Busbar structure and electric machine

Abstract

The utility model discloses a busbar structure and motor, the busbar structure includes insulating framework, outgoing line busbar, neutral point busbar, terminal row and heat shrink tube, a plurality of outgoing line busbar all with neutral point busbar links to each other, and integrative injection molding on insulating framework, outgoing line busbar with terminal row all are provided with a plurality of, a plurality of outgoing line busbar and a plurality of terminal row corresponding link to each other, the heat shrink tube outer cover in terminal row with outgoing line busbar's connecting place. According to the busbar structure of the utility model, the assembly mode is simple, and the assembly efficiency is high, and the insulating property is better.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to a busbar structure and a motor. Background Technology

[0002] The efficient operation of flat wire motors in new energy vehicles relies on stable current transmission and heat dissipation performance. Traditional flat wire motors often use a modular assembly design for their busbars, which involves complex assembly processes and low assembly efficiency. In addition, under vibration, the connections of the assembled busbars are prone to loosening, affecting their reliability. Utility Model Content

[0003] The present invention aims to solve at least one of the technical problems existing in the prior art. Therefore, one objective of the present invention is to provide a busbar structure that is simple to assemble, has high assembly efficiency, and good insulation.

[0004] According to the busbar structure of this utility model embodiment, the busbar structure includes: an insulating frame, lead wire busbars, neutral point busbars, terminal blocks, and heat shrink tubing. Multiple lead wire busbars are connected to the neutral point busbars and are integrally injection molded onto the insulating frame. Multiple lead wire busbars and multiple terminal blocks are provided, and the multiple lead wire busbars and multiple terminal blocks are correspondingly connected. The heat shrink tubing is sleeved at the connection between the terminal blocks and the lead wire busbars.

[0005] According to the busbar structure of this utility model embodiment, by integrally injection molding the lead-out busbar and the neutral point busbar onto the insulating frame, the assembly method of the busbar structure can be simplified and the assembly efficiency improved. In addition, the lead-out busbar and the neutral point busbar integrally injection molded onto the insulating frame have high connection strength and are not easily loosened due to vibration. Furthermore, the heat shrink tubing can better connect the terminal block and the lead-out busbar, and can further optimize the reliability of the insulation between the terminal block and the lead-out busbar, thereby extending the service life.

[0006] In addition, the busbar structure of this utility model may also have the following additional technical features:

[0007] In some embodiments of this utility model, the outer surface of the terminal block is provided with a nickel plating layer, and the nickel plating layer is located at the end of the terminal block connected to the lead bus.

[0008] In some embodiments of this utility model, the terminal block includes multiple metal laminations, which are stacked to form the terminal block, and the metal laminations are integrally formed from copper.

[0009] In some embodiments of this utility model, the thickness D of the terminal block satisfies: 5mm≤D≤6mm.

[0010] In some embodiments of this utility model, the neutral point bus is a one-piece molded part.

[0011] In some embodiments of this utility model, the neutral point bus includes multiple terminals, which are arranged circumferentially along the insulating frame.

[0012] In some embodiments of this utility model, the insulating frame is a circular ring joined end to end.

[0013] In some embodiments of this utility model, the lead bus includes a U-phase bus, a V-phase bus, and a W-phase bus, and the U-phase bus, the V-phase bus, and the W-phase bus are connected to the neutral point bus.

[0014] In some embodiments of this utility model, at least one of the plurality of terminal blocks includes a first segment and a second segment connected at an angle, the first segment being connected to the lead bus.

[0015] This utility model also proposes a motor having the busbar structure described in the above embodiments.

[0016] According to the embodiments of the present invention, the motor is equipped with the busbar structure described above. The busbar structure is integrally injection molded onto the insulating frame via lead wire busbars and neutral point busbars. This simplifies the assembly method of the busbar structure and improves assembly efficiency. In addition, the lead wire busbars and neutral point busbars integrally injection molded onto the insulating frame have high connection strength and are not easily loosened due to vibration. Furthermore, the heat shrink tubing can effectively connect the terminal blocks and lead wire busbars, and can further optimize the reliability of the insulation between the terminal blocks and lead wire busbars, thereby extending the service life. Thus, the motor of the present invention has high assembly efficiency and reliability.

[0017] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0018] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0019] Figure 1 This is a schematic diagram of the busbar structure according to an embodiment of the present utility model.

