Busbar assembly and brake motor

Abstract

The utility model relates to a busbar assembly and a brake motor. The busbar assembly comprises a first busbar, the first busbar comprises a first busbar main body, a first connecting part and a first end part, the first end part is used for arranging a first through hole, and the area of the first end part is larger than that of the first through hole by three times; the second busbar comprises a second busbar main body, a second connecting part and a second end part, the second end part is used for arranging a second through hole, and the area of the second end part is larger than twice of the area of the second through hole; and the third busbar comprises a third busbar main body, a third connecting part and a third end part, the third end part is used for arranging a third through hole, and the area of the third end part is larger than that of the third through hole by three times. The busbar can be suitable for controllers of various specifications, can quickly respond to changes of markets and customers, and greatly reduces die cost.

Description

Technical Field

[0001] This utility model relates to the field of vehicle braking technology, and in particular to a busbar assembly and a brake motor including the busbar assembly. Background Technology

[0002] For vehicle braking systems, one approach is to use a hydraulic braking structure incorporating an electric motor. In this case, the braking system requires both a motor and components including various valves and hydraulic lines. In one known embodiment, a portion of the hydraulic system is positioned between the motor and its controller along the motor's axial direction, necessitating a connecting cable to link the motor and controller. One end of the cable connects to the motor's busbar assembly, which employs a pre-assembly followed by injection molding process. The phase busbars are first subjected to multi-step stamping and bending before being assembled onto a cage, then welded to the stator coils, and finally injection molded.

[0003] In this approach, the controller and motor are typically manufactured by different companies. The controller's interface position is determined after the strip is stamped and bent, and the motor determines the corresponding position of the busbar based on relevant parameters to connect the two via a connecting cable. If the controller design changes, the corresponding busbar stamping die needs to be modified, resulting in additional mold costs and extended production cycles. Furthermore, the busbar and plastic retainer are assembled, and each component has inherent errors, making dimensional accuracy unreliable. Significant positional deviations affect subsequent assembly and welding. Additionally, the plastic retainer requires two sets of injection molds, complicating the product design and increasing mold costs. Utility Model Content

[0004] The purpose of this utility model is to solve at least one of the above-mentioned problems and / or other problems existing in the prior art.

[0005] To achieve the above objectives, according to one aspect of the present invention, a bus assembly is provided, the bus assembly comprising:

[0006] The first busbar includes an arc-shaped first busbar body, a first connecting portion extending from the first busbar body, and a first end portion connected to the first connecting portion. The first end portion is used to provide a first through hole, and the area of ​​the first end portion is more than three times the area of ​​the first through hole.

[0007] The second busbar includes an arc-shaped second busbar body, a second connecting portion extending from the second busbar body, and a second end portion connected to the second connecting portion. The second end portion is used to provide a second through hole, and the area of ​​the second end portion is greater than twice the area of ​​the second through hole.

[0008] The third busbar includes an arc-shaped third busbar body, a third connecting portion extending from the third busbar body, and a third end portion connected to the third connecting portion. The third end portion is used to provide a third through hole, and the area of ​​the third end portion is more than three times the area of ​​the third through hole.

[0009] According to one aspect of the present invention, the first end is rectangular, and its length direction is perpendicular to the radial direction of the first busbar body;

[0010] The second end is rectangular, and its width direction is perpendicular to the radial direction of the second busbar body;

[0011] The third end is rectangular, and its length direction is perpendicular to the radial direction of the third busbar body.

[0012] According to one aspect of the present invention, the length of the first end is greater than twice the diameter of the through hole but not more than four times the diameter of the through hole, and the width is greater than 1.5 times the diameter of the through hole but not more than 2.5 times the diameter of the through hole.

[0013] The length of the second end is greater than twice the diameter of the through hole but not more than three times the diameter of the through hole, and the width is not more than twice the diameter of the through hole;

[0014] The length of the third end is greater than twice the diameter of the through hole but not more than four times the diameter of the through hole, and the width is greater than 1.5 times the diameter of the through hole but not more than 2.5 times the diameter of the through hole.

