Output copper bar module and vehicle-mounted motor controller

Abstract

The utility model discloses an output copper bar module and a vehicle-mounted motor controller, and the output copper bar module comprises an insulating base which is provided with a magnetic ring embedding groove; the output copper bar and the insulation base are integrally formed in an injection molding mode, one end of the output copper bar is a first wiring end, the other end of the output copper bar is a second wiring end, one of the first wiring end and the second wiring end is used for being connected with a current sensor module of the vehicle-mounted motor controller, and the other one of the first wiring end and the second wiring end is used for being connected with a motor; and the magnetic ring is embedded in the magnetic ring embedding groove and is arranged around the output copper bar. According to the utility model, the insulating base and the output copper bar are injection-molded together, so that the insulating base and the output copper bar are of an integrated structure. Meanwhile, a magnetic ring caulking groove is formed in the insulating base in an injection molding mode, and the magnetic ring is embedded in the magnetic ring caulking groove. According to the output copper bar module, the insulating base and the output copper bar are integrated together, so that the integrated design of the output copper bar module is realized, the assembly process is simplified, and the assembly efficiency is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicle-mounted motor controller structure, more particularly to an output copper bar module and a vehicle-mounted motor controller. BACKGROUND

[0002] The electric drive system of a new energy vehicle is a core component of the vehicle, mainly including a motor and a vehicle-mounted motor controller and the like. In recent years, with the continuous development of the new energy vehicle industry, the electric drive system is facing the requirements of higher integration and higher reliability.

[0003] In order to improve the integration of the system, the existing scheme directly integrates the vehicle-mounted motor controller with the motor and the reducer, and the three-phase output of the power module in the vehicle-mounted motor controller is directly connected with the three-phase input of the motor through an output copper bar module, thereby reducing the volume and cost of the system.

[0004] The output copper bar module in the prior art generally has an insulating base and a copper bar body, and the copper bar body and the insulating base are independent of each other and need to be assembled together, which is relatively cumbersome and has low assembly efficiency.

[0005] Therefore, how to simplify the assembly process and improve the assembly efficiency is a problem to be solved by those skilled in the art. CONTENT OF THE INVENTION

[0006] Therefore, the purpose of the present application is to provide an output copper bar module to simplify the assembly process and improve the assembly efficiency.

[0007] Another purpose of the present application is to provide a vehicle-mounted motor controller having the above output copper bar module.

[0008] To achieve the above purpose, the present application provides the following technical solutions:

[0009] The first aspect of the present application provides an output copper bar module for a vehicle-mounted motor controller, comprising:

[0010] An insulating base, the insulating base having a magnetic ring embedding groove;

[0011] An output copper bar, the output copper bar being integrally injection molded with the insulating base, one end of the output copper bar being a first wiring end and the other end being a second wiring end, one of the first wiring end and the second wiring end being used for connecting with a current sensor module of the vehicle-mounted motor controller, and the other being used for connecting with a motor;

[0012] A magnetic ring, embedded in the magnetic ring embedding groove and arranged around the output copper bar.

[0013] In a possible implementation manner, the magnetic ring is filled in the magnetic ring embedding groove through a filling glue body.

[0014] In one possible implementation, the insulating base includes a plastic core and a plastic shell, with the magnetic ring groove formed between the plastic core and the plastic shell;

[0015] Part of the output copper busbar is enclosed within the plastic core, while the first terminal and the second terminal are exposed outside the plastic core.

[0016] In one possible implementation, the first terminal is used to connect to the current sensor module, and the second terminal is used to connect to the motor.

[0017] A sealing ring is provided at one end of the plastic core near the second terminal. The second terminal extends out of the controller housing from the output copper busbar hole on the controller housing of the vehicle motor controller, and the sealing ring is used to seal against the inner wall of the output copper busbar hole.

[0018] In one possible implementation, the plastic core is provided with a sealing ring mounting groove, and the sealing ring is embedded in the sealing ring mounting groove.

[0019] In one possible implementation, the sealing ring mounting groove has a guide slope on the flange near the second terminal to facilitate the pushing of the sealing ring into the sealing ring mounting groove.

[0020] In one possible implementation, one end of the output copper busbar connected to the motor extends beyond the first end of the insulating base;

[0021] An adhesive reservoir is provided on the end face of the first end of the insulating base, and the adhesive reservoir is used for filling with sealant.

