Electric vehicle

Abstract

The utility model provides an electric vehicle which comprises a vehicle frame, a vehicle body covering part, a walking system, a power assembly, a motor assembly and a current detection assembly, the motor assembly comprises a motor and a driving circuit, and the current detection assembly comprises a copper bar, a shell and a current sensor. The first end of the copper bar is electrically connected with a motor, and the second end of the copper bar is electrically connected with a driving circuit. The shell is formed by injection molding, is provided with an accommodating cavity and comprises an insulating part, and the insulating part wraps a partial region of the copper bar. The current sensor is accommodated in the accommodating cavity; the current sensor penetrates through the copper bar, and the insulating part is located between the current sensor and the copper bar so as to isolate the current sensor from the copper bar. According to the invention, the housing is formed through injection molding, so that the copper bar is wrapped by the insulating part, and the copper bar can be fixed on the housing. Compared with the mode that the copper bar and the shell are fixed through bolts, the shell is formed through injection molding of the copper bar and the mold, so that connection between the copper bar and the shell is firmer, and falling is not prone to occurring.

Description

Technical Field

[0001] The present application relates to the field of vehicles, and in particular to an electric vehicle. Background Art

[0002] Electric vehicles include pure electric vehicles and hybrid vehicles. In electric vehicles, the motor assembly can be used to drive the wheels to rotate, turn, etc., and is an indispensable driving element. The motor assembly includes a motor and a motor controller. In addition, it also includes multiple components, such as a copper busbar, a current sensor, a drive circuit, etc. for transmitting power between the motor and the motor controller. Corresponding mounting structures are designed between the multiple components for assembly, and multiple installations are required during assembly. For example, the copper busbar needs to be fixed in the housing first, and then the current sensor is installed on the housing close to the copper busbar and fixed, and then the copper busbar is installed and fixed to the motor and drive circuit respectively. This results in many assembly steps, long assembly time, and low efficiency. Utility Model Content

[0003] In order to solve the problems in the prior art, the present application provides an electric vehicle with a motor assembly having high assembly efficiency.

[0004] The present application provides an electric vehicle, comprising:

[0005] Frame;

[0006] a body covering, the body covering at least partially covering the vehicle frame;

[0007] A traveling system connected to the vehicle frame;

[0008] a powertrain, the powertrain being at least partially connected to the vehicle frame and connected to the travel system;

[0009] The electric vehicle further includes a motor assembly and a current detection assembly, wherein the motor assembly includes a motor and a drive circuit, and the current detection assembly includes:

[0010] a copper busbar, wherein a first end of the copper busbar is electrically connected to the motor, and a second end of the copper busbar is electrically connected to the drive circuit;

[0011] A housing, the housing being formed by injection molding, the housing including an insulating portion, the insulating portion wrapping around a portion of the copper busbar;

[0012] The current sensor, the shell has a accommodating cavity, the current sensor is accommodated in the accommodating cavity; the copper busbar is passed through the current sensor.

[0013] In one embodiment, the copper busbar has a protrusion, the housing has a groove, and the protrusion cooperates with the groove.

[0014] In one embodiment, the insulating portion is located between the current sensor and the copper busbar to isolate the current sensor from the copper busbar.

[0015] In one embodiment, the current detection component further includes a circuit board, the circuit board is accommodated in the accommodating cavity, and the current sensor is electrically connected to the circuit board.

[0016] In one embodiment, the current sensor includes an open magnetic ring and a sensing chip, wherein the sensing chip is located at the opening of the open magnetic ring; the open magnetic ring is spaced apart from the circuit board, and the sensing chip is electrically connected to the circuit board.

[0017] In one embodiment, the motor assembly further includes a controller, the circuit board includes a connecting terminal, and the housing is provided with a through hole at a position corresponding to the connecting terminal;

[0018] The first end of the connecting terminal is fixed to the circuit board, and the second end of the connecting terminal extends out of the shell through the through hole; the first end of the connecting terminal is electrically connected to the sensing chip, and the second end of the connecting terminal is used to be electrically connected to the controller.

[0019] In one embodiment, the housing further includes a side plate, the side plate being disposed outside the insulating portion and connected to the insulating portion;

[0020] The shell includes a structural rib, a first side of the structural rib is connected to the insulating portion, and a second side of the structural rib is connected to the side plate; the first side and the second side of the structural rib are arranged opposite to each other.