[0020] Figure 2 This is a schematic diagram of the stator winding structure according to an embodiment of the present utility model.

[0021] Figure 3 This is a top view of the busbar structure according to an embodiment of the present utility model.

[0022] Figure 4 yes Figure 3 A cross-sectional view along line AA.

[0023] Figure 5 yes Figure 4 A magnified view of region B in the middle.

[0024] Figure label:

[0025] 100. Busbar structure; 200. Stator winding; 1. Insulation frame; 11. Positioning component; 21. U-phase busbar; 22. V-phase busbar; 23. W-phase busbar; 3. Neutral point busbar; 31. Terminal; 4. Terminal block; 5. Heat shrink tubing. Detailed Implementation

[0026] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0027] In the description of this utility model, it should be understood that the terms "upper," "lower," "front," "rear," "left," and "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used solely for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0028] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0029] The following is for reference. Figures 1-5 Description of busbar structure 100 according to an embodiment of the present utility model.

[0030] like Figures 1-5 As shown, the busbar structure 100 according to an embodiment of the present invention includes an insulating frame 1, lead-out busbars, neutral point busbars 3, terminal blocks 4, and heat shrink tubing 5. Multiple lead-out busbars are connected to the neutral point busbars 3 and are integrally injection molded onto the insulating frame 1. Multiple lead-out busbars and multiple terminal blocks 4 are provided, and the multiple lead-out busbars and multiple terminal blocks 4 are correspondingly connected. The heat shrink tubing 5 is sleeved at the connection between the terminal blocks 4 and the lead-out busbars.

[0031] Combination Figure 1 As shown in the specific example, the lead-out bus may include a U-phase bus 21, a V-phase bus 22, and a W-phase bus 23. The U-phase bus 21, V-phase bus 22, and W-phase bus 23 are all end-molded into the insulating frame 1. In addition, the neutral point bus 3 is also molded into the insulating frame 1. Through the integrally molded insulating frame 1, the U-phase bus 21, V-phase bus 22, and W-phase bus 23 can all be well connected to the neutral point return bus, resulting in high reliability and good stability.

[0032] Compared to related technologies where the lead busbars are assembled onto the insulating frame 1 via snap-fit, the lead busbars in this application are injection molded onto the insulating frame 1. This results in better structural strength and reduces the likelihood of deformation affecting the connection between the lead busbars and the neutral point busbar 3, thus enhancing the reliability of the busbar structure 100. Furthermore, even if the lead busbars deform, those located inside the insulating frame 1 are less prone to bending, providing better insulation and reducing the risk of short circuits.

[0033] Furthermore, the heat shrink tubing 5 can be partially wrapped around the outer surface of the terminal block 4 and partially wrapped around the outer surface of the lead busbar, thereby better connecting the terminal block 4 and the lead busbar. It can also further optimize the reliability of the insulation between the terminal block 4 and the lead busbar, thus extending the service life.

[0034] For example, the heat shrink tubing 5 can be formed of silicone or other materials, and this application does not impose any restrictions.

[0035] According to the busbar structure 100 of this utility model embodiment, the lead wire busbar and the neutral point busbar 3 are integrally injection molded on the insulating frame 1, which can simplify the assembly method of the busbar structure 100 and improve the assembly efficiency. In addition, the lead wire busbar and the neutral point busbar 3 integrally injection molded on the insulating frame 1 have high connection strength and are not easy to loosen due to vibration. Furthermore, the heat shrink tubing 5 can better connect the terminal block 4 and the lead wire busbar, and can further optimize the reliability of the insulation between the terminal block 4 and the lead wire busbar, thereby extending the service life.

[0036] In some embodiments of this utility model, a nickel plating layer is provided on the outer surface of the terminal block 4, and the nickel plating layer is located at the end of the terminal block 4 connected to the lead bus.

[0037] In other words, the nickel plating layer can effectively improve the conductivity of the terminals of terminal block 4, reduce contact resistance, decrease power loss during transmission, and improve equipment operating efficiency. Simultaneously, the nickel plating layer has good corrosion resistance and oxidation resistance, effectively isolating corrosive media such as air and moisture, reducing poor contact caused by oxidation and corrosion at the connection between terminal block 4 and the lead bus. Furthermore, the nickel plating layer can enhance the surface hardness of the terminals of terminal block 4, improving the problem of excessive resistance and subsequent burning between terminal block 4 and the lead bus.