[0022] In one possible implementation, the output copper busbar is a three-phase output copper busbar, with the first terminal used to connect to the current sensor module and the second terminal used to connect to the motor.

[0023] Each of the first terminals of the three-phase output copper busbar is independently wrapped by the insulating base, and each of the second terminals of the three-phase output copper busbar is uniformly wrapped by the insulating base, with a protrusion and / or groove provided between any two adjacent second terminals on the insulating base.

[0024] In one possible implementation, the outer wall of the insulating base is provided with a plurality of mounting seats, each mounting seat having a through hole, a metal insert being embedded in the through hole, the metal insert having a fastening hole for a fastener to pass through, and both ends of the metal insert protruding from the two side surfaces of the mounting seat respectively.

[0025] And / or,

[0026] The outer wall of the insulating base is provided with several reinforcing ribs.

[0027] The output copper busbar module provided in this application integrates the insulating base and the output copper busbar through injection molding, resulting in a single, integrated structure. Simultaneously, a magnetic ring recess is injection molded into the insulating base, and the magnetic ring is embedded within this recess. This integration of the insulating base and the output copper busbar achieves an integrated design for the output copper busbar module, simplifying the assembly process and improving assembly efficiency.

[0028] A second aspect of this application provides an on-board motor controller, including an output copper busbar module as described in any of the preceding claims.

[0029] The vehicle motor controller provided in this application has the aforementioned output copper busbar module, and therefore possesses all the technical effects of the aforementioned output copper busbar module, which will not be elaborated upon here. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the output copper busbar module disclosed in an embodiment of this application;

[0032] Figure 2 This is a schematic diagram of the output copper busbar module disclosed in the embodiments of this application from a bottom view.

[0033] Figure 3 This is an exploded view of the output copper busbar module disclosed in an embodiment of this application;

[0034] Figure 4 This is a cross-sectional view of the output copper busbar module disclosed in an embodiment of this application;

[0035] Figure 5 This is a schematic diagram of the structure of the insulating base disclosed in the embodiments of this application;

[0036] Figure 6 This is a schematic diagram of the insulating base disclosed in the embodiments of this application from a bottom view.

[0037] The meanings of the various reference numerals in the figure are as follows:

[0038] 100-Insulating base; 101-Glue reservoir; 102-Wiring hole; 103-Mounting base; 104-Metal insert; 105-Reinforcing rib; 106-Sealing ring mounting groove; 107-Groove; 108-Side guard; 109-Plastic core; 110-Plastic shell; 111-Magnetic ring groove;

[0039] 200 - Output copper busbar; 201 - U-phase output copper busbar; 202 - V-phase output copper busbar; 203 - W-phase output copper busbar;

[0040] 300 - Sealing ring;

[0041] 400-Magnetic Ring;

[0042] 500 - Potting colloid. Detailed Implementation

[0043] The core of this application is to provide an output copper busbar module to simplify the assembly process and improve assembly efficiency;

[0044] Another core aspect of this application is to provide an on-board motor controller with the aforementioned output copper busbar module.

[0045] Hereinafter, embodiments will be described with reference to the accompanying drawings. Furthermore, the embodiments shown below do not limit the scope of the application as described in the claims. Additionally, the complete composition represented in the embodiments below is not limited to what is necessary as the solution to the application described in the claims. It should be noted that, for ease of description, only the parts relevant to the application are shown in the drawings. Unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0046] like Figures 1-6 As shown in the embodiment of this application, the output copper busbar module is used in an on-board motor controller. The output copper busbar module includes an insulating base 100, an output copper busbar 200, and a magnetic ring 400. The insulating base 100 has a magnetic ring groove 111. The insulating base 100 is an injection-molded part, formed into the corresponding structure through an injection molding process, so that the insulating base 100 has the magnetic ring groove 111 to facilitate the installation of the magnetic ring 400. The insulating base 100 can be made of any material that can achieve insulation, such as plastic or rubber. This embodiment does not limit the specific material of the insulating base 100, as long as it can achieve insulation.

[0047] The output copper busbar 200 and the insulating base 100 are integrally injection molded. That is, during the injection molding of the insulating base 100, the output copper busbar 200 is injection molded within the structure of the insulating base 100, making them a single integrated structure. One end of the output copper busbar 200 is a first terminal, and the other end is a second terminal. One of the first and second terminals is used to connect to the current sensor module of the vehicle motor controller, and the other is used to connect to the motor, thereby realizing the connection between the vehicle motor controller and the motor. The magnetic ring 400 is embedded in the magnetic ring groove 111 and surrounds the output copper busbar 200.