[0015] According to one aspect of the present invention, the area of ​​the first end and the third end is 11.5mm × 7.5mm, and the area of ​​the second end is 5.4mm × 9.5mm.

[0016] According to one aspect of the present invention, the first end, the second end, and the third end are located in the same plane.

[0017] According to one aspect of the present invention, it further includes an injection-molded component that partially covers the first busbar, the second busbar, and the third busbar by overmolding.

[0018] According to one aspect of the present invention, the first busbar body is located on a first plane, and the second busbar body is located on a second plane, the second plane being parallel to the first plane; viewed from a direction perpendicular to the first plane and the second plane, the first busbar body and the second busbar body have an overlapping portion.

[0019] According to one aspect of the present invention, the third busbar body includes a first segment and a second segment located on the first plane and the second plane respectively, and a connecting segment connecting the two segments, wherein the first segment on the first plane overlaps with the second busbar body.

[0020] According to one aspect of the present invention, viewed axially, there is a gap between the first circumferential end of the first busbar body and the first circumferential end of the third busbar body, the second connecting portion is located in the gap, the first connecting portion is disposed at the first circumferential end of the first busbar body, and the third connecting portion is disposed at the first circumferential end of the third busbar body.

[0021] This utility model also provides a brake motor, including the busbar assembly described above.

[0022] The busbar according to this invention has three ends, a first end, and a third end, extending radially along its plane. The extended surfaces of these three ends have multiple different positions for setting corresponding first, second, and third through holes. This allows for adaptability to various connection requirements by simply setting the three through holes at different positions on each end and changing the positions of these three through holes. This enables rapid response to market and customer changes, allows for compatibility with more controllers, and significantly reduces mold costs. Attached Figure Description

[0023] The features and advantages of this utility model will become clear from the following detailed description provided with reference to the accompanying drawings. It should be understood that the following drawings are merely schematic and not necessarily drawn to scale, and therefore should not be considered as limitations on this utility model, wherein:

[0024] Figure 1 A perspective view of a bus assembly according to an embodiment of the present invention is shown.

[0025] Figure 2 Show Figure 1 The diagram shows an exploded view of the bus assembly.

[0026] Figure 3 Show Figure 1 A perspective view of the first busbar of the busbar assembly shown.

[0027] Figure 4 Show Figure 1 A perspective view of the second busbar of the busbar assembly shown.

[0028] Figure 5 Show Figure 1 A perspective view of the third busbar of the busbar assembly shown.

[0029] Figure 6 Show Figure 1 The diagram shown is a 3D view of the busbar assembly without the injection-molded components.

[0030] Figure 7 A perspective view of a brake motor according to an embodiment of the present invention is shown. Detailed Implementation

[0031] Embodiments of the present invention are described below with reference to the accompanying drawings. In the following description, numerous specific details are set forth to enable those skilled in the art to more fully understand and implement the present invention. However, it will be apparent to those skilled in the art that implementations of the present invention may not include some of these specific details. Furthermore, it should be understood that the present invention is not limited to the specific embodiments described. Rather, the present invention can be conceived to be implemented with any combination of the features and elements described below, regardless of whether they relate to different embodiments. Therefore, the following aspects, features, embodiments, and advantages are for illustrative purposes only and should not be construed as elements or limitations of the claims unless expressly set forth in the claims.

[0032] The terms "first" and "second" are used below to describe the elements of this application. These terms are used only to distinguish the individual elements and not to limit the nature, order, or number of these elements. The terms "comprising" and "having" are used to indicate an open-ended inclusion and mean that there may be additional elements / components besides those listed.

[0033] Figure 1 A perspective view of a bus assembly according to an embodiment of the present invention is shown. Figure 2 Show Figure 1 The diagram shows an exploded view of the busbar assembly. This busbar assembly is preferably used in the braking system of a vehicle. Figure 1 As shown, the bus assembly is generally annular and may include a first bus 1, a second bus 2, a third bus 3, and an injection-molded component 4. The injection-molded component 4 is formed via an overmolding process and covers most of the circumferential surfaces of the first bus 1, the second bus 2, and the third bus 3, thereby providing insulation between them. The first bus 1, the second bus 2, and the third bus 3 correspond to the U-phase, V-phase, and W-phase of the motor, respectively.

