Drive motor, powertrain and electric vehicle

Abstract

The application provides a driving motor, a power assembly and an electric vehicle. A stator core of a stator of the driving motor is used for accommodating a winding frame, and the winding frame is used for isolating the stator core and a stator winding. A plastic part is used for wrapping a plurality of bus bars, and the plurality of bus bars are used for transmitting received three-phase alternating current to the stator winding. The plastic part and the winding frame are distributed along an axial direction of the driving motor, wherein a surface of the winding frame towards the plastic part comprises a plurality of protrusions, and the plastic part comprises a plurality of through holes, each of which is used for clamping one protrusion. In the driving motor provided by the application, the protrusions of the winding frame share and absorb the impact of vibrations generated during the operation of the electric vehicle on the welding points of the plurality of bus bars and the stator winding, the connection rigidity of the plurality of bus bars and the stator winding is improved, the risk of fracture failure of the welding points of the plurality of bus bars and the stator winding is reduced, and the performance of the driving motor is improved, such as the torque, efficiency, service life and safety of the driving motor.

Description

Technical Field

[0001] This application relates to the field of electric vehicle technology, specifically to a drive motor, powertrain, and electric vehicle. Background Technology

[0002] In electric vehicles, the drive motor of the powertrain includes a rotor and a stator. The stator includes a stator core and stator windings. The stator windings receive three-phase alternating current through a busbar and generate a magnetic field to drive the motor rotor to rotate and output power.

[0003] The stator windings are welded to multiple busbars to achieve electrical connection between the stator windings and the busbars. However, during the operation of an electric vehicle, the welded joints between the stator windings and the busbars are prone to breakage, leading to short circuits or open circuits in the drive motor and affecting its performance. Utility Model Content

[0004] This application provides a drive motor, a powertrain, and an electric vehicle. The connection stiffness between the busbar and the stator winding of the drive motor is improved, reducing the risk of fracture failure at the welding point between the busbar and the stator winding, thus improving the performance of the drive motor and contributing to the improvement of the performance of the powertrain and the electric vehicle.

[0005] In a first aspect, a drive motor is provided, wherein the stator core of the stator of the drive motor is used to house a winding frame, and the winding frame is used to isolate the stator core and the stator winding. A plastic component is used to enclose multiple busbars for transmitting received three-phase alternating current to the stator winding. The plastic component and the winding frame are distributed along the axial direction of the drive motor, wherein the surface of the winding frame facing the plastic component includes multiple protrusions, and the plastic component includes multiple through holes, each through hole for engaging one protrusion.

[0006] In the drive motor provided in this embodiment, through holes on the plastic component encasing multiple busbars engage with protrusions in the winding frame, thus securing the winding frame and the plastic component. The protrusions in the winding frame distribute and absorb the impact of vibrations generated during electric vehicle operation on the welding points between the multiple busbars and the stator windings. This improves the connection stiffness between the multiple busbars and the stator windings, reduces the risk of fracture failure at the welding points, and helps improve the performance of the drive motor, such as its torque, efficiency, service life, and safety.

[0007] Furthermore, if the winding frame and plastic parts are fixed using claws or clips, the radial dimension of the winding frame or plastic parts with the claws or clips would need to be increased to improve the stability of the fixation. If the winding frame and plastic parts are fixed using potting or coating materials, the axial dimension of the stator along the drive motor would need to be increased. However, in the drive motor provided in this application embodiment, the fixing method using protrusions and through holes eliminates the need to increase the radial or axial dimension of the winding frame or plastic parts along the drive motor, which is beneficial for miniaturizing the drive motor.

[0008] In one implementation, each protrusion passes through a through-hole, and each through-hole engages a portion of the protrusion protruding from the plastic part. For example, the protrusion on the winding frame is a thermoplastic protrusion. After heating the portion of the protrusion on the winding frame protruding from the plastic part, it melts onto the surface of the plastic part away from the winding frame until the molten protrusion covers the through-hole of the plastic part, thus achieving the through-hole engaging the portion of the protrusion protruding from the plastic part. The protrusion of the winding frame protruding from the plastic part effectively prevents the plastic part from moving along the side away from the winding frame, improving the firmness of the engagement between the through-hole on the plastic part and the protrusion on the winding frame.

[0009] In one implementation, the diameter of one segment of each protrusion is larger than the diameter of each through hole. The diameter of the molten portion of the protrusion on the winding frame protruding from the plastic part is larger than the diameter of each through hole, and the molten protrusion completely covers the through holes of the plastic part. This simplifies the assembly process between the winding frame and the plastic part while ensuring a firm fixation between them.

[0010] In one implementation, the diameter of each protrusion not protruding from the other end of the plastic part is smaller than the diameter of each through hole. During the assembly of the winding frame and the plastic part, interference between the protrusions on the winding frame and the hole walls of the through holes on the plastic part is reduced, thus improving the assembly efficiency of the protrusions on the winding frame and the plastic part.

[0011] In one implementation, multiple protrusions are evenly distributed along the circumference of the drive motor, while multiple through holes are distributed at unequal intervals along the circumference of the drive motor. The protrusions are divided into two groups, and the through holes are used to engage one group of protrusions and to avoid the other group of protrusions.

