pressure plate; 8. Second fixing block; 9. First fixing block; 10. Wiring copper column; 11. Wire harness bracket; 12. Sealing gasket; 13. Motor rear end cover; 14. Wiring bolt; 16. Waterproof lock nut; 17. Wire harness fixing frame; 18. Wire harness pressure plate; 20. Lower junction box; 21. O-ring; 22. Wiring seat gasket. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0025] Next, the technical solutions in the embodiments of the present utility model will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present utility model without creative efforts shall fall within the protection scope of the present utility model.

[0026] See Figure 1 、 Figure 2 , the present utility model discloses a double-layer wiring structure for a high-power commercial vehicle oil-cooled motor, which includes a motor rear end cover 13, a lower wiring box 20, an upper wiring box 5, and a waterproof lock nut 16. The motor rear end cover 13 and the lower wiring box 20 are integrally cast. A lower wiring seat 19 is installed in the lower wiring box 20. A sealing gasket 12 is provided between the upper wiring box 5 and the lower wiring box 20. A lower wiring seat 6 is provided in the lower wiring seat 19. Preferably, a wiring seat gasket 22 is provided between the lower wiring seat 6 and the lower wiring box 20. A wiring copper column 10 and an O-ring 21 are provided in the lower wiring seat 6. The lower wiring seat 6, the sealing gasket 12, the wiring copper column 10, and the O-ring 21 achieve sealing with the motor cavity, so that the oil and gas inside the oil-cooled motor cannot enter the wiring box to cause poor contact problems, and at the same time, the water vapor inside the motor cavity is prevented from entering the wiring box to form condensed water and cause insulation failures.

[0027] Further, an upper wiring box 5 is installed above the lower wiring box 20. Specifically, the upper wiring box 5 is installed above the lower wiring box 20 by 10 M6 bolts. An upper wiring seat 4 is provided in the upper wiring box 5. The upper wiring seat 4 is connected to a wiring copper row 3. The upper wiring seat 4 and the connecting copper row 3 are pre-assembled into one body. A groove is provided on the connecting copper row 3, and a protrusion is provided on the upper wiring seat 4. The connecting copper row 3 and the upper wiring seat 4 are stably combined together through the groove on the connecting copper row 3 and the protrusion on the upper wiring seat 4, which can prevent the displacement and dropping during the assembly process. Further, the upper connecting seat 4 is assembled on the upper wiring box 5 by 4 M8 bolts. The connecting copper row 3 is in a "Z" shape. One end of the connecting copper row 3 is fixed in the upper wiring seat 4 through a wiring bolt 14, and the other end of the connecting copper row 3 is fixed in the lower wiring seat 6 through a wiring bolt 14. This structure not only realizes the connection of two installation points per phase, but also can meet the installation requirements of two cables per phase, and solves the problem of cable installation through the axial misalignment of the upper and lower layers.

[0028] Further, a wiring box cover 1 is connected to the top of the upper wiring box 5. Preferably, a sealing rubber strip 2 is provided between the wiring box cover 1 and the upper wiring box 5. The wiring box cover 1 is fixed on the upper wiring box 5 by 9 M6 bolts. Six waterproof lock nuts 16 are installed in upper and lower layers, thus forming a double-layer wiring structure.

[0029] The purpose of reducing the junction box is achieved through a compact double-layer wiring, with a certain axial offset distance, and the volume of the new double-layer wiring structure is basically equivalent to that of the ordinary wiring structure, avoiding the problems of occupying the vehicle space and the support of the junction box caused by vibration.

[0030] Furthermore, the rear end cover 13 of the motor is also connected with a wiring harness bracket 11. Preferably, the wiring harness bracket 11 is concave. The wiring harness bracket 11 is installed on the rear end cover 13 of the motor by 4 M8 bolts. A wiring harness fixing bracket 17 is arranged on the wiring harness bracket 11. Specifically, the wiring harness bracket 17 includes a first fixing block 9. The bottom end of the first fixing block 9 is fixed to the side of the wiring harness bracket 11 by bolts. The first fixing block 9 is in an "L" shape. The straight section of the first fixing block 9 is connected with a second fixing block 8 by bolts. The top end of the vertical section of the first fixing block 9 is connected with a wiring harness pressing plate 7 by bolts. The whole wiring harness fixing bracket 17 is in a double-layer fixing structure, which can realize the assembly of upper and lower layers of cable wires.