[0034] Figure 3 A three-dimensional view of the first busbar 1 is shown. Combined with... Figure 2 and Figure 3The first busbar 1 may include a first busbar body 11, a first connecting portion 12, a first end portion 13, and two first terminals 14. The first busbar body 11 is generally semi-circular and has a first circumferential end portion and a second circumferential end portion. The first connecting portion 12 is disposed at the first circumferential end portion of the first busbar body 11, and its starting end first extends radially outward along the first busbar body 11, then extends axially to one side along the first busbar body 11 to form a middle portion, and then continues to extend radially outward along the first busbar body 11 to form an end portion, thereby forming a general "Z" shape. The first end portion 13 is connected to the end portion of the first connecting portion 12, and the first end portion is generally located in a plane perpendicular to the axial direction of the busbar body. A first through hole 131 is provided on the first end portion 13, extending axially along the first busbar body 11. The first end portion 13 may form an extension surface with a generally flat plate shape in this plane, so the first through hole 131 can be disposed at any position in this extension surface according to actual needs. One first terminal 14 extends radially outward from the first busbar body 11 on one side of the first connecting portion 12 to form a generally hook-shaped structure, and the other first terminal 14 extends radially outward from the second circumferential end of the first busbar body 11 to form a generally hook-shaped busbar. Optionally, the first busbar body 11, the first connecting portion 12, the first end 13, and the two first terminals 14 are integrally formed from copper, aluminum, or other materials with good conductivity, and then bent through a stamping process or other forming processes to form an integral first busbar 1.

[0035] Figure 4 A three-dimensional view of the second busbar 2 is shown. Combined with... Figure 2 and Figure 4As shown, the second busbar 2 may include a second busbar body 21, a second connecting portion 22, a second end portion 23, and two second terminals 24. The second busbar body 21 is generally semi-circular and has a first circumferential end portion and a second circumferential end portion. The second connecting portion 22 is located approximately in the middle of the second busbar body 21, and its starting end first extends radially outward along the second busbar body 21, then extends axially to one side along the second busbar body 21 to form a middle portion, and then continues to extend radially outward along the first busbar body 11 to form an end portion. This forms a general "Z" shape. The second end portion 23 is connected to the end of the second connecting portion 22, and the second end portion is generally located in a plane perpendicular to the axial direction of the busbar body. A second through hole 231 is provided on the second end portion 23, extending axially along the second busbar body 21. The second end portion 23 may form an extension surface with a generally flat plate shape in this plane, so the second through hole 231 can be located at any position in this extension surface according to actual needs. One second terminal 24 extends radially outward from the first circumferential end of the second busbar body 21 to form a generally hook-shaped portion, and the other second terminal 24 extends radially outward from the second circumferential end of the second busbar body 21 to form a generally hook-shaped portion. Optionally, the second busbar body 21, the second connecting portion 22, the second end 23, and the two second terminals 24 are integrally formed from copper, aluminum, or other materials with good conductivity, and then bent through a stamping process or other forming processes to form an integral second busbar 2.

[0036] Figure 5 A three-dimensional view of the third busbar 3 is shown. Combined with... Figure 2 and Figure 5As shown, the third busbar 3 may include a third busbar body 31, a third connecting portion 32, a third end portion 33, and two third terminals 34. The third busbar body 31 is generally formed in a semi-circular arc shape and has a first circumferential end portion and a second circumferential end portion. The third connecting portion 32 is disposed at the first circumferential end portion of the third busbar body 31, and its starting end first extends radially outward along the third busbar body 31, then extends axially to one side along the third busbar body 31 to form a middle portion, and then continues to extend radially outward along the third busbar body 31 to form an end portion, thereby forming a general "Z" shape. The third end portion 33 is connected to the end portion of the third connecting portion 32, and the third end portion is generally located in a plane perpendicular to the axial direction of the busbar body. The third end portion 33 may form an extension surface with a generally flat plate shape in this plane, so that the third through hole 331 can be disposed at any position in this extension surface according to actual needs. One third terminal 34 extends radially outward from the third bus body 31 on one side of the third connecting portion 32, forming a generally hook shape. The other third terminal 34 extends radially outward from the second circumferential end of the third bus body 31, also forming a generally hook shape. Optionally, the third bus body 31, the third connecting portion 32, the third end 33, and the two third terminals 34 are integrally formed from copper, aluminum, or other materials with good conductivity, and then bent through a stamping process or other forming processes to form an integral third bus 3.