[0012] The winding frame is injection molded in sections using a single injection mold, ensuring that each injection-molded winding frame is identical. After splicing multiple winding frames along the circumference of the drive motor, the multiple protrusions on the winding frame are evenly distributed along the circumference of the drive motor. Furthermore, the spacing of the multiple through holes on the plastic part is set differently, reducing the number of through holes on the plastic part that mate with the protrusions on the winding frame. This allows each through hole on the plastic part to engage with one set of protrusions while avoiding another set, thus balancing the manufacturing cost of the drive motor with the reliability of the engagement between the through holes on the plastic part and the protrusions on the winding frame.

[0013] In one implementation, the outer peripheral surface of the plastic part includes multiple fixed ends, each fixed end including a through hole, and the multiple fixed ends are distributed at unequal intervals along the circumferential direction of the drive motor. Two of the fixed ends with a larger interval are used to avoid another set of protrusions. This simplifies the processing of the through holes, improves the space utilization rate of the drive motor along its circumferential direction, and facilitates the cost reduction and miniaturization of the drive motor.

[0014] In one implementation, two of the multiple fixed ends with a large gap are also used to avoid one end of the stator winding electrical connection bus. This further improves the space utilization of the drive motor along its circumference, which is beneficial for miniaturizing the drive motor.

[0015] In one implementation, the number of protrusions in the other set is less than the number of protrusions in the first set. The increased number of protrusions on the winding frame engaging with the through-holes in the plastic component increases the clamping force between the plastic component and the winding frame, thus improving the secure connection between the through-holes in the plastic component and the protrusions on the winding frame.

[0016] In one implementation, another set of protrusions is evenly distributed along the circumference of the drive motor. The engagement force between the winding frame and the plastic part is evenly distributed along the circumference of the drive motor, improving the reliability of the engagement between the protrusions on the winding frame and the through holes on the plastic part.

[0017] In one implementation, multiple through holes are divided into two groups, with the number of through holes in one group being less than the number of through holes in the other group, and the diameter of the through holes in one group being less than the diameter of the through holes in the other group.

[0018] A small number of through holes with small diameters are provided on the plastic part as positioning through holes to mate with the protrusions on the winding frame. During the assembly process of the protrusions on the winding frame and the through holes on the plastic part, the set of through holes on the plastic part and the protrusions on the winding frame passing through the set of through holes achieve the initial positioning of the winding frame and the plastic part, thereby improving the assembly accuracy of the protrusions on the winding frame and the through holes on the plastic part.

[0019] In one implementation, the diameter of a set of through holes is equal to the diameter of a protrusion passing through the set of through holes. During the assembly process of the protrusion on the winding frame and the through holes on the plastic part, the set of through holes on the plastic part and the protrusion passing through the set of through holes on the winding frame achieve precise positioning of the winding frame and the plastic part, further improving the assembly accuracy of the protrusion on the winding frame and the through holes on the plastic part.

[0020] In one implementation, the diameter of the other set of through holes is larger than the diameter of the protrusion passing through the other set of through holes. During the assembly process of the protrusion on the winding frame and the through holes on the plastic part, interference between the other set of through holes on the plastic part and the protrusion passing through the other set of through holes on the winding frame is avoided, thus improving the assembly efficiency of the protrusion on the winding frame and the plastic part.

[0021] In one implementation, the distance between one end of each busbar electrically connected to the stator winding along the axial direction of the drive motor and the surface is greater than the length of each protrusion. That is, the length of the stator winding between the plastic part and the winding frame is greater than the length of each protrusion.

[0022] The vibrations generated during the operation of electric vehicles impact the drive motor. The connection between the protrusions on the winding frame and the through holes in the plastic parts becomes the stress point, with the connection between the stator winding and the busbar being the primary stress point. Compared to the connection between the stator winding and the busbar, the connection between the protrusions on the winding frame and the through holes in the plastic parts absorbs the impact force first, further reducing the risk of multiple busbar and stator winding welding points breaking and failing.

[0023] In one implementation, the surface of the winding frame along the axial direction of the drive motor protrudes beyond the surface of the stator winding wound around the winding frame. The engagement between the protrusion on the winding frame and the through-hole of the plastic part does not affect the winding of the stator winding.

[0024] In one implementation, the surface of the winding frame is bonded to the surface of the plastic component facing the winding frame. This increases the stress points between the plastic component and the winding frame, further reducing the risk of fracture failure at the weld points between the multiple busbars and the stator windings.

[0025] In a second aspect, a powertrain is provided, comprising a reducer and a drive motor as described in any one of the first aspects and possible implementations thereof, wherein the motor shaft of the drive motor is used for transmission connection to the input shaft of the reducer.

[0026] The performance of the drive motor provided in this application embodiment is improved, which helps to improve the performance of the powertrain provided in the second aspect.

[0027] Thirdly, an electric vehicle is provided, the electric vehicle including wheels, a transmission mechanism and a powertrain as described in the second aspect, the powertrain being used to drive the wheels via the transmission mechanism.