[0031] By pre-casting the wiring harness bracket 11 on the rear end cover 13 of the motor, the problem of the wiring harness fixing failure caused by the over-long cantilever support under the vibration condition is solved, and the excessive bending of the wiring harness bracket 11 is avoided. The strength and reliability are greatly improved. The double-layer wiring harness fixing bracket can realize the assembly of upper and lower layers of cable wires. Finally, the cable wires are fixed by the wiring harness pressing plate 7, forming a reliable and stable double-layer wiring structure as a whole.

[0032] By shortening the cantilever distance of the bracket and the double-layer wiring harness fixing bracket structure, the cable bracket can meet the use requirements of the vibration and impact conditions of commercial vehicles. At the same time, when the customer assembles the cable wires, there is no need to disassemble the wiring harness bracket and the wiring harness fixing bracket, improving the manufacturability.

[0033] This structure can meet the needs of the vast majority of heavy trucks by canceling the upper-layer junction box 5, the upper-layer junction seat 4, and the connecting copper bar 3, and can realize quick switching, saving costs and development cycles.

[0034] The new double-layer wiring structure can be quickly switched with the 3-outlet motor for heavy trucks, improving the compatibility of the platform product molds and production lines, and greatly reducing the production and development costs.

[0035] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the term "including", "comprising" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0036] Although the embodiments of the present utility model have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principle and spirit of the present utility model. The scope of the present utility model is defined by the appended claims and their equivalents.

Claims

1. A double-layer wiring structure for a high-power oil-cooled motor of a commercial vehicle, characterized in that: It includes a motor rear end cover (13), a lower wiring box (20), an upper wiring box (5) and a waterproof lock nut (16). The motor rear end cover (13) and the lower wiring box (20) are integrally cast. A lower wiring seat (6) is installed in the lower wiring box (20). A wiring copper column (10) and an O-ring (21) are arranged in the lower wiring seat (6). The upper wiring box (5) is installed above the lower wiring box (20). An upper wiring seat (4) is arranged in the upper wiring box (5). A connecting copper bar (3) is connected between the upper wiring seat (4) and the lower wiring seat (6). A wiring box cover (1) is connected to the top of the upper wiring box (5). The waterproof lock nut (16) is installed in two layers, upper and lower. The motor rear end cover (13) is also connected to a wire harness bracket (11). A wire harness fixing bracket (17) is arranged on the wire harness bracket (11). A wire harness pressing plate (7) is arranged on the wire harness fixing bracket (17).

2. The double-layer wiring structure of a high-power commercial vehicle oil-cooled motor according to claim 1, wherein: A sealing gasket (12) is arranged between the upper wiring box (5) and the lower wiring box (20). A wiring seat gasket (22) is arranged between the lower wiring seat (6) and the lower wiring box (20).

3. The double-layer wiring structure of a high-power commercial vehicle oil-cooled motor according to claim 1, characterized in that: The upper wiring box (5) is installed above the lower wiring box (20) by bolts. The upper wiring seat (4) is assembled on the upper wiring box (5) by bolts. The wiring box cover (1) is fixed on the upper wiring box (5) by bolts. The wire harness bracket (11) is installed on the motor rear end cover (13) by bolts.

4. The double-layer wiring structure of a high-power commercial vehicle oil-cooled motor according to claim 1, characterized in that: The upper wiring seat (4) and the connecting copper bar (3) are pre-assembled into one body. Grooves are arranged on the connecting copper bar (3). Protrusions are arranged on the upper wiring seat (4). The connecting copper bar (3) and the upper wiring seat (4) are stably combined together through the grooves on the connecting copper bar (3) and the protrusions on the upper wiring seat (4).

5. The double-layer wiring structure of a high-power commercial vehicle oil-cooled motor according to claim 4, characterized in that: The connecting copper bar (3) is in a "Z" shape. One end of the connecting copper bar (3) is fixed in the upper wiring seat (4) by a wiring bolt (14). The other end of the connecting copper bar (3) is fixed in the lower wiring seat (6) by a wiring bolt (14).

6. The double-layer wiring structure of a high-power commercial vehicle oil-cooled motor according to claim 1, characterized in that: The wire harness fixing bracket (17) is of a double-layer fixed structure. The wire harness fixing bracket (17) includes a first fixing block (9). The bottom of the first fixing block (9) is fixed to the side of the wire harness bracket (11) by bolts. The first fixing block (9) is in an "L" shape. The straight section of the first fixing block (9) is connected to a second fixing block (8) by bolts. The top of the vertical section of the first fixing block (9) is connected to the wire harness pressing plate (7) by bolts.

7. The double-layer wiring structure of a high-power commercial vehicle oil-cooled motor according to claim 1, characterized in that: A sealing rubber strip (2) is arranged between the wiring box cover (1) and the upper wiring box (5).

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