[0021] In one embodiment, there are multiple copper bars, and the multiple copper bars are arranged at intervals; the number of the current sensors is consistent with the number of the copper bars.

[0022] In one embodiment, the number of the copper bars is three, and the number of the current sensors is three; the first ends of the three copper bars are respectively electrically connected to the three-phase coils of the motor, and the second ends of the three copper bars are respectively electrically connected to the three-phase output ends of the drive circuit; the three current sensors are respectively inserted into the three copper bars, and an insulating portion is provided between each current sensor and the corresponding copper bar.

[0023] In one embodiment, there are multiple current detection components.

[0024] This application forms a housing by injection molding, forming an insulating portion around the copper busbar, allowing the copper busbar to be fixed to the housing. Compared to using bolts to fix the copper busbar and housing, forming the housing by injection molding the copper busbar and mold can make the connection between the copper busbar and the housing more secure and less likely to fall off. Furthermore, the current sensor is inserted outside the insulating portion of the copper busbar, allowing the copper busbar, housing, and current sensor to be subsequently assembled as a whole, saving the assembly steps of the motor component and improving assembly efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a structural diagram of an embodiment of an electric vehicle of the present application.

[0026] Figure 2 This is a three-dimensional diagram of an embodiment of the current detection component of the present application.

[0027] Figure 3 This is an application structure diagram of an embodiment of the current detection component of the present application.

[0028] Figure 4 This is a cross-sectional view of an embodiment of the current detection component of the present application.

[0029] Figure 5 This is a structural diagram of an embodiment of a current sensor of the present application.

[0030] Figure 6 This is a module structure diagram of an embodiment of the motor assembly of the present application.

[0031] Description of main component symbols

[0032] Current detection component 15

[0033] Copper busbar 151

[0034] Housing 152

[0035] Current sensor 153

[0036] Insulating portion 152a

[0037] Accommodating chamber 152b

[0038] protrusion 151a

[0039] Groove 152c

[0040] Side panel 152d

[0041] Open magnetic ring 153a

[0042] Sensor chip 153b

[0043] Circuit board 154

[0044] Connection terminal 154a

[0045] Structural reinforcement 152f

[0046] Through hole 152e

[0047] Motor assembly 16

[0048] Motor 161

[0049] Drive circuit 162

[0050] Controller 163

[0051] Electric vehicle 100

[0052] Frame 11

[0053] Body panels 12

[0054] Walking system 13

[0055] Powertrain 14

[0056] The following specific implementation methods will further illustrate this application in conjunction with the above-mentioned drawings. DETAILED DESCRIPTION

[0057] The following description will refer to the accompanying drawings to more fully describe the contents of this application. Illustrated in the accompanying drawings are exemplary embodiments of the present application. However, the present application can be implemented in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. These exemplary embodiments are provided to make this application thorough and complete and to fully convey the scope of this application to those skilled in the art. Like reference numerals represent identical or similar components.

[0058] Reference Figure 1 The present application proposes an electric vehicle 100, which includes a frame 11, a body cover 12, a running system 13 and a powertrain 14. The body cover 12 at least partially covers the frame 11. The running system 13 is connected to the frame 11. The powertrain 14 is at least partially connected to the frame 11, and the powertrain 14 is connected to the running system 13. Figure 2 、 Figure 3 and Figure 4The electric vehicle 100 further includes a motor assembly 166 and a current detection assembly 15. The motor assembly 166 includes a motor 161 and a drive circuit 162. The current detection assembly 15 includes a copper busbar 151, a housing 152, and a current sensor 153. The first end of the copper busbar 151 is electrically connected to the motor 161, and the second end of the copper busbar 151 is electrically connected to the drive circuit 162. The housing 152 is formed by injection molding and includes an insulating portion 152a. The insulating portion 152a wraps around a portion of the copper busbar 151. The housing 152 has a receiving cavity 152b, in which the current sensor 153 is housed. The copper busbar 151 is inserted through the current sensor 153.