[0037] The first through hole 131, the second through hole 231 and the third through hole 331 are each used to accommodate the connecting wires connected to the controller. After the connecting wires are inserted into the through holes, they can be connected to the end by laser welding.

[0038] Those skilled in the art will understand that the first connecting portion 12, the second connecting portion 22, and the third connecting portion 32 can be configured in ways other than those described above. For example, they can extend radially from the busbar body and then cease to extend axially. In this case, the corresponding ends can be in the same plane as the busbar body.

[0039] like Figure 7As shown, the controller 8 and the motor 7 are connected by a connecting line 6. At least a portion of the hydraulic section 5 of the braking system is provided between the controller 8 and the motor 7. In the prior art, due to differences in the specifications and dimensions of different controllers, the busbar is manufactured to fit the controller's dimensions in order to connect to different controllers via the connecting line 6. Therefore, it is necessary to manufacture busbars with matching specifications for controllers of different sizes, which increases manufacturing costs. Furthermore, if the controller design changes, the dimensional parameters of the matching busbar also need to be changed and remanufactured. With the solution of this invention, since the first end 13, the second end 23, and the third end 33 form a generally flat extension surface in their respective planes, punching is not required beforehand; instead, punching is performed after the dimensional parameters of the matching controller are finally determined. Thus, only one type of busbar needs to be manufactured to meet the connection requirements of multiple controller specifications.

[0040] Figure 6 A perspective view of the busbar assembly according to this embodiment without the injection-molded component 4 is shown. (Refer to...) Figure 6 As shown, the first busbar body 11 extends in a first plane on the upper side. The second busbar body 21 extends in a second plane on the lower side, parallel to the first plane, and is offset from the first busbar body 11 by approximately 90°, thereby causing a portion of the first busbar body 11 and a portion of the second busbar body 21 to overlap by a portion a. The third busbar body 31 may include two segments located in different planes and a connecting segment 313 connecting these two segments. The first segment 311 extends in the first plane along with the first busbar body 11 and overlaps with the second busbar body 21 in the second plane by a portion b. The second segment 312 extends in the second plane along with the second busbar body 21 and overlaps with the first busbar body 11 in the first plane by a portion c. The connecting segment 313 extends obliquely from the first plane to the second plane. This allows the three busbar bodies to be arranged within a small axial space. There is a gap d between the first circumferential end of the first busbar body 11 and the first circumferential end of the third busbar body 31. The first connecting part 12 is disposed at the first circumferential end of the first busbar body 11, the second connecting part 22 is disposed at the position corresponding to the gap d of the second busbar body 21, and the third connecting part 32 is disposed at the first circumferential end of the third busbar body 31. This arrangement facilitates the placement of the first connecting part 12, the second connecting part 22, and the third connecting part 32 in relatively close positions, which is convenient for connection with external devices such as controllers.

[0041] As mentioned above, in order to enable the busbar to connect to controllers of various specifications, the first end 13, the second end 23, and the third end 33 are configured to have a certain area to increase the adaptability of the positions of the first through hole 131, the second through hole 231, and the third through hole 331. Figure 6 The specific locations of the three through holes are shown. When connected to controllers of other specifications, the positions of the connecting wires change accordingly due to the change in controller size. Accordingly, holes can be punched at corresponding positions on the three ends to set the positions of the matching through holes. For example, the third through hole 331 and the first through hole 131 can be moved closer to the second through hole 231.

[0042] Herein, this utility model specifies that the first end 13 and the third end 33 may have the same or different shapes. In terms of the area of ​​the first end 13 and the third end 33, their areas are greater than three times the area of ​​the through hole, and preferably not more than six times the area of ​​the through hole. The area of ​​the second end 23 is greater than twice the area of ​​the through hole, and preferably not more than three times the area of ​​the through hole.

