Busbar assembly of brushless motor

Abstract

The utility model provides a busbar assembly of a brushless motor. The busbar assembly of the brushless motor comprises a housing and a busbar assembly arranged in the housing. The busbar assembly comprises a plurality of busbar units which are arranged at intervals in the axial direction of the motor, and each busbar unit is in a circular arc shape; each busbar unit is provided with a hook assembly, the hook assemblies penetrate through the avoiding parts on the shell to be connected with external electrical parts, and the hook assemblies are arranged in a staggered mode in the circumferential direction of the motor. According to the busbar assembly of the brushless motor, the arrangement form of the busbar units is changed, and particularly, the hook assemblies on the busbar units are arranged in the circumferential direction of the motor in a staggered manner, so that the radial and axial sizes of the motor assembly can be effectively reduced, and the size of the motor assembly can be greatly reduced; and the application range of the motor assembly is wider and the deployment is more flexible.

Description

Technical Field

[0001] The utility model relates to the technical field of brushless motors, in particular to a busbar assembly of a brushless motor. Background Art

[0002] The brushless motor bus assembly is a key component in the motor drive system, transmitting electrical signals and ensuring the motor operates as required. In existing bus assembly designs, multiple bus units are typically arranged in the same plane, spaced out from the inside out. This layout results in a larger radial dimension for the motor, which in turn increases the overall motor volume. This increased size makes it difficult to install the motor assembly in compact spaces, limiting its application scope and deployment flexibility. Utility Model Content

[0003] In view of this, the present invention aims to provide a busbar assembly for a brushless motor to solve the problem of the large overall size of the motor assembly.

[0004] In order to achieve the above-mentioned purpose, the technical solution of the utility model is achieved as follows:

[0005] A busbar assembly for a brushless motor comprises a housing and a busbar component arranged inside the housing;

[0006] The busbar assembly comprises a plurality of busbar units spaced apart along the axial direction of the motor, and each of the busbar units is in an arc shape;

[0007] Each of the busbar units is provided with a hook assembly, which passes through the avoidance portion on the shell to connect with external electrical components, and each of the hook assemblies is staggered in the circumferential direction of the motor.

[0008] Furthermore, the plurality of bus-bar units include a first bus-bar unit, a second bus-bar unit, a third bus-bar unit and a fourth bus-bar unit arranged at intervals along the axial direction of the motor; the second bus-bar unit includes a first connecting segment located in the same plane as the first bus-bar unit, and a second connecting segment spaced apart from the first bus-bar unit in the axial direction of the motor, and the first connecting segment and the second connecting segment are connected via a first bending portion; the third bus-bar unit includes a third connecting segment located in the same plane as the second connecting segment, and a fourth connecting segment spaced apart from the second connecting segment in the axial direction of the motor, the fourth connecting segment and the fourth bus-bar unit are located in the same plane, and the third connecting segment and the fourth connecting segment are connected via a second bending portion.

[0009] Furthermore, in the axial direction of the motor, the ratio of the arc length dimension L of the projection of each bus unit to the circumference dimension C of the entire circle where the projection is located is between 3 / 5 and 3 / 4.

[0010] Furthermore, in the axial direction of the motor, a spacing dimension S between two adjacent busbar units is between 0.5-2 mm.

[0011] Furthermore, the first connecting section, the third connecting section and the fourth busbar unit are all provided with connecting portions for connecting to the wiring terminals.

[0012] Furthermore, the connecting portions are all located in the same plane.

[0013] Furthermore, the connecting portion is provided with a melting portion, and the melting portion is used for laser welding with the connecting terminal to form a connection between the connecting portion and the connecting terminal.

[0014] Furthermore, the fusion portion is arranged around the connection terminal.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] The bus assembly of the brushless motor described in the present invention arranges the bus units at intervals along the axial direction of the motor. Compared with the traditional design in which the bus units are arranged in the radial direction within the same plane, the radial size of the motor can be effectively reduced. In addition, the hook components on each bus unit are staggered in the circumferential direction of the motor, which effectively reduces the axial size of the motor and significantly reduces the volume of the motor, thereby improving the adaptability of the motor in a compact space and the flexibility of application.

[0017] Secondly, by setting the bending portion, the second bus unit and the third bus unit can make full use of the remaining space in the corresponding plane. In this way, while shortening the length of the shell in the axial direction, the bus assembly can also be better arranged, which can not only reduce the radial size of the motor, but also reduce the axial size of the motor, further reducing the volume of the motor.