[0059] In this embodiment, the electric vehicle 100 can be an electric bicycle, an all-terrain vehicle, a motorcycle, etc. The shell 152 can be formed by mold injection molding. For example, the copper busbar 151 is placed in a mold and fixed, and then plastic liquid is injected into the mold so that the plastic liquid completely wraps around a specific area of ​​the copper busbar 151. After the plastic liquid solidifies and forms, an insulating portion 152a is formed outside the specific area of ​​the copper busbar 151. After the mold is demolded, a shell 152 with the copper busbar 151 fixedly installed can be obtained. In this way, the insulating portion 152a of the shell 152 can fit tightly with the copper busbar 151 and be firmly connected, so that the shell 152 and the copper busbar 151 can be subsequently assembled as a whole. Among them, the specific area of ​​the copper busbar 151 can be the area between the first end and the second end of the copper busbar 151, so that the first end and the second end of the copper busbar 151 are not covered by the plastic liquid, so as to facilitate connection with the motor 161 and the drive circuit 162.

[0060] The injection-molded housing 152 also has a housing cavity 152b, which houses the current sensor 153. The current sensor 153 can be secured to the housing 152 by glue injection. For example, the current sensor 153 can be secured to the insulating portion 152a located in the center of the housing 152, or to the sidewalls, top, or bottom of the housing cavity 152b. In this way, the copper busbar 151, housing 152, and current sensor 153 can be assembled as a single unit into the motor assembly 16.

[0061] In one embodiment, the insulating portion 152 a is located between the current sensor 153 and the copper busbar 151 to isolate the current sensor 153 from the copper busbar 151 .

[0062] The accommodating cavity 152b can be arranged around the insulating portion 152a, so that the current sensor 153 can be arranged outside the copper busbar 151 and the insulating portion 152a and accommodated in the accommodating cavity 152b. In this way, the current sensor 153 can detect the current on the copper busbar 151 through electromagnetic induction.

[0063] The input end of the drive circuit 162 is used to receive the power supply voltage, and the output end of the drive circuit 162 is electrically connected to the motor 161 via the copper busbar 151. Based on the power supply voltage, the drive circuit 162 can output a drive signal to the motor 161 to drive the motor 161 to rotate. The current sensor 153 is disposed outside the copper busbar 151 and is insulated from the copper busbar 151 by an insulating portion 152a. When a varying current flows on the copper busbar 151, the current sensor 153 can detect the current on the copper busbar 151 through electromagnetic induction.

[0064] In one embodiment, the motor assembly 16 further includes a controller 163. The current sensor 153 transmits the detected current of the copper busbar 151 to the controller 163 to implement current feedback of the driving signal, so that the controller 163 can adjust the driving signal based on the detection result of the current sensor 153.

[0065] In one embodiment, the first end or the second end of the copper busbar 151 can be configured to have different shapes according to actual applications. For example, the first end of the copper busbar 151 can be configured to be curved to adapt to different installation scenarios.

[0066] The present application forms the housing 152 by injection molding to form an insulating portion 152a around the copper busbar 151, so that the copper busbar 151 can be fixed to the housing 152. Compared to using bolts to fix the copper busbar 151 and the housing 152, forming the housing 152 by injection molding the copper busbar 151 and the mold can make the connection between the copper busbar 151 and the housing 152 more secure and less likely to fall off. Furthermore, the copper busbar 151 is inserted into the current sensor 153, so that the copper busbar 151, the housing 152, and the current sensor 153 can be subsequently assembled as a whole, saving the assembly steps of the motor assembly 16 and improving assembly efficiency.

[0067] Reference Figure 4 In one embodiment, the copper bus 151 has a protrusion 151 a, and the housing 152 has a groove 152 c, and the protrusion 151 a is used to cooperate with the groove 152 c.

[0068] In this embodiment, since the copper bar 151 has a protrusion 151a, the housing 152 forms a corresponding groove 152c according to the shape of the protrusion 151a during injection molding. In this way, after demolding, the protrusion 151a and the groove 152c can cooperate to fix the copper bar 151 and the housing 152, limiting the relative displacement of the copper bar 151 and the housing 152 in the length direction of the copper bar 151. In this way, the copper bar 151 is not easy to fall off, making the assembly of the copper bar 151 and the housing 152 more secure. The number of protrusions 151a can be set to multiple, and the shapes of the multiple protrusions 151a can be the same or different. The number of grooves 152c is consistent with the number of protrusions 151a.

[0069] In one embodiment, the first end and / or the second end of the copper busbar 151 are bent. The first end and / or the second end of the copper plate can be bent at a certain angle, such as 90° or 110°, depending on the actual application, to facilitate electrical connection with the motor 161 or the drive assembly, while also saving planar space.