[0043] In one specific embodiment, the first end portion 13 and the third end portion 33 are rectangular in shape, both having the same shape, with their length direction perpendicular to the radial direction and their width direction parallel to the radial direction. In terms of dimensions, their length is greater than twice the diameter of the through hole, preferably greater than three times the diameter of the through hole, and preferably not exceeding four times the diameter of the through hole; their width is greater than 1.5 times the diameter of the through hole, but not exceeding 2.5 times the diameter of the through hole. The second end portion 23 is rectangular in shape, with its length direction parallel to the radial direction and its width direction perpendicular to the radial direction. In terms of dimensions, its length is greater than twice the diameter of the through hole, preferably not exceeding three times the diameter of the through hole; its width is not more than twice the diameter of the through hole, preferably not exceeding 1.5 times the diameter of the through hole.

[0044] In one specific implementation, the area of ​​the first end and the third end is 11.5mm × 7.5mm, while the area of ​​the second end is 5.4mm × 9.5mm.

[0045] The above-mentioned size design avoids the disadvantage that the bus size in the prior art can only be applied to a single specification of controller, so that the end area can meet the connection requirements of a variety of known controller specifications, without causing the end area to be too large and resulting in material waste.

[0046] Return to reference Figure 1 and Figure 2As shown, the injection-molded component 4 may include an annular portion, a connecting portion extending axially upward from the annular portion, and an extension portion extending radially outward from the extension portion. The annular portion covers the outer periphery of the first busbar body 11, the second busbar body 21, and the third busbar body 31, insulating the three bodies from each other. The connecting portion covers the outer periphery of the first connecting portion 12, the second connecting portion 22, and the third connecting portion 33, insulating the three connecting ends from each other. The extension portion may completely cover the outer periphery of the first end 13, the second end 23, and the third end 33, insulating the three ends from each other, and exposing the first through hole 131, the second through hole 231, and the third through hole 331. Of course, the extension portion may also be as follows: Figure 1 The second end 23 is completely covered and the first end 13 and the third end 33 are partially covered, while the right side of the first end 13 opposite to the second end 23 and the left side of the third end 33 opposite to the second end 23 are exposed.

[0047] This utility model also provides a brake motor assembly. The brake motor assembly may include, for example, a connecting wire 6 in the form of pins, a brake motor 7, and a bus 100 as described above, such as... Figure 7 As shown. Busbar 100 is generally arranged in the upper half of housing 7, with the stator arranged below it. The stator includes a stator core and stator windings wound on the stator core. The three-phase coils of the stator windings are respectively connected to the first terminal 14, the second terminal 24, and the third terminal 34 of busbar 100. The rotor is arranged axially in the middle of motor 7. The three pins can be three independent structures or integrated into one plug-in. The entire plug-in passes through the hydraulic part 5 of the braking system, with its upper end connected to the controller 8 and its lower end inserted into the corresponding first through hole 131, second through hole 231, and third through hole 331.

[0048] Compared with the prior art, the busbar according to this utility model is provided with a first end 13, a second end 23 and a third end 33 extending along its radial plane respectively. The extension surfaces of the three ends have multiple different positions to set the corresponding first through hole 131, second through hole 231 and third through hole 331, so that only the corresponding three through holes need to be set at different positions of each end, thereby changing the position between the three through holes, which can be adapted to various connection requirements.

[0049] Furthermore, compared to the existing technology, which requires first injection molding to form a retainer and then assembling the three busbars into the retainer before another injection molding, the present invention fixes the first busbar 1, the second busbar 2, and the third busbar 3 into the same injection mold. After one injection molding, an injection-molded component 4 covering the outer periphery of the three busbars and insulating them from each other can be formed. Compared to the existing technology, the busbar of this utility model can save an injection mold, reduce manufacturing costs, and ensure the dimensional accuracy of the busbar, which is beneficial to improving dimensional stability.