[0048] The output copper bus module disclosed in this application integrates the insulating base 100 and the output copper bus 200 through injection molding, making them a single integrated structure. Simultaneously, a magnetic ring recess 111 is injection molded into the insulating base 100, and the magnetic ring is embedded within the recess 111. This integration of the insulating base 100 and the output copper bus 200 achieves an integrated design for the output copper bus 200 module, simplifying the assembly process and improving assembly efficiency.

[0049] In one specific embodiment of this application, the magnetic ring 400 can be encapsulated in the magnetic ring groove 111 using potting compound 500. In this embodiment, during the injection molding of the insulating base 100 and the output copper busbar 200, a magnetic ring groove 111 for the magnetic ring 400 to be embedded is reserved on the insulating base 100. After the magnetic ring 400 is embedded in the magnetic ring groove 111, the magnetic ring groove 111 can be sealed with potting compound 500, so that the magnetic ring 400 is stably fixed within the magnetic ring groove 111. This embodiment uses potting compound 500 to fix the magnetic ring 400, which can reduce electromagnetic interference in the circuit and improve the vibration resistance of the magnetic ring.

[0050] The magnetic ring groove 111 can be designed to be larger than the magnetic ring 400, so that the size of the magnetic ring 400 can be changed according to different needs, so that magnetic rings 400 of various sizes can be installed in the magnetic ring groove 111, and the corresponding size of the magnetic ring 400 can be fixed in the magnetic ring groove 111 by using potting compound 500.

[0051] In one specific embodiment of this application, the insulating base 100 includes a plastic core 109 and a plastic shell 110. It should be noted that the plastic core 109 and the plastic shell 110 are not two separate components, but are defined as plastic core 109 and plastic shell 110 respectively, based on the different functions of different positions of the plastic core 109. Those skilled in the art will understand that the insulating base 100 is an injection-molded part; therefore, the plastic core 109 and the plastic shell 110 are an integral structure.

[0052] The plastic housing 110 is located outside the plastic core 109, forming a magnetic ring groove 111 between the plastic core 109 and the plastic housing 110. A portion of the output copper busbar 200 is enclosed within the plastic core 109, while the first and second terminals are exposed outside the plastic core 109. The plastic core 109 serves to insulate the main body of the output copper busbar 200, while the exposed connection portion facilitates electrical connection with the current sensor module of the motor and the vehicle motor controller.

[0053] It should be noted that, for ease of electrical connection with the current sensor module of the motor and the vehicle motor controller, the output copper busbar 200 includes a first copper busbar body and a second copper busbar body, which are bent at a right angle. One of the first terminal and the second terminal is located on the first copper busbar body, and the other is located on the second copper busbar body. Those skilled in the art will understand that, depending on the location of the current sensor module and the motor, the output copper busbar 200 can be selected in other shapes and is not limited to the right-angled bend shape disclosed in the above embodiments.

[0054] Taking the first terminal for connection to the current sensor module and the second terminal for connection to the motor as an example, a sealing ring 300 is provided at the end of the plastic core 109 near the second terminal. The controller housing of the vehicle motor controller has output copper busbar holes, and the second terminal of the output copper busbar 200 extends out of the controller housing through the output copper busbar holes for easy connection to the motor.

[0055] The sealing ring 300 is used to seal against the inner wall of the output copper busbar hole. That is, after the output copper busbar module is installed on the controller box of the vehicle motor controller, the second terminal passes through the output copper busbar hole, so that the sealing ring 300 of the plastic core 109 is embedded in the output copper busbar hole, thereby sealing the gap between the plastic core 109 and the output copper busbar hole.

[0056] To ensure the positioning of the sealing ring 300 on the plastic core 109, in this embodiment, a sealing ring mounting groove 106 is provided on the plastic core 109, and the sealing ring 300 is embedded in the sealing ring mounting groove 106. The upper and lower side walls of the sealing ring mounting groove 106 can limit the sealing ring 300, preventing the sealing ring 300 from moving along the plastic core 109 and changing its position on the plastic core 109, thus preventing the sealing ring 300 from being accurately sealed at the sealing ring mounting groove 106.