[0070] In one embodiment, the current detection assembly 15 further includes a circuit board 154 . The circuit board 154 is received in the accommodating cavity 152 b , and the current sensor 153 is electrically connected to the circuit board 154 .

[0071] In this embodiment, the size of the circuit board 154 can be adjusted based on the length and width of the housing 152 to increase the number of points at which the circuit board 154 can be fixed to the side panels 152d, thereby improving stability. Alternatively, the circuit board 154 can be configured in other shapes based on actual needs, such as an L-shape, where the sides of the L-shaped circuit board 154 contact the side panels 152d for fixation. This can save material for the circuit board 154, thereby reducing costs.

[0072] Reference Figure 5 In one embodiment, the current sensor 153 includes an open magnetic ring 153a and a sensing chip 153b, and the sensing chip 153b is located at the opening of the open magnetic ring 153a; the open magnetic ring 153a is spaced apart from the circuit board 154, and the sensing chip 153b is electrically connected to the circuit board 154.

[0073] In this embodiment, when copper busbar 151 transmits a drive signal, the current changes on copper busbar 151 generate electromagnetic induction on split magnetic ring 153a. The sensing chip 153b, at the split magnetic ring opening, senses the magnetic field changes in split magnetic ring 153a and generates corresponding current changes. This current change is processed by a signal processing circuit (e.g., an analog-to-digital conversion circuit) on circuit board 154, which then outputs a corresponding detection signal to controller 163, allowing controller 163 to determine the current magnitude of the drive signal. The sensing chip 153b may be a Hall effect element.

[0074] In one embodiment, the circuit board 154 includes a connection terminal 154a, and the housing 152 defines a through hole 152e at a location corresponding to the connection terminal 154a. The first end of the connection terminal 154a is fixed to the circuit board 154, and the second end of the connection terminal 154a extends out of the housing 152 through the through hole 152e. The first end of the connection terminal 154a is electrically connected to the sensing chip 153b, and the second end of the connection terminal 154a is used to electrically connect to the controller 163.

[0075] In this embodiment, the connection terminal 154a may include multiple pins. The pins may be arranged perpendicularly, parallel to, or at an angle to the circuit board 154. The housing 152 includes through holes 152e corresponding to the direction in which each pin extends, allowing the pins to pass through and electrically connect to the controller 163.

[0076] In one embodiment, the housing 152 further includes a side plate 152d, which surrounds and connects to the insulating portion 152a. The housing 152 includes a structural rib 152f, a first side of which is connected to the insulating portion 152a, and a second side of which is connected to the side plate 152d. The first and second sides of the structural rib 152f are disposed opposite each other.

[0077] In this embodiment, the insulating portion 152a and the side plate 152d are connected by the structural rib 152f, so that the strength of the shell 152 can be improved and it is not easily damaged by external force.

[0078] Furthermore, the first side of the structural rib 152 f may be configured to be higher than the second side to further improve the strength of the shell 152 .

[0079] In one embodiment, there are multiple copper bars 151 , and the multiple copper bars 151 are spaced apart from each other; the number of current sensors 153 is the same as the number of copper bars 151 .

[0080] In this embodiment, the number of copper bars 151 can be set according to the actual application. For example, when used in a two-phase motor 161, the number of copper bars 151 can be set to two; when used in a three-phase motor 161, the number of copper bars 151 can be set to three; when used in a dual motor 161, the number of copper bars 151 can be set to six. The shapes of the multiple copper bars 151 can be the same or different depending on the actual application.

[0081] During the injection molding process, the housing 152 is formed with a plurality of insulating portions 152a that wrap around specific areas of each copper busbar 151 , and each insulating portion 152a is connected to the side plate 152d . A current sensor 153 is provided outside each insulating portion 152a to detect the current of each copper busbar 151 .

[0082] In one embodiment, the number of copper bars 151 is three, and the number of current sensors 153 is three; the first ends of the three copper bars 151 are respectively electrically connected to the three-phase coils of the motor 161, and the second ends of the three copper bars 151 are respectively electrically connected to the three-phase output ends of the drive circuit 162; the three current sensors 153 are respectively disposed through the three copper bars 151, and an insulating portion 152a is provided between each current sensor 153 and the corresponding copper bar 151.