[0050] The first busbar body 11 and the second busbar body 21 are respectively arranged on the first plane and the second plane. The first section 311 of the third busbar body 31 is on the same plane as the first busbar body 11, and the second section 312 is on the same plane as the second busbar body 21. This helps to reduce the space occupied by the entire busbar in the brake motor.

[0051] Various modifications and variations can be made to the embodiments disclosed above without departing from the scope or spirit of this invention. Other embodiments of this invention will be apparent to those skilled in the art based on the practice of this invention disclosed in this specification. This specification and the examples disclosed herein should be considered illustrative only, and the true scope of this invention is defined by the appended claims and their equivalents.

Claims

1. A busbar assembly, characterized in that, The busbar assembly comprises: a first busbar (1) comprising an arc-shaped first busbar body (11), a first connecting portion (12) extending from the first busbar body, and a first end portion (13) connected to the first connecting portion, the first end portion being configured to define a first through hole (131), the area of the first end portion being greater than three times the area of the first through hole; a second busbar (2) comprising an arc-shaped second busbar body (21), a second connecting portion (22) extending from the second busbar body, and a second end portion (23) connected to the second connecting portion, the second end portion being configured to define a second through hole (231), the area of the second end portion being greater than two times the area of the second through hole; a third busbar (3) comprising an arc-shaped third busbar body (31), a third connecting portion (32) extending from the third busbar body, and a third end portion (33) connected to the third connecting portion, the third end portion being configured to define a third through hole (331), the area of the third end portion being greater than three times the area of the third through hole.

2. The busbar assembly of claim 1, wherein, The first end portion is rectangular, and the length direction thereof is perpendicular to the radial direction of the first busbar body; The second end portion is rectangular, and the width direction thereof is perpendicular to the radial direction of the second busbar body; The third end portion is rectangular, and the length direction thereof is perpendicular to the radial direction of the third busbar body.

3. The busbar assembly of claim 2, wherein, The length of the first end portion is greater than 2 times the diameter of the through hole, and does not exceed 4 times the diameter of the through hole, and the width thereof is greater than 1.5 times the diameter of the through hole, and does not exceed 2.5 times the diameter of the through hole; The length of the second end portion is greater than 2 times the diameter of the through hole, and does not exceed 3 times the diameter of the through hole, and the width thereof does not exceed 2 times the diameter of the through hole; The length of the third end portion is greater than 2 times the diameter of the through hole, and does not exceed 4 times the diameter of the through hole, and the width thereof is greater than 1.5 times the diameter of the through hole, and does not exceed 2.5 times the diameter of the through hole.

4. The busbar assembly of claim 2, wherein, The area of the first end portion and the third end portion is 11.5 mm x 7.5 mm, and the area of the second end portion is 5.4 mm x 9.5 mm.

5. The busbar assembly of any one of claims 1 to 4, wherein, The first end portion (13), the second end portion (23), and the third end portion (33) are located in the same plane.

6. The busbar assembly of any one of claims 1 to 4, wherein, An injection molding member (4) is further included, which partially covers the first busbar (1), the second busbar (2), and the third busbar (3) in an overmolding manner.

7. The busbar assembly of any one of claims 1 to 4, wherein, The first busbar body (11) is located in a first plane, and the second busbar body (21) is located in a second plane, which is parallel to the first plane; as viewed from a direction perpendicular to the first plane and the second plane, the first busbar body and the second busbar body have an overlapping portion (a).

8. The busbar assembly of claim 7, wherein, The third busbar body (31) comprises a first section (311) and a second section (312) located in the first plane and the second plane respectively, and a connecting section (313) connecting the two sections, and the first section (311) of the first plane and the second busbar body (21) have an overlapping portion (b).

9. The busbar assembly of claim 8, wherein, From an axial direction, a gap (d) is provided between a first circumferential end of the first busbar body (11) and a first circumferential end of the third busbar body (31), the second connecting portion (22) is located in the gap, the first connecting portion (12) is provided at the first circumferential end of the first busbar body (11), and the third connecting portion (32) is provided at the first circumferential end of the third busbar body (31).

10. A braking motor, characterized by A busbar assembly comprising any one of the busbar assemblies according to claims 1 to 9.

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