Three-phase fixed seat integrated structure and controller thereof

Abstract

The utility model discloses a three-phase fixed seat integrated structure and a controller thereof, and relates to the technical field of oil cooling electric driving systems, the three-phase fixed seat integrated structure comprises a three-phase fixed seat body, the three-phase fixed seat body is integrally formed by a copper bar, a plastic shell and a magnetic core through a plastic coating process, and the plastic shell is provided with a dispensing groove which is arranged between the copper bar and an injection molding interface of the plastic shell and is provided with a magnetic core; a sealant is filled to seal the injection molding gap; the sealing groove is formed in the side edge of the plastic shell in the circumferential direction and used for installing a sealing ring so as to form interface sealing with the electric control shell; the EMC assembling groove is formed in the outer side of the dispensing groove and used for embedding a magnetic ring, and the magnetic ring is arranged around the copper bar; and the isolation structure is formed by integrally extending the plastic shell and is arranged between the adjacent copper bars to increase the creepage distance. According to the utility model, the copper bars, the plastic shell and the magnetic core are integrally formed through the plastic coating process, so that the structure is highly integrated to reduce the occupied space; and the isolation structure is used for preventing sparking among the three-phase copper bars, so that insulation and shielding effects are achieved.

Description

Technical Field

[0001] This utility model relates to the technical field of oil-cooled electric drive systems, specifically to a three-phase fixed base integrated structure and its controller. Background Technology

[0002] Currently, electric drive systems, as core components of new energy vehicles, are developing towards higher integration and higher reliability.

[0003] In terms of sealing and protection, the motor cavity of an oil-cooled drive motor is an oil cavity, while the controller cavity is a dry cavity. Cooling oil can easily seep into the controller cavity through the gap. Existing sealing structures mostly use a single sealing ring or adhesive application, which is difficult to withstand long-term temperature shocks and copper busbar deformation. Oil and gas corrosion can lead to accelerated aging and short circuits of electronic components.

[0004] In terms of space utilization and cost control, the traditional solution involves the independent arrangement of current sensors, EMC magnetic rings, sealing components, etc., resulting in a loose internal structure of the controller and a large space occupation.

[0005] It is evident that there is an urgent need to develop a three-phase mounting bracket assembly with good sealing performance and high space utilization. Utility Model Content

[0006] In a first aspect, to solve the above-mentioned technical problems, this utility model provides an integrated structure for a three-phase mounting base, comprising a three-phase mounting base body, wherein the three-phase mounting base body is integrally formed from a copper busbar, a plastic shell, and a magnetic core through a plastic coating process, and the plastic shell is provided with:

[0007] A dispensing groove is provided between the copper busbar and the injection molding interface of the plastic shell, and is used to fill the sealant to seal the injection gap;

[0008] A sealing groove is circumferentially disposed on the side of the plastic shell and is used to install a sealing ring to form an interface seal with the electrical control shell;

[0009] An EMC assembly slot, located outside the dispensing slot, is used to embed a magnetic ring, which surrounds the copper busbar; and

[0010] An isolation structure, integrally formed from the plastic shell, is disposed between adjacent copper busbars to increase creepage distance.

[0011] Furthermore, the isolation structure is an insulating rib extending along the copper busbar arrangement direction, the height of the insulating rib is greater than the thickness of the copper busbar, and the width of the insulating rib is 1 / 2 to 2 / 3 of the spacing between the copper busbars.

[0012] Furthermore, the sealing groove is an annular groove with a trapezoidal cross-sectional shape.

[0013] Furthermore, the magnetic ring is fixed in the EMC assembly groove by sealant.

[0014] Furthermore, the depth of the dispensing groove is 1 / 3 to 1 / 2 of the thickness of the copper busbar; the sealant is a two-component epoxy resin adhesive.

[0015] In a second aspect, the present invention provides a controller, including a three-phase mounting base assembly, wherein the three-phase mounting base assembly is an integrated structure of the three-phase mounting base, and wherein the three-phase mounting base assembly is sealed to the electrical control housing through the sealing ring.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] This invention achieves a high degree of structural integration by integrally molding the copper busbar, plastic shell, and magnetic core through a plastic coating process, thereby reducing the space occupied; and prevents arcing between the three-phase copper busbars through an isolation structure, thus providing insulation and shielding. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the three-phase fixed base integrated structure disclosed in the embodiment of this utility model;

[0019] Figure 2 This is an exploded view of the integrated structure of the three-phase fixed base disclosed in the embodiment of this utility model;

[0020] Figure 3 This is a partial assembly cross-sectional view of the electrical control and motor disclosed in an embodiment of this utility model.