[0018] Furthermore, the ratio of the arc length L of each busbar unit's projection to the circumference C of the circle on which the projection is located is between 3 / 5 and 3 / 4. This allows for the placement of hook components on each busbar unit while avoiding wasted space, improving space utilization, and preventing busbar units from being too short, impacting the motor's electrical performance, or too long, increasing the motor's radial dimensions. Furthermore, in the axial direction of the motor, the spacing S between two adjacent busbar units is between 0.5 and 2 mm. This prevents excessive spacing from affecting the system's spatial layout, while also preventing the risk of short-circuit failure in the motor due to excessive spacing, making production and processing more convenient.

[0019] Furthermore, the first connecting section, the third connecting section, and the fourth busbar unit are all equipped with connectors for connecting to the wiring terminals. This ensures a more stable connection between the wiring terminals and the busbar unit, reduces electrical failures caused by poor contact, reduces the risk of installation errors, and improves the overall performance of the motor. The fact that all connectors are located on the same plane standardizes the installation process for the wiring terminals, reducing installation complexity and the probability of errors. Furthermore, installers can more quickly locate and connect the wiring terminals, shortening work hours and improving work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The accompanying drawings, which constitute part of the present invention, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an improper limitation of the present invention. In the accompanying drawings:

[0021] Figure 1 This is a schematic structural diagram of a busbar assembly of a brushless motor according to an embodiment of the present utility model;

[0022] Figure 2 This is a schematic structural diagram of the housing according to an embodiment of the present utility model;

[0023] Figure 3 This is a schematic structural diagram of a busbar assembly according to an embodiment of the present utility model;

[0024] Figure 4 This is a schematic structural diagram of the first busbar unit according to an embodiment of the present utility model;

[0025] Figure 5 This is a schematic structural diagram of the second bus unit according to an embodiment of the present utility model;

[0026] Figure 6 This is a schematic structural diagram of the third bus unit according to an embodiment of the present utility model;

[0027] Figure 7 This is a structural diagram of the fourth busbar unit according to an embodiment of the present utility model;

[0028] Description of reference numerals:

[0029] 1. Shell; 101. Avoidance portion;

[0030] 2. Busbar assembly; 201. First busbar unit; 202. Second busbar unit; 2021. First connecting section; 2022. Second connecting section; 2023. First bending portion;

[0031] 203, third busbar unit; 2031, third connecting section; 2032, fourth connecting section; 2033, second bending portion;

[0032] 204, fourth bus unit;

[0033] 3. Hook assembly;

[0034] 4. Connecting portion; 401 melting portion; 402. Third bending portion; 403. Fourth bending portion;

[0035] 5. Wiring terminals. DETAILED DESCRIPTION

[0036] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features therein can be combined with each other.

[0037] In the description of this utility model, it should be noted that if terms such as "upper," "lower," "inner," and "outer" appear to indicate orientation or positional relationships, these are based on the orientation or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this utility model and simplify the description. They do not indicate or imply that the device or component referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, if terms such as "first" and "second" appear, they are used solely for descriptive purposes and should not be construed as indicating or implying relative importance.

[0038] Furthermore, in the description of this utility model, unless otherwise expressly defined, the terms "mounted," "connected," "connection," and "connector" should be interpreted broadly. For example, these terms may refer to fixed connections, removable connections, or integral connections; mechanical connections, electrical connections, direct connections, indirect connections through an intermediary, or internal connections between two components. Those skilled in the art will understand the specific meanings of these terms in this utility model based on specific circumstances.

[0039] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0040] Example 1

[0041] This embodiment relates to a busbar assembly for a brushless motor, which has a more compact structure and can reduce the overall volume of the motor, making the motor more flexible during installation.

[0042] In terms of overall structure, Figures 1 to 7As shown, the busbar assembly of the brushless motor of this embodiment includes a housing 1 and a busbar assembly 2 disposed within the housing 1. The busbar assembly 2 comprises a plurality of arc-shaped busbar units spaced apart along the motor's axial direction. Furthermore, each busbar unit is provided with a hook assembly 3. The hook assembly 3 passes through a relief portion 101 on the housing 1 to connect to external electrical components. The hook assemblies 3 are staggered circumferentially around the motor.

[0043] At this time, as set above, the bus units are arranged at intervals along the axial direction of the motor. Compared with the traditional design in which the bus units are arranged in the radial direction in the same plane, the radial size of the motor can be effectively reduced, and the hook components 3 on each bus unit are staggered in the circumferential direction of the motor, which effectively reduces the axial size of the motor while avoiding mutual interference between electrical components, and also facilitates connection with external electrical components, simplifies the installation process, and improves work efficiency.

[0044] By reducing the radial and axial dimensions of the motor, the volume of the motor can be greatly reduced, making the motor more flexible during installation and adaptable to more different types of equipment and space conditions, thereby broadening the application range of the motor. Specifically, the electrical parts are wires.