[0038] In some embodiments of this utility model, the terminal block 4 includes multiple metal stacks, which are stacked to form the terminal block 4. The metal stacks are integrally formed from copper.

[0039] In other words, copper has good electrical conductivity, and the stacked structure design can effectively increase the current-carrying cross-sectional area, thereby enhancing the current-carrying capacity of terminal block 4 and meeting the requirements of high current transmission. The metal laminations are integrally formed from copper, resulting in a more uniform structure and improving the overall mechanical stability of terminal block 4. Furthermore, the stacked structure design allows for flexible adjustment of the number of laminations to adapt to different current specifications, enhancing product versatility. Simultaneously, each metal lamination can be designed with different bending shapes according to actual needs, effectively keeping adjacent terminal blocks 4 away from each other, thus reducing the risk of short circuits and ensuring good safety.

[0040] In some embodiments of this utility model, the thickness D of the terminal block 4 satisfies: 5mm≤D≤6mm.

[0041] For example, the thickness of the metal laminations is 0.1 mm. Therefore, the number of metal laminations can be adjusted according to actual needs. That is, the number of metal laminations can be 50 to 60, such as 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, etc. This utility model does not impose any limitations.

[0042] In some embodiments of this utility model, the neutral point bus 3 is an integrally molded part.

[0043] In other words, the one-piece molding structure reduces the number of connection points in traditional spliced ​​busbars, minimizing the increased resistance caused by poor contact at solder joints or splices. This facilitates a smoother current transmission path, thereby reducing power loss. Furthermore, the one-piece molding process simplifies the production process, reduces assembly steps, lowers the risk of human error, and ensures greater structural consistency, thus improving the stability and reliability of mass production.

[0044] For example, the neutral point bus 3 can be processed by stamping, casting or 3D printing, and this application does not limit this.

[0045] In some embodiments of this utility model, such as Figures 1-5 As shown, the neutral point bus 3 includes multiple terminals 31, which are arranged circumferentially along the insulating frame 1. The terminals 31 can be welded to the flat wire ends of the stator winding 200.

[0046] In other words, the circumferential spacing design allows for a more even distribution of the terminals 31, avoiding space congestion caused by concentrated wiring, providing ample operating space for lead wire connections, and reducing the welding difficulty of the stage sections and flat wire ends. Simultaneously, the spacing arrangement increases the distance between the terminals 31, which, combined with the isolation effect of the insulating frame 1, effectively reduces the risk of phase-to-phase short circuits and enhances insulation safety.

[0047] In some embodiments of this utility model, such as Figures 1-3 As shown, the insulating frame 1 is a circular ring connected end to end.

[0048] In other words, the circular shape allows for more even stress distribution on the frame, which can better improve the overall structural strength and deformation resistance of the insulation frame 1, and better meet the long-term operating requirements of the busbar structure 100. The circumferentially closed circular layout, combined with the circumferentially spaced terminal blocks 31, can effectively reduce line crossing interference and enhance wiring regularity.

[0049] In some embodiments of this utility model, such as Figures 1-3 As shown, the lead-out bus includes a U-phase bus 21, a V-phase bus 22, and a W-phase bus 23, which are connected to the neutral point bus 3.

[0050] In other words, the busbar structure 100 of this utility model can be applied to three-phase motors. The power transmission of three-phase motors is relatively stable, the vibration during motor operation is small, the noise is low, and the energy conversion efficiency is high. By making the lead-out busbars include U-phase busbar 21, V-phase busbar 22 and W-phase busbar 23, the busbar structure 100 of this utility model can be used well for three-phase motors, which can make the three-phase motors have high assembly efficiency and reliability.

[0051] In some embodiments of this utility model, such as Figures 1-4 As shown, at least one of the multiple terminal blocks 4 includes a first segment and a second segment connected at an angle, the first segment being connected to the lead bus.

[0052] In other words, the terminal block 4 can be a bent terminal block 4. The bending structure can make two adjacent terminal blocks 4 move away from each other, thereby increasing the distance between two adjacent terminal blocks 4. This can better reduce the risk of short circuits caused by the close proximity of two adjacent terminal blocks 4. In addition, the bending design can also flexibly adjust the orientation of the terminal block 4, which is conducive to the orderly arrangement of the circuit in a limited space and avoids the circuit crossing and tangling.

[0053] This utility model also proposes a motor having the busbar structure 100 of the above embodiments.