[0028] The powertrain provided in this application embodiment has improved performance, which helps to increase the driving range of electric vehicles and improve the driving experience of electric vehicles. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of an electric vehicle provided in an embodiment of this application.

[0030] Figure 2 This is a schematic diagram of a drive motor provided in an embodiment of this application.

[0031] Figure 3 A schematic diagram of the stator of a drive motor provided in this application embodiment.

[0032] Figure 4 A schematic diagram of a stator core provided in this application embodiment.

[0033] Figure 5 This is a schematic diagram of a winding frame provided in an embodiment of this application.

[0034] Figure 6 This is a schematic diagram of a stator winding provided in an embodiment of this application.

[0035] Figure 7 This is a schematic diagram of a stator winding provided in an embodiment of this application.

[0036] Figure 8 This is another schematic diagram of the stator core provided in the embodiments of this application.

[0037] Figure 9 This is another schematic diagram of the winding frame provided in an embodiment of this application.

[0038] Figure 10 Another schematic diagram of the stator provided in the embodiments of this application.

[0039] Figure 11 Another schematic diagram of the stator provided in the embodiments of this application.

[0040] Figure 12 This is another schematic diagram of a plastic part provided in an embodiment of this application.

[0041] Figure 13 This is a partial schematic diagram of a stator provided in an embodiment of this application.

[0042] Figure 14 This is another schematic diagram of the winding frame provided in an embodiment of this application.

[0043] Figure 15 This is another schematic diagram of a plastic part provided in an embodiment of this application.

[0044] Figure 16 Another schematic diagram of the stator provided in the embodiments of this application. Detailed Implementation

[0045] The technical solutions in this application will now be described with reference to the accompanying drawings.

[0046] The terms "equal to" or "equal to" in this application are not strictly equal or equal in the strict sense, but rather within the allowable error range. Similarly, "parallel" is not strictly parallel, but within the allowable error range. And "perpendicular" is not strictly perpendicular, but within the allowable error range.

[0047] In this embodiment, the same reference numeral denotes the same component or part. In this embodiment, for multiple identical parts, the reference numeral may only be used to label one of the parts as an example. The reference numerals also apply to other identical parts or components. Furthermore, the dimensions and sizes of the parts shown in the drawings are merely exemplary.

[0048] Figure 1 This is a schematic diagram of an electric vehicle provided in an embodiment of this application. The electric vehicles provided in this application include pure electric vehicles, hybrid electric vehicles, range-extended electric vehicles, plug-in hybrid electric vehicles, or new energy vehicles. Pure electric vehicles are also called pure electric vehicles / battery electric vehicles, or simply pure EVs / battery EVs. Hybrid electric vehicles are also called hybrid electric vehicles, or simply HEVs. Range-extended electric vehicles are also called range-extended electric vehicles, or simply REEVs. Plug-in hybrid electric vehicles are also called plug-in hybrid electric vehicles, or simply PHEVs. New energy vehicles are also called newenergy vehicles, or simply NEVs.

[0049] like Figure 1 As shown, the electric vehicle 1 includes a powertrain 10 and a power battery 20. The powertrain 10 receives power from the power battery 20 and converts electrical energy into mechanical energy to power the wheels of the electric vehicle 1.

[0050] In one embodiment, the electric vehicle 1 includes two powertrains 10, one of which drives the two front wheels of the electric vehicle 1, and the other of which drives the two rear wheels of the electric vehicle 1. In another embodiment, the electric vehicle 1 includes four powertrains 10, which drive the four wheels of the electric vehicle 1 respectively.

[0051] like Figure 1 As shown, the electric vehicle 1 also includes a power module 30. The power module 30 is used to receive power from an external power source 40 to charge the power battery 20. In one embodiment, the external power source 40 is an AC power grid, an AC charging station, or a DC charging station. The power module 30 includes at least one of a DC charger or an AC charger.

[0052] This application also provides a powertrain. For example... Figure 1 As shown, the powertrain 10 provided in this embodiment includes a drive motor 100, which is used to drive the wheels of the electric vehicle 1.

[0053] In one embodiment, such as Figure 1 As shown, the powertrain 10 provided in this embodiment of the application also includes a reducer 200, and the drive motor 100 is used to drive the wheels of the electric vehicle 1 through the reducer 200.

[0054] In one embodiment, such as Figure 1 As shown, the powertrain 10 provided in this application embodiment also includes a motor controller 300. The motor controller 300 is used to receive the DC power output from the power battery 20, convert the DC power output from the power battery 20 into AC power, and control the drive motor 100 to drive the wheels of the electric vehicle 1 through the reducer 200.

[0055] Figure 2 This is a schematic diagram of a drive motor provided in an embodiment of this application. Figure 2 As shown, the drive motor 100 includes a stator 110, a rotor 120, and a motor shaft 130. The stator 110 houses the rotor 120, and the rotor 120 is used to drive the motor shaft 130. During the operation of the drive motor 100 controlled by the motor controller 300, the rotor 120 rotates relative to the stator 110, and the rotor 120 drives the motor shaft 130 to rotate.