[0057] To facilitate the insertion of the sealing ring 300 from the end of the plastic core 109 into the sealing ring mounting groove 106, in this embodiment, a guide slope is provided on the retaining edge 108 near the second terminal of the sealing ring mounting groove 106 to facilitate the insertion of the sealing ring 300 into the sealing ring mounting groove 106. Specifically, the side of the retaining edge 108 facing the end of the plastic core 109 is the guide slope, so that when the sealing ring 300 is pushed to the position of the retaining edge 108, it is gradually expanded and enlarged by the guide slope until it falls into the sealing ring mounting groove 106.

[0058] Furthermore, since the second terminal of the output copper busbar 200 needs to extend out of the controller housing from the output copper busbar hole when the output copper busbar module is installed inside the controller housing, the flange 108 also needs to pass through the output copper busbar hole to ensure that the sealing ring 300 seals the output copper busbar hole. In this embodiment, a guide slope is provided on the flange 108, which also facilitates the flange 108 passing through the output copper busbar hole, making it convenient for the assembly of the output copper busbar module and the controller housing.

[0059] Since the output copper busbar 200 and the insulating base 100 are injection molded as a single unit, the end of the output copper busbar 200 that connects to the motor needs to extend beyond the insulating base 100. This increases the likelihood of poor fit between the output copper busbar 200 and the insulating base 100, resulting in gaps between them. To ensure the airtightness of the output copper busbar 200 and the insulating base 100, in a specific embodiment of this application, a glue storage groove 101 is pre-reserved on the insulating base 100.

[0060] For ease of understanding, the end of the output copper busbar 200 that extends out of the insulating base 100 from the end connected to the motor is defined as the first end of the insulating base 100. A glue reservoir 101 is provided on the end face of the first end of the insulating base 100 (i.e., the end near the connection between the output copper busbar 200 and the motor), and the glue reservoir 101 is used for potting sealant. By providing the glue reservoir 101 on the end face of the first end of the insulating base 100, sealant can be easily potted into the glue reservoir 101, thereby sealing the first end of the insulating base 100 and improving the airtightness of the output copper busbar 200 and the insulating base 100.

[0061] In this embodiment, the output copper busbar 200 is a three-phase output copper busbar, such as... Figure 1 As shown, the three-phase output copper busbars are U-phase output copper busbar 201, V-phase output copper busbar 202, and W-phase output copper busbar 203. The U-phase output copper busbar 201, V-phase output copper busbar 202, and W-phase output copper busbar 203 can adopt the same structure, which allows them to be manufactured using a single mold, improving product consistency and reducing product costs.

[0062] The first terminal of the output copper busbar 200 is used to connect to the current sensor module, and the second terminal of the output copper busbar 200 is used to connect to the motor.

[0063] like Figure 4 and Figure 6 As shown, each first terminal of the three-phase output copper busbar can be independently wrapped by the insulating base 100. For ease of understanding, the portion of the insulating base 100 that independently wraps the first terminal is defined as the first terminal wrapping body. To enable the first terminal wrapped by the first terminal wrapping body to be connected, the first terminal wrapping body is provided with a wiring hole 102 at a position corresponding to the wiring hole on the first terminal. In this embodiment, each first terminal is wrapped separately, and the copper busbar is exposed only at the contact position by providing a wiring hole 102, thereby increasing the insulation performance of the three-phase output copper busbar.

[0064] Each of the second terminals of the three-phase output copper busbar is uniformly wrapped by an insulating base 100, and the insulating base 100 has a protrusion and / or groove 107 between any two adjacent second terminals (e.g., Figure 5 (As shown). In this embodiment, by providing a protrusion and / or groove 107 on the end face of the insulating base 100 and placing the protrusion and / or groove 107 between any two adjacent second terminals, the creepage distance between the three-phase output copper busbars can be increased. The width and depth of the protrusion and / or groove 107 can be designed according to the creepage distance requirements.

[0065] like Figure 5 and Figure 6 As shown in a specific embodiment of this application, the outer wall of the insulating base 100 is provided with a plurality of mounting seats 103. The mounting seats 103 have through holes, and metal inserts 104 are embedded in the through holes. The metal inserts 104 have fastening holes for fasteners to pass through. The two ends of the metal inserts 104 protrude from the two side surfaces of the mounting seats 103, so that when the output copper busbar module is installed, the metal inserts 104 contact the nuts of the fasteners and the controller housing, preventing the mounting seats 103 (which are part of the insulating base 100 and are all made of plastic) with low hardness from being damaged due to excessive clamping force of the fasteners.