[0045] In this embodiment, as a preferred implementation form, refer to Figures 2 to 7 As shown, multiple bus-bar units include a first bus-bar unit 201, a second bus-bar unit 202, a third bus-bar unit 203 and a fourth bus-bar unit 204 arranged at intervals along the axial direction of the motor. The second bus-bar unit 202 includes a first connecting segment 2021 located in the same plane as the first bus-bar unit 201, and a second connecting segment 2022 spaced apart from the first bus-bar unit 201 in the axial direction of the motor. The first connecting segment 2021 and the second connecting segment 2022 are connected via a first bending portion 2023. The third bus-bar unit 203 includes a third connecting segment 2031 located in the same plane as the second connecting segment 2022, and a fourth connecting segment 2032 spaced apart from the second connecting segment 2022 in the axial direction of the motor. The fourth connecting segment 2032 and the fourth bus-bar unit 204 are located in the same plane, and the third connecting segment 2031 and the fourth connecting segment 2032 are connected via a second bending portion 2033.

[0046] It can be understood that the first bending portion 2023 can be used to connect the first connecting segment 2021 and the second connecting segment 2022 located in different planes, and the second bending portion 2033 can be used to connect the third connecting segment 2031 and the fourth connecting segment 2032 located in different planes, so that they are connected as a whole. The first connecting segment 2021 and the first bus unit 201 are located in the same plane, and the remaining space of the first bus unit 201 in the plane can be fully utilized, and the first connecting segment 2021 can be arranged using the remaining space.

[0047] Similarly, the third connecting segment 2031 and the second connecting segment 2022 are located in the same plane, and can make full use of the remaining space of the second connecting segment 2022 in the plane, and the fourth connecting segment 2032 and the fourth bus unit 204 are located in the same plane, so that the fourth bus unit 204 can make more full use of the remaining space of the fourth connecting segment 2032 in the plane, while shortening the axial length of the shell 1, and better arranging the bus assembly 2, thereby not only reducing the radial size of the motor, but also reducing the axial size of the motor, further reducing the volume of the motor.

[0048] Furthermore, as a preferred embodiment, in the axial direction of the motor, the ratio of the arc length L of the projection of each busbar unit to the circumference C of the entire circle on which the projection is located is between 3 / 5 and 3 / 4. For example, a ratio of 3 / 5 or 3 / 4 can be used to ensure that the hook assembly 3 is arranged on each busbar unit while avoiding redundancy and improving space utilization.

[0049] Here, if the busbar unit is too short, it will not be possible to install a sufficient number of hooks on each busbar unit, which will not meet the requirements of the complex circuitry within the motor, affecting the motor's electrical performance and causing unstable operation or motor failure. If the busbar unit is too long, it will occupy more radial space, increase the radial size of the motor, and increase the size of the motor, making it difficult to adapt to space-constrained installation environments. In addition, longer busbar units require more space and tools during installation and maintenance, increasing the complexity of installation and maintenance and hindering time costs.

[0050] Furthermore, as a preferred embodiment, the spacing S between two adjacent busbar units in the axial direction of the motor is between 0.5 and 2 mm. Excessive axial spacing not only increases the overall length of the motor and affects the spatial arrangement of the system, but may also cause the internal structure of the motor to become loose, affecting mechanical stability and heat dissipation performance.

[0051] Conversely, if the axial spacing is too small, not only does it increase the risk of motor short circuits, it can also lead to increased electromagnetic interference between the hooks, affecting the motor's electromagnetic compatibility. Furthermore, too small a spacing can pose challenges to the manufacturing process, increasing production difficulty and cost, and reducing yield.

[0052] Therefore, controlling the spacing between adjacent busbar units to between 0.5 and 2 mm can effectively avoid short circuit risks, reduce electromagnetic interference, and ensure the reliability and efficient operation of the motor while maintaining system compactness and mechanical strength. Specifically, S can be 0.5 mm, 1 mm, or 2 mm, with S preferably being 1 mm.

[0053] In addition, as a preferred embodiment, refer to Figures 5 to 7 As shown, the first connecting section 2021, the third connecting section 2031 and the fourth busbar unit 204 are each provided with a connecting portion 4 for connecting to the terminal block 5. Connection via the connecting portion 4 ensures a more stable connection between the terminal block 5 and the busbar unit, reducing electrical faults caused by poor contact.

[0054] Furthermore, the standardized shape of the connecting portion 4 makes the connection between the terminal 5 and the connecting portion 4 more accurate and convenient, while reducing the risk of installation errors. In addition, a stable connection can reduce contact resistance, improve current transmission efficiency, reduce energy loss, and thus improve the operating stability of the motor, thereby improving the overall performance.