[0056] like Figure 2As shown, the stator 110 includes a stator core 111 and a stator winding 112. The stator winding 112 is wound around the stator core 111. The stator winding 112 is used to receive AC power provided by the motor controller 300 to generate a magnetic field to drive the rotor 120. The rotor 120 rotates relative to the stator 110, and the rotor 120 drives the motor shaft 130 to rotate.

[0057] Figure 3 A schematic diagram of the stator of a drive motor provided in an embodiment of this application. For example... Figure 3 As shown, the stator 110 also includes a winding frame 113. The stator core 111 is used to accommodate the winding frame 113, and the winding frame 113 is used to isolate the stator core 111 and the stator winding 112. The winding frame 113 can achieve insulation between the stator core 111 and the stator winding 112. In one embodiment, the winding frame 113 is made of insulating material, which improves the insulation performance between the stator core 111 and the stator winding 112.

[0058] Figure 4 A schematic diagram of a stator core provided in an embodiment of this application. (See diagram below.) Figure 4 As shown, the stator core 111 includes an inner circumferential surface S1 and an outer circumferential surface S2, which are distributed opposite to each other along the radial direction of the drive motor 100. Figure 4 As shown, the inner circumferential surface S1 of the stator core 111 includes a plurality of protrusions P1, each protruding from the inner circumferential surface S1 toward a side opposite to the outer circumferential surface S2. The plurality of protrusions P1 on the inner circumferential surface S1 are distributed radially along the drive motor 100, and a groove G is formed between two adjacent protrusions P1 on the inner circumferential surface S1 of the stator core 111.

[0059] In this embodiment of the application, the radial direction of the drive motor 100 can be understood as the radial direction of the stator 110 of the drive motor 100, the radial direction of the rotor 120 of the drive motor 100, the radial direction of the stator core 111, and the radial direction of the motor shaft 130 of the drive motor 100.

[0060] Figure 5 This is a schematic diagram of a winding frame provided in an embodiment of this application. Figure 5 As shown, the winding frame 113 includes multiple wrapping segments 1131, which are distributed radially along the drive motor 100. The winding frame 113 isolates the stator core 111 from the stator winding 112 through the multiple wrapping segments 1131.

[0061] Figure 6 This is a schematic diagram of a stator winding provided in an embodiment of this application. Figure 7 This is a schematic diagram of a stator winding provided in an embodiment of this application. In one embodiment, as shown... Figure 6As shown, the stator winding 112 includes a plurality of winding coils 1121, each wrapping segment 1131 being used to isolate the outer peripheral surface of a protrusion P1 on the inner peripheral surface S1 of the stator core 111 from a winding coil 1121. For example, as Figure 7 As shown, two adjacent grooves G of the stator core 111 are used to accommodate a wrapping segment 1131 of the winding frame 113. Each wrapping segment 1131 is used to wrap the outer peripheral surface of a protrusion P1 on the inner peripheral surface S1. Each winding coil 1121 is used to wind around the outer peripheral surface of each wrapping segment 1131.

[0062] In this embodiment, the outer peripheral surface of the protrusion P1 includes all surfaces of the protrusion P1 except for the surface facing the central axis of the stator core 111. Furthermore, in this embodiment, the stator winding 112 is a round wire, and the drive motor 100 is also referred to as a drive round wire motor.

[0063] In one embodiment, each groove G of the stator core 111 is used to receive a wrapping segment 1131 of the winding frame 113, and each wrapping segment 1131 is used to isolate the groove wall of a groove G on the inner circumferential surface S1 of the stator core 111 from a winding coil 1121. For example, each groove G is used to receive a wrapping segment 1131, and the stator winding 112 passes through each wrapping segment 1131 and is wound around the stator core 111. In this embodiment, the stator winding 112 is a flat wire, and the drive motor 100 is also referred to as a flat wire drive motor.

[0064] In one embodiment, such as Figure 6 As shown, the stator winding 112 includes multi-phase windings, with the start and end of each multi-phase winding connected sequentially, and the connection point of every two phase windings is used to receive one phase of alternating current. For example, as... Figure 6 As shown, the stator winding 112 includes three-phase windings: U, V, and W. The first segment U1 of the U-phase winding is connected to the last segment W2 of the W-phase winding, and both the first segment U1 of the U-phase winding and the last segment W2 of the W-phase winding are used to receive U-phase AC power. The last segment V2 of the V-phase winding is connected to the first segment W1 of the W-phase winding, and both the last segment V2 of the V-phase winding and the first segment W1 of the W-phase winding are used to receive W-phase AC power. The last segment U2 of the U-phase winding is connected to the first segment V1 of the V-phase winding, and both the last segment U2 of the U-phase winding and the first segment V1 of the V-phase winding are used to receive V-phase AC power.

[0065] In one embodiment, the stator core 111 is an integrally formed structure, which improves the production efficiency of the stator core 111.

[0066] Figure 8 This is another schematic diagram of a stator core provided in an embodiment of this application. In one embodiment, to improve the slot fill factor of the stator 110, the stator core 111 adopts a split structure. For example, as... Figure 8As shown, the stator core 111 includes multiple sub-stator cores 1111, which are spliced ​​together along the circumference of the drive motor 100 to form the stator core 111.