[0066] To improve the vibration resistance of the insulating base 100, in this embodiment, a plurality of reinforcing ribs 105 are provided on the outer side wall of the insulating base 100. The reinforcing ribs 105 can be arranged at the stiffness angle position of the insulating base 100 to increase the stiffness at this position, thereby improving the vibration resistance.

[0067] The vehicle motor controller disclosed in this application includes the output copper busbar module as described in the above embodiments. Since the vehicle motor controller disclosed in this application has the aforementioned output copper busbar module, it possesses all the technical effects of the aforementioned output copper busbar module, which will not be repeated here.

[0068] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "a," and / or "the" are not specifically singular and may include the plural. Generally, the terms "comprising" and "including" only indicate the inclusion of expressly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements. An element defined by the phrase "comprising an..." does not exclude the presence of other identical elements in the process, method, product, or apparatus that includes the element.

[0069] In the description of this application, unless otherwise expressly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0070] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0071] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this application. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

Claims

1. An output copper busbar module, characterized in that, For use in vehicle motor controllers, including: An insulating base (100) having a magnetic ring groove (111). Output copper busbar (200), the output copper busbar (200) and the insulating base (100) are integrally injection molded, one end of the output copper busbar (200) is a first terminal and the other end is a second terminal, one of the first terminal and the second terminal is used to connect to the current sensor module of the vehicle motor controller, and the other terminal is used to connect to the motor. A magnetic ring (400) is fitted into the magnetic ring groove (111) and is arranged around the output copper busbar (200).

2. The output copper busbar module as described in claim 1, characterized in that, The magnetic ring (400) is encapsulated in the magnetic ring groove (111) by potting colloid (500).

3. The output copper busbar module as described in claim 1, characterized in that, The insulating base (100) includes a plastic core (109) and a plastic shell (110), and the magnetic ring groove (111) is formed between the plastic core (109) and the plastic shell (110). Part of the structure of the output copper busbar (200) is enclosed in the plastic core (109), and the first terminal and the second terminal are exposed outside the plastic core (109).

4. The output copper busbar module as described in claim 3, characterized in that, The first terminal is used to connect to the current sensor module, and the second terminal is used to connect to the motor. A sealing ring (300) is provided at one end of the plastic core (109) near the second terminal. The second terminal extends out of the controller housing from the output copper busbar hole on the controller housing of the vehicle motor controller, and the sealing ring (300) is used to seal against the inner wall of the output copper busbar hole.

5. The output copper busbar module as described in claim 4, characterized in that, The plastic core (109) is provided with a sealing ring mounting groove (106), and the sealing ring (300) is embedded in the sealing ring mounting groove (106).

6. The output copper busbar module as described in claim 5, characterized in that, The sealing ring mounting groove (106) has a guide slope on the flange (108) near the second terminal to facilitate the sealing ring (300) being pushed into the sealing ring mounting groove (106).

7. The output copper busbar module as described in any one of claims 1-6, characterized in that, One end of the output copper busbar (200) connected to the motor extends out of the first end of the insulating base (100); An adhesive reservoir (101) is provided on the end face of the first end of the insulating base (100), the adhesive reservoir (101) being used for filling with sealant.

8. The output copper busbar module as described in any one of claims 1-6, characterized in that, The output copper busbar (200) is a three-phase output copper busbar. The first terminal is used to connect to the current sensor module, and the second terminal is used to connect to the motor. Each of the first terminals of the three-phase output copper busbar is independently wrapped by the insulating base (100), and each of the second terminals of the three-phase output copper busbar is uniformly wrapped by the insulating base (100). The insulating base (100) is provided with a protrusion and / or a groove (107) between any two adjacent second terminals.

9. The output copper busbar module as described in any one of claims 1-6, characterized in that, The outer wall of the insulating base (100) is provided with a plurality of mounting seats (103). The mounting seats (103) have through holes, and metal inserts (104) are embedded in the through holes. The metal inserts (104) have fastening holes for fasteners to pass through, and the two ends of the metal inserts (104) protrude from the two side surfaces of the mounting seats (103). And / or, The outer wall of the insulating base (100) is provided with several reinforcing ribs (105).

10. A vehicle-mounted motor controller, characterized in that, Includes the output copper busbar module as described in any one of claims 1-9.

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