[0021] In the picture:

[0022] 00. Three-phase mounting base body; 10. Copper busbar; 20. Plastic shell; 21. Glue dispensing groove; 22. Sealing groove; 22a. Sealing ring; 23. EMC assembly groove; 23a. Magnetic ring; 24. Isolation structure; 30. Magnetic core; 40. Electrical control housing; 50. Motor cavity. Detailed Implementation

[0023] To make the technical solutions and effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0024] Please see Figure 1 This utility model aims to provide an integrated structure for a three-phase mounting base with good sealing performance and high space utilization. It includes a three-phase mounting base body 00, which is integrally formed from a copper busbar 10, a plastic shell 20, and a magnetic core 30 through a plastic coating process, creating a compact structure. The copper busbar includes U-phase, V-phase, and W-phase copper busbars.

[0025] Please see Figure 2 The plastic shell 20 is equipped with an adhesive groove 21, a sealing groove 22, an EMC assembly groove 23, and an isolation structure 24. Specifically:

[0026] The dispensing groove 21 is located between the copper busbar 10 and the plastic shell 20 at the injection molding interface. It is used to fill the sealant to seal the injection gap, block the oil and gas penetration path, and form the first sealing barrier. The depth of the dispensing groove 21 is 1 / 3 to 1 / 2 of the thickness of the copper busbar 10; the sealant material is a two-component epoxy resin.

[0027] A sealing groove 22 is circumferentially disposed on the side of the plastic shell 20 for mounting a sealing ring 22a to form an interface seal with the electrical control housing 40. The sealing groove 22 is an annular groove with a trapezoidal cross-sectional shape. Preferably, the sealing ring 22a is made of oil-resistant fluororubber. After being deformed under pressure, the sealing ring 22a fits tightly against the electrical control housing 40, forming a second sealing barrier.

[0028] The EMC assembly slot 23 is located outside the dispensing slot 21 and is used to embed the magnetic ring 23a, which is then fixed by dispensing adhesive. The magnetic ring 23a surrounds the copper busbar 10 to suppress electromagnetic interference; the magnetic ring 23a is fixed in the EMC assembly slot 23 by sealant.

[0029] The isolation structure 24 is integrally formed by extending the plastic shell 20 and is disposed between adjacent copper busbars 10 to increase the creepage distance, prevent arcing between copper busbars, and serve as an insulating shield. Preferably, the isolation structure 24 is an insulating rib extending along the arrangement direction of the copper busbars 10, the height of the insulating rib is greater than the thickness of the copper busbars 10, and the width of the insulating rib is 1 / 2 to 2 / 3 of the spacing between the copper busbars 10.

[0030] This utility model also protects a controller, which includes a three-phase mounting bracket assembly. The three-phase mounting bracket assembly is the three-phase mounting bracket integrated structure described above. The three-phase mounting bracket assembly is sealed to the electrical control housing 40 through a sealing ring 22a, so that the three-phase mounting bracket body 00 and the electrical control housing 40 form a sealed structure, separating the electrical control housing 40 from the motor cavity 50, thus solving the problem of oil and gas corrosion in oil-cooled motors.

[0031] This invention greatly improves space utilization through high integration; at the same time, it enhances the sealing performance of the three-phase fixed base body 00, reduces the possibility of oil and gas erosion, and improves product reliability.

[0032] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A three-phase fixed base integrated structure, characterized in that, Includes a three-phase mounting base body (00), which is integrally formed from a copper busbar (10), a plastic shell (20), and a magnetic core (30) through a plastic coating process. The plastic shell (20) is provided with: A dispensing groove (21) is provided between the copper busbar (10) and the injection interface of the plastic shell (20) for filling with sealant to seal the injection gap; A sealing groove (22) is circumferentially disposed on the side of the plastic shell (20) for installing a sealing ring (22a) to form an interface seal with the electrical control shell (40); EMC assembly slot (23), located outside the dispensing slot (21), is used to embed a magnetic ring (23a), the magnetic ring (23a) surrounding the copper busbar (10); and An isolation structure (24), integrally formed from the plastic shell (20), is disposed between adjacent copper busbars (10) to increase creepage distance.

2. The three-phase fixed base integrated structure according to claim 1, characterized in that, The isolation structure (24) is an insulating rib extending along the arrangement direction of the copper busbar (10). The height of the insulating rib is greater than the thickness of the copper busbar (10), and the width of the insulating rib is 1 / 2 to 2 / 3 of the spacing between the copper busbars (10).

3. The three-phase fixed base integrated structure according to claim 1, characterized in that, The sealing groove (22) is an annular groove with a trapezoidal cross-sectional shape.

4. The three-phase fixed base integrated structure according to claim 1, characterized in that, The magnetic ring (23a) is fixed in the EMC assembly groove (23) by sealant.

5. The three-phase fixed base integrated structure according to claim 1, characterized in that, The depth of the dispensing groove (21) is 1 / 3 to 1 / 2 of the thickness of the copper busbar (10); the sealant is a two-component epoxy resin adhesive.

6. A controller comprising a three-phase mounting bracket assembly, characterized in that, The three-phase mounting bracket assembly is the three-phase mounting bracket integrated structure according to any one of claims 1-5, wherein the three-phase mounting bracket assembly is sealed to the electrical control housing (40) through the sealing ring (22a).

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