[0067] In one embodiment, the number of protrusions P1 in each sub-stator core 1111 is equal to the number of coils in multiple sets of windings connected in parallel in each phase winding of the stator winding 112. For example, each phase winding of the stator winding 112 includes two sets of windings connected in parallel, and each set of windings includes two winding coils. The number of winding coils in the two sets of windings connected in parallel in each phase winding of the stator winding 112 is 4, and the number of protrusions P1 in each sub-stator core 1111 is also 4.

[0068] In one embodiment, the number of protrusions P1 in each sub-stator core 1111 is equal to the number of winding coils in each group of windings connected in parallel in each phase winding of the stator winding 112. For example, if each phase winding of the stator winding 112 includes two groups of windings connected in parallel, and each group of windings includes two winding coils, the number of winding coils in each group of windings connected in parallel in each phase winding of the stator winding 112 is 2, such as... Figure 8 As shown, the number of protrusions P1 in each sub-stator core 1111 is also 2.

[0069] In one embodiment, the winding frame 113 is a one-piece molded structure. For example, using a single injection mold to form the winding frame 113 in one injection molding process improves the production efficiency of the winding frame 113.

[0070] Figure 9 This is another schematic diagram of a winding frame provided in an embodiment of this application. In one embodiment, to improve the slot fill factor of the stator 110, the winding frame 113 adopts a split structure. For example, as... Figure 9 As shown, the winding frame 113 includes multiple sub-winding frames 1132, which are spliced ​​together along the circumference of the drive motor 100 to form the winding frame 113.

[0071] In one embodiment, multiple sub-winding frames 1132 have identical structures. For example, the winding frame 113 is formed by multiple injection molding processes along the circumference of the drive motor 100 using the same injection mold. The sub-winding frames 1132 formed by multiple injection molding processes all have identical structures, which reduces the production cost of the winding frame 113.

[0072] In one embodiment, the number of wrapping segments 1131 in each sub-winding frame 1132 is equal to the number of coils in multiple sets of windings connected in parallel in each phase winding of the stator winding 112. For example, if each phase winding of the stator winding 112 includes two sets of windings connected in parallel, and each set of windings includes two winding coils, then the number of winding coils in the two sets of windings connected in parallel in each phase winding of the stator winding 112 is 4, and the number of wrapping segments 1131 in each sub-winding frame 1132 is also 4.

[0073] In one embodiment, the number of wrapping segments 1131 in each sub-winding frame 1132 is equal to the number of coils in each group of windings connected in parallel in each phase winding of the stator winding 112. For example, if each phase winding of the stator winding 112 includes two groups of windings connected in parallel, and each group of windings includes two winding coils, the number of winding coils in each group of windings connected in parallel in each phase winding of the stator winding 112 is 2, such as... Figure 9 As shown, the number of wrapping segments 1131 in each sub-winding frame 1132 is also 2.

[0074] Figure 10 This is another schematic diagram of a stator provided in an embodiment of this application. The stator winding 112 is used to receive three-phase alternating current through multiple busbars 114. For example, as... Figure 10 As shown, one end 1141 of each bus 114 is electrically connected to the stator winding 112, and the other end 1142 is electrically connected to the electrical components of the motor controller 300. The multiple bus 114s receive three-phase AC power from the electrical components of the motor controller 300 and transmit the received three-phase AC power to the stator winding 112.

[0075] In one embodiment, multiple sets of windings connected in parallel in each phase of the stator winding 112 receive one phase of alternating current through a busbar. For example, as Figure 10 As shown, the stator winding 112 includes three busbars 114-U, 114-V and 114-W. The first segment U1 of the U-phase winding and the end segment W2 of the W-phase winding receive U-phase AC power through busbar 114-U. The last segment V2 of the V-phase winding and the first segment W1 of the W-phase winding receive W-phase AC power through busbar 114-W. The last segment U2 of the U-phase winding and the first segment V1 of the V-phase winding receive V-phase AC power through busbar 114-V.

[0076] like Figure 10 As shown, multiple busbars 114 are exposed on the stator core 111 along the axial direction of the drive motor 100, facilitating the electrical connection of the multiple busbars 114 with the electrical components of the motor controller 300.

[0077] In this embodiment of the application, the axial direction of the drive motor 100 can be understood as the axial direction of the stator 110 of the drive motor 100, the axial direction of the rotor 120 of the drive motor 100, the axial direction of the stator core 111, and the axial direction of the motor shaft 130 of the drive motor 100.

[0078] Figure 11 Another schematic diagram of the stator provided in an embodiment of this application. (See diagram below.) Figure 11 As shown, the stator 110 also includes a plastic component 115, which, along with the winding frame 113, is distributed along the axial direction of the drive motor 100. The plastic component 115 is used to enclose multiple busbars 114. For example, as... Figure 10 As shown, each busbar 114 includes a straight segment 1143 and a curved segment 1144, as... Figure 11 As shown, the plastic part 115 includes a circular wrapping segment 1161 and multiple straight wrapping segments 1162. (Combined) Figure 10 and Figure 11 As shown, the circular wrapping section 1161 is used to wrap the curved sections 1144 of multiple busbars 114, and each straight wrapping section 1162 is used to wrap the straight section 1143 of a busbar 114, which enhances the protective effect of the plastic part 115 on the busbar 114 and improves the reliability of the electrical connection between the stator winding 112 and the electrical components of the motor controller 300.