[0054] According to the embodiment of the present invention, the motor is equipped with the busbar structure 100 described above. The busbar structure 100 is integrally injection molded onto the insulating frame 1 via the lead wire busbar and the neutral point busbar 3. This simplifies the assembly method of the busbar structure 100 and improves assembly efficiency. In addition, the lead wire busbar and the neutral point busbar 3 integrally injection molded onto the insulating frame 1 have high connection strength and are not easily loosened due to vibration. Furthermore, the heat shrink tubing 5 can better connect the terminal block 4 and the lead wire busbar, and can further optimize the reliability of the insulation between the terminal block 4 and the lead wire busbar, thereby extending the service life. Thus, the motor of the present invention has high assembly efficiency and reliability.

[0055] For example, a positioning element 11 can be provided on the insulating frame 1. The positioning element 11 can be a positioning groove or a positioning block. The positioning element 11 can be positioned with the motor housing, thereby improving the assembly efficiency of the busbar structure 100.

[0056] For example, the motor may include a stator winding 200, which may have multiple flat wires. The number of flat wires in each stator slot may also be multiple. The multiple flat wires are arranged in a radial stack along the stator winding 200. An insulating layer is provided on the outer surface of the flat wires. The insulating layer may be formed of a polyimide film, thereby reducing eddy current losses.

[0057] In a specific example, the motor is a three-phase AC motor with 72 slots on the stator core and designed as 8 magnetic poles; its stator winding 200 adopts a structure of 4 parallel branches, that is, each phase winding is evenly divided into 4 independent branches, and each branch forms a complete circuit by connecting 18 coils in the slots in series.

[0058] The windings employ a 6-layer flat wire lamination process, with the insulation layer thickness between adjacent flat wires being less than or equal to 0.2mm. This effectively reduces the winding volume while ensuring insulation performance, achieving a compact structure. Furthermore, the four branches are evenly distributed on the stator circumference, with a 90° mechanical angle phase difference between adjacent branches. This spatial layout effectively counteracts electromagnetic interference caused by uneven winding distribution, ensuring symmetrical waveforms and balanced amplitudes of the back electromotive forces during motor operation, thus improving operational stability.

[0059] The busbar structure 100 and other components and operations of the motor according to the embodiments of this utility model are known to those skilled in the art and will not be described in detail here.

[0060] In the description of this specification, references to terms such as "some embodiments," "optionally," "furthermore," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0061] Although embodiments of the present invention have been shown and described, those skilled in the art will understand 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 claims and their equivalents.

Claims

1. A busbar structure, characterized in that, include: Insulating frame (1), lead bus, neutral point bus (3), terminal block (4), and heat shrink tubing (5), Multiple lead-out busbars are connected to the neutral point busbar (3) and are integrally injection molded onto the insulating frame (1). Multiple lead-out busbars and multiple terminal blocks (4) are provided, and multiple lead-out busbars and multiple terminal blocks (4) are connected to each other. The heat shrink tubing (5) is sleeved on the connection between the terminal block (4) and the lead-out busbar.

2. The busbar structure according to claim 1, characterized in that, The outer surface of the terminal block (4) is provided with a nickel plating layer, which is located at the end of the terminal block (4) connected to the lead bus.

3. The busbar structure according to claim 1, characterized in that, The terminal block (4) includes multiple metal laminations, which are stacked to form the terminal block (4). The metal laminations are integrally formed from copper.

4. The busbar structure according to claim 3, characterized in that, The thickness D of the terminal block (4) satisfies: 5mm≤D≤6mm.

5. The busbar structure according to claim 1, characterized in that, The neutral point bus (3) is a one-piece molded part.

6. The busbar structure according to claim 1, characterized in that, The neutral point bus (3) includes multiple terminals (31) which are spaced apart along the circumference of the insulating frame (1).

7. The busbar structure according to claim 1, characterized in that, The insulating frame (1) is a circular ring with its ends connected.

8. The busbar structure according to claim 1, characterized in that, The lead-out bus includes a U-phase bus (21), a V-phase bus (22), and a W-phase bus (23), and the U-phase bus (21), the V-phase bus (22), and the W-phase bus (23) are connected to the neutral point bus (3).

9. The busbar structure according to claim 1, characterized in that, At least one of the plurality of terminal blocks (4) includes a first segment and a second segment connected at an angle, the first segment being connected to the lead bus.

10. An electric motor, characterized in that, The busbar structure includes any one of claims 1-9.

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