[0083] In this embodiment, when the motor 161 is a three-phase motor 161, the number of copper bars 151 can be set to three. Three current sensors 153 are respectively installed outside the insulation parts 152a of the three copper bars 151 to detect the current of each phase drive signal of the three-phase motor 161.

[0084] Reference Figure 6 The motor assembly 16 includes a motor 161, a drive circuit 162, and a controller 163. The current detection assembly 15 is electrically connected to the motor 161 and the drive circuit 162, respectively. The input terminal of the drive circuit 162 is used to receive a power supply voltage, and the drive circuit 162 is used to output a drive signal based on the received power supply voltage. The current detection assembly 15 is used to transmit the drive signal to the motor 161 and detect the current magnitude of the drive signal. The drive circuit 162 can be implemented using an IGBT (Insulated-Gate Bipolar Transistor).

[0085] In one embodiment, there are multiple current detection components 15 .

[0086] The number of current detection components 15 can be set according to actual application. For example, in a device including two motors, the number of current detection components 15 can be set to two. In addition, the number of current detection components 15 can be set to other values ​​according to actual application, which is not limited here.

[0087] The specific embodiments of the present application have been described above with reference to the accompanying drawings. However, those skilled in the art will appreciate that various modifications and substitutions may be made to the specific embodiments of the present application without departing from the spirit and scope of the present application. Such modifications and substitutions are intended to fall within the scope of the present application.

Claims

1. An electric vehicle comprising: Frame; a body covering, the body covering at least partially covering the vehicle frame; A traveling system connected to the vehicle frame; a powertrain, the powertrain being at least partially supported by the vehicle frame and driving the travel system; It is characterized in that the electric vehicle further includes a motor assembly and a current detection assembly, the motor assembly includes a motor and a drive circuit, and the current detection assembly includes: a copper busbar, wherein a first end of the copper busbar is electrically connected to the motor, and a second end of the copper busbar is electrically connected to the drive circuit; A housing is formed by injection molding and has a receiving cavity. The housing includes an insulating portion that wraps around a portion of the copper busbar. A current sensor is housed in the accommodating cavity; the copper busbar is passed through the current sensor.

2. The electric vehicle according to claim 1, wherein: The copper busbar has a protrusion, the housing has a groove, and the protrusion matches the groove.

3. The electric vehicle according to claim 1, wherein: The insulating portion is located between the current sensor and the copper busbar to isolate the current sensor from the copper busbar.

4. The electric vehicle according to claim 1, wherein: The current detection component further includes a circuit board, which is accommodated in the accommodating cavity, and the current sensor is electrically connected to the circuit board.

5. The electric vehicle according to claim 4, wherein: The current sensor includes an open magnetic ring and a sensing chip. The sensing chip is located at the opening of the open magnetic ring. The open magnetic ring is spaced apart from the circuit board, and the sensing chip is electrically connected to the circuit board.

6. The electric vehicle according to claim 5, wherein: The motor assembly further includes a controller, the circuit board includes a connecting terminal, and the housing is provided with a through hole at a position corresponding to the connecting terminal; The first end of the connecting terminal is fixed to the circuit board, and the second end of the connecting terminal extends out of the shell through the through hole; the first end of the connecting terminal is electrically connected to the sensing chip, and the second end of the connecting terminal is used to be electrically connected to the controller.

7. The electric vehicle according to claim 1, wherein: The housing further includes a side plate, which is disposed outside the insulating portion and connected to the insulating portion; The shell includes a structural rib, a first side of the structural rib is connected to the insulating portion, and a second side of the structural rib is connected to the side plate; the first side and the second side of the structural rib are arranged opposite to each other.

8. The electric vehicle according to any one of claims 1 to 7, characterized in that: There are multiple copper bars, and the multiple copper bars are arranged at intervals; the number of the current sensors is consistent with the number of the copper bars.

9. The electric vehicle according to claim 8, wherein: There are three copper bars and three current sensors; the first ends of the three copper bars are electrically connected to the three-phase coils of the motor, and the second ends of the three copper bars are electrically connected to the three-phase output ends of the drive circuit; the three current sensors are respectively inserted into the three copper bars, and an insulating portion is provided between each current sensor and the corresponding copper bar.

10. The electric vehicle according to claim 1, wherein There are multiple current detection components.

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