[0079] Figure 12 This is another schematic diagram of a plastic part provided in an embodiment of this application. For example... Figure 5 As shown, the surface 1133 of the winding frame 113 facing the plastic part 115 includes a plurality of protrusions P2, such as Figure 12 As shown, the plastic part 115 includes multiple through holes T, each through hole T being used to snap onto a protrusion P2, thus fixing the winding frame 113 and the plastic part 115. The protrusion P2 of the winding frame 113 shares and absorbs the impact of vibrations generated during the operation of the electric vehicle 1 on the welding points of the multiple busbars 114 and the stator winding 112, improving the connection stiffness of the multiple busbars 114 and the stator winding 112, reducing the risk of fracture failure of the welding points of the multiple busbars 114 and the stator winding 112, and helping to improve the performance of the drive motor 100, such as the torque, efficiency, service life, and safety of the drive motor 100.

[0080] Furthermore, if the winding frame 113 and the plastic part 115 are fixed by claws or clips, the radial dimension of the winding frame 113 or the plastic part 115 with claws or clips will be increased to improve the firmness of the fixation. If the winding frame 113 and the plastic part 115 are fixed by potting or coating materials, the axial dimension of the stator 110 along the drive motor 100 will be increased. However, in the drive motor 100 provided in this embodiment, the fixing method by the engagement of the protrusion P2 with the through hole T does not require increasing the radial dimension of the winding frame 113 or the plastic part 115 along the drive motor 100 or the axial dimension of the drive motor 100, which is beneficial for miniaturizing the drive motor 100.

[0081] In one embodiment, each protrusion P2 of the winding frame 113 is used to embed a through hole T, and each through hole T is used to engage a protrusion P2. For example, the diameter of the protrusion P2 is equal to the diameter of the through hole T. The protrusion P2 is embedded in the through hole T, and the hole wall of the through hole T on the plastic part 115 is in almost complete contact with the outer peripheral surface of the protrusion P2. The protrusion P2 on the winding frame 113 is directly engaged around the hole wall of the through hole T on the plastic part 115, which simplifies the fixing method between the winding frame 113 and the plastic part 115.

[0082] In one embodiment, each protrusion P2 of the winding frame 113 is used to pass through a through hole T, and each through hole T is used to engage a section of protrusion P2 exposed on the plastic part 115. For example, the protrusion P2 on the winding frame 113 is a heat-fused protrusion. After heating the section of protrusion P2 on the winding frame 113 exposed on the plastic part 115, it melts onto the surface of the plastic part 115 away from the winding frame 113 until the molten protrusion P2 covers the through hole T of the plastic part 115, thus achieving the engagement of the through hole T with the section of protrusion P2 exposed on the plastic part 115. The protrusion P2 of the winding frame 113 exposed on the plastic part 115 effectively prevents the plastic part 115 from moving along the side away from the winding frame 113, improving the firmness of the engagement between the through hole T on the plastic part 115 and the protrusion P2 of the winding frame 113.

[0083] Figure 13 This is a partial schematic diagram of a stator provided in an embodiment of this application. In one embodiment, as shown... Figure 13 As shown, each protrusion P2 on the winding frame 113 includes a section P21 exposed above the plastic part 115 and another section P22 not exposed above the plastic part 115. The diameter D11 of the section P21 of each protrusion P2 on the winding frame 113 is larger than the diameter D2 of each through hole T. The diameter D11 of the section P21 exposed above the plastic part 115 after melting is larger than the diameter D2 of each through hole T. The molten protrusion P2 completely covers the through hole T of the plastic part 115. This simplifies the assembly process between the winding frame 113 and the plastic part 115 while ensuring the firmness of the fixation between the plastic part 115 and the winding frame 113.

[0084] In one embodiment, such as Figure 13 As shown, the diameter D12 of the other section P22 of each protrusion P2 that is not exposed in the plastic part 115 is smaller than the diameter D2 of each through hole T. During the assembly process of the winding frame 113 and the plastic part 115, the interference between the protrusion P2 on the winding frame 113 and the hole wall of the through hole T on the plastic part 115 is reduced, thereby improving the assembly efficiency of the protrusion P2 of the winding frame 113 and the plastic part 115.

[0085] In this embodiment, the diameter D12 of the other segment P22 of each protrusion P2 that is not exposed on the plastic part 115 can be understood as the diameter of each protrusion P2 before the protrusion P2 on the winding frame 113 is heated.

[0086] In one embodiment, multiple protrusions P2 are evenly distributed along the circumference of the drive motor 100. In an embodiment where the winding frame 113 is a one-piece molded structure, the structure of the injection mold for the winding frame 113 is simplified. In an embodiment where the winding frame 113 is a split structure, multiple sub-winding frames 1132 of the winding frame 113 can be injection molded using the same injection mold, reducing the production cost of the winding frame 113.