[0055] The brushless motor is driven by three-phase alternating current. In detail, the wiring method of the electrical components and the hook assembly 3 can adopt the motor star connection method, wherein the hook assembly 3 on the first bus unit 201 is used for common point wiring. The relevant structural parts not mentioned in the electrical components and the hook assembly 3 in this embodiment can refer to the various structures familiar to those skilled in the art and will not be repeated here.

[0056] Secondly, as a preferred embodiment, refer to Figure 2 As shown, each connection portion 4 is located in the same plane, making the process of installing the terminal blocks 5 more standardized and unified, reducing the complexity and error probability during installation, and allowing installers to find and connect each terminal block 5 more quickly, shortening installation time and improving work efficiency.

[0057] Specifically, since the first connecting section 2021, the third connecting section 2031 and the fourth bus unit 204 are not located in the same plane, and the third connecting section 2031 is located between the first connecting section 2021 and the fourth bus unit 204, the plane where the third connecting section 2031 is located can be selected as the plane where the connecting portion 4 is located, the first connecting section 2021 can be connected to the corresponding connecting portion 4 through the melting portion 402 of the third bending portion 401, and the fourth bus unit 204 can be connected to the corresponding connecting portion 4 through the fourth bending portion 403.

[0058] In addition, as a preferred embodiment, refer to Figures 5 to 7 As shown, the connection portion 4 is provided with a molten portion for laser welding with the terminal 5 to form a connection between the connection portion 4 and the terminal 5. The molten portion is precisely heated by laser to a molten state, and then forms a strong metal bond during the cooling process, ensuring that the connection between the terminal 5 and the connection portion 4 is not only physically strong and reliable, but also electrically low in resistance and high in conductivity.

[0059] Furthermore, since the connecting parts 4 are all located in the same plane, the distance between the laser welding head and each welding point is ensured to be consistent, thereby improving the accuracy and consistency of welding. At the same time, the welding operation is more standardized, reducing the number of times the welding head position is adjusted, and improving welding efficiency.

[0060] It should be noted that, as a preferred embodiment, the molten portion is arranged around the terminal 5. This ensures a stronger connection between the terminal 5 and the connecting portion 4, and the molten portion can evenly distribute stress after cooling, reducing loosening or breakage of the connection caused by uneven local force.

[0061] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A busbar assembly for a brushless motor, characterized by: It comprises a housing (1) and a busbar assembly (2) arranged inside the housing (1); The busbar assembly (2) comprises a plurality of busbar units spaced apart along the axial direction of the motor, and each of the busbar units is in an arc shape; Each busbar unit is provided with a hook assembly (3), which passes through an avoidance portion (101) on the housing (1) to connect to an external electrical component, and each hook assembly (3) is staggered in the circumferential direction of the motor.

2. The busbar assembly of the brushless motor according to claim 1, characterized in that: The plurality of busbar units include a first busbar unit (201), a second busbar unit (202), a third busbar unit (203), and a fourth busbar unit (204) arranged at intervals along the axial direction of the motor; The second bus-bar unit (202) comprises a first connecting section (2021) located in the same plane as the first bus-bar unit (201), and a second connecting section (2022) spaced apart from the first bus-bar unit (201) in the axial direction of the motor, wherein the first connecting section (2021) and the second connecting section (2022) are connected via a first bending portion (2023); The third busbar unit (203) comprises a third connecting segment (2031) located in the same plane as the second connecting segment (2022), and a fourth connecting segment (2032) spaced apart from the second connecting segment (2022) in the axial direction of the motor, the fourth connecting segment (2032) and the fourth busbar unit (204) being located in the same plane, and the third connecting segment (2031) and the fourth connecting segment (2032) being connected via a second bending portion (2033).

3. The busbar assembly of the brushless motor according to claim 2, characterized in that: In the axial direction of the motor, the ratio of the arc length dimension L of the projection of each busbar unit to the circumference dimension C of the entire circle where the projection is located is between 3 / 5 and 3 / 4.

4. The busbar assembly of the brushless motor according to claim 3, characterized in that: In the axial direction of the motor, a spacing dimension S between two adjacent busbar units is between 0.5-2 mm.

5. The busbar assembly of the brushless motor according to claim 2, characterized in that: The first connecting section (2021), the third connecting section (2031) and the fourth busbar unit are all provided with connecting portions (4) for connecting to the connection terminals (5).

6. The busbar assembly of the brushless motor according to claim 5, characterized in that: Each of the connecting parts (4) is located on the same plane.

7. The busbar assembly of the brushless motor according to claim 6, characterized in that: The connecting portion (4) is provided with a melting portion, and the melting portion is used for laser welding with the connecting terminal (5) to form a connection between the connecting portion (4) and the connecting terminal (5).

8. The busbar assembly of the brushless motor according to claim 7, characterized in that: The fusion portion is arranged around the connection terminal (5).

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