[0087] In this embodiment of the application, the circumferential direction of the drive motor 100 can be understood as the circumferential direction of the stator 110 of the drive motor 100, the circumferential direction of the rotor 120 of the drive motor 100, the circumferential direction of the stator core 111, and the circumferential direction of the motor shaft 130 of the drive motor 100.

[0088] In one embodiment, multiple through holes T are evenly distributed along the circumference of the drive motor 100. Correspondingly, each through hole T engages with a protrusion P2, ensuring that the winding frame 113 and the plastic part 115 are evenly stressed along the circumference of the drive motor 100, thereby increasing the reliability of the engagement between the winding frame 113 and the plastic part 115.

[0089] In one embodiment, such as Figure 11 As shown, the multiple protrusions P2 are divided into two groups, P2A and P2B, and the multiple through holes T are distributed at unequal intervals along the circumference of the drive motor 100. Figure 11 As shown, multiple through holes T are used to engage one set of protrusions P2A and to avoid another set of protrusions P2B.

[0090] By setting the spacing of the multiple through holes T on the plastic part 115 differently, the number of through holes T on the plastic part 115 that cooperate with the protrusions P2 on the winding frame 113 is reduced. This allows each through hole T on the plastic part 115 to engage with one set of protrusions P2 and avoid another set of protrusions P2, while taking into account both the manufacturing cost of the drive motor 100 and the reliability of the engagement between the through holes T on the plastic part 115 and the protrusions P2 on the winding frame 113.

[0091] In one embodiment, such as Figure 12 As shown, the outer peripheral surface of the plastic part 115 includes a plurality of fixing ends 1151, each fixing end 1151 including a through hole T, and the plurality of fixing ends 1151 are distributed at unequal intervals along the circumferential direction of the drive motor 100. For example, as Figure 12As shown, the multiple fixed ends 1151 are distributed circumferentially along the drive motor 100 at intervals including two types, J1 and J2. Among these, the two fixed ends 1151 with the larger interval are used to avoid another set of protrusions P2B. (Combined with...) Figure 11 and Figure 12 As shown, the two fixed ends 1151 with a spacing of J2 are used to avoid another set of protrusions P2B, which simplifies the processing technology of the through hole T, improves the space utilization of the drive motor 100 along the circumference of the drive motor 100, and is conducive to the cost reduction and miniaturization of the drive motor 100.

[0092] In one embodiment, combined with Figure 11 and Figure 12 As shown, two of the larger fixed ends 1151 among the multiple fixed ends 1151 are also used to avoid one end 1141 of the stator winding 112 electrically connecting to the busbar 114. This further improves the space utilization of the drive motor 100 along the circumference of the drive motor 100, which is conducive to the miniaturization of the drive motor 100.

[0093] In one embodiment, the number of protrusions P2B in another set is less than the number of protrusions P2A in one set. The increased number of protrusions P2A on the winding frame 113 engages with the through holes T of the plastic part 115, increasing the engagement force between the plastic part 115 and the winding frame 113, and improving the firmness of the engagement between the through holes T on the plastic part 115 and the protrusions P2A on the winding frame 113.

[0094] In one embodiment, another set of protrusions P2 are evenly distributed along the circumference of the drive motor 100. The engagement force between the winding frame 113 and the plastic part 115 is evenly distributed along the circumference of the drive motor 100, which improves the reliability of the engagement between the protrusions P2 on the winding frame 113 and the through holes T on the plastic part 115.

[0095] Figure 14 Another schematic diagram of the winding frame provided in an embodiment of this application. In one embodiment, where the plurality of protrusions P2 are divided into two groups of protrusions P2A and P2B, as shown... Figure 14 As shown, a set of protrusions P2A is divided into two types. One type of protrusion, P2A-1, is used as a positioning protrusion for assembling the winding frame 113 and the plastic part 115, which improves the assembly accuracy of the winding frame 113 and the plastic part 115.

[0096] like Figure 14 As shown, a set of protrusions P2A is divided into two types. One type of protrusion, P2A-1, is used as a positioning protrusion for assembling the winding frame 113 and the plastic part 115, which improves the assembly accuracy of the winding frame 113 and the plastic part 115.

[0097] In one embodiment, the number of one type of protrusion P2A-1 is less than the number of another type of protrusion P2A-2, and the diameter of one type of protrusion P2A-1 is larger than the diameter of the other type of protrusion P2A-2. A smaller number of one type of protrusion P2A-1 with a smaller diameter is provided on the winding frame 113 as positioning protrusions that mate with the through holes T on the plastic part 115. During the assembly process of the protrusion P2A-1 on the winding frame 113 and the through holes T on the plastic part 115, the passage of the one type of protrusion P2A-1 on the winding frame 113 through the through holes T on the plastic part 115 achieves preliminary positioning of the winding frame 113 and the plastic part 115, improving the assembly accuracy of the protrusion P2A-1 on the winding frame 113 and the through holes T on the plastic part 115.

[0098] In one embodiment, the diameter of a type of protrusion P2A-1 is equal to the diameter of the through hole T through which the type of protrusion P2A-1 passes. During the assembly process of the protrusion P2 on the winding frame 113 and the through hole T on the plastic part 115, the type of protrusion P2A-1 on the winding frame 113 and the through hole T on the plastic part 115 through which the type of protrusion P2A-1 on the winding frame 113 passes achieve precise positioning of the winding frame 113 and the plastic part 115, further improving the assembly accuracy of the winding frame 113 and the plastic part 115.

[0099] In one embodiment, the diameter of the other type of protrusion P2A-2 is smaller than the diameter of the through hole T through which the other type of protrusion P2A-2 passes. During the assembly process of the protrusion P2 on the winding frame 113 and the through hole T on the plastic part 115, interference between the other type of protrusion P2A-2 on the winding frame 113 and the through hole T on the plastic part 115 through which the other type of protrusion P2A-2 on the winding frame 113 passes is avoided, thereby improving the assembly efficiency of the winding frame 113 and the plastic part 115.

[0100] In one embodiment, such as Figure 14 As shown, a type of protrusion P2A-1 includes two protrusions P2A-1. The centers of the two protrusions P2A-1 are almost on a straight line, which facilitates the precise alignment of the protrusion P2 on the winding frame 113 with the through hole T on the plastic part 115, thereby improving the assembly efficiency of the winding frame 113 and the plastic part 115.

[0101] In one embodiment, where the multiple protrusions P2 are not divided into two groups of protrusions P2A and P2B, the multiple protrusions P2 can also be divided into the two types of protrusions described above. For a detailed description of the two types of protrusions, please refer to the relevant description above, which will not be repeated here.

[0102] Figure 15 This is another schematic diagram of a plastic part provided in an embodiment of this application. In one embodiment, as... Figure 15As shown, the multiple through holes T are divided into two groups. One of the two groups of through holes T1 and T2, through hole T1, is used as a positioning through hole for assembling the winding frame 113 and the plastic part 115, which improves the assembly accuracy of the winding frame 113 and the plastic part 115.

[0103] In one embodiment, the number of through holes T1 is less than the number of through holes T2 in another set, and the diameter of the through holes T1 is smaller than the diameter of the through holes T2 in another set. A smaller number of through holes T1 with smaller diameters are provided on the plastic part 115 as positioning through holes to mate with the protrusion P2 on the winding frame 113. During the assembly process between the protrusion P2 on the winding frame 113 and the through holes T1 on the plastic part 115, the through holes T1 on the plastic part 115 and the protrusion P2 passing through the through holes T1 on the winding frame 113 achieve initial positioning of the winding frame 113 and the plastic part 115, improving the assembly accuracy of the protrusion P2 on the winding frame 113 and the through holes T1 on the plastic part 115.

[0104] In one embodiment, the diameter of a set of through holes T1 is equal to the diameter of the protrusion P2 passing through the set of through holes T1. During the assembly process of the protrusion P2 on the winding frame 113 and the through holes T on the plastic part 115, the set of through holes T1 on the plastic part 115 and the protrusion P2 passing through the set of through holes T on the winding frame 113 achieve precise positioning of the winding frame 113 and the plastic part 115, further improving the assembly accuracy of the winding frame 113 and the plastic part 115.

[0105] In one embodiment, the diameter of the other set of through holes T2 is larger than the diameter of the protrusion P2 passing through the other set of through holes T2. During the assembly process of the protrusion P2 on the winding frame 113 and the through holes T on the plastic part 115, interference between the other set of through holes T2 on the plastic part 115 and the protrusion P2 passing through the other set of through holes T2 on the winding frame 113 is avoided, thereby improving the assembly efficiency of the winding frame 113 and the plastic part 115.

[0106] In one embodiment, such as Figure 15 As shown, a set of through holes T1 includes two through holes T1. The centers of the two through holes T1 in the set of through holes T1 are almost on a straight line, which facilitates the precise alignment of the protrusion P2 on the winding frame 113 and the through hole T on the plastic part 115, thereby improving the assembly efficiency of the winding frame 113 and the plastic part 115.

[0107] Figure 16 Another schematic diagram of the stator provided for an embodiment of this application. In one embodiment, as shown... Figure 16As shown, along the axial direction of the drive motor 100, the distance d between one end 1141 of each busbar 114 electrically connecting the stator winding 112 and the surface 1133 of the winding frame 113 is greater than the length h of each protrusion P2. That is, the length of the stator winding 112, which is bent between the plastic part 115 and the winding frame 113, is greater than the length of each protrusion P2.

[0108] The vibration generated during the operation of the electric vehicle 1 impacts the drive motor 100. The connection between the protrusion P2 on the winding frame 113 and the through hole T of the plastic part 115 will preferentially become the stress point at the connection between the stator winding 112 and the busbar 114. Compared with the connection between the stator winding 112 and the busbar 114, the connection between the protrusion P2 on the winding frame 113 and the through hole T of the plastic part 115 will preferentially absorb the impact force, further reducing the risk of breakage failure of the welding points of multiple busbars 114 and stator winding 112.

[0109] In one embodiment, such as Figure 5 As shown, the surface 1133 of the winding frame 113 along the axial direction of the drive motor 100 protrudes from the stator winding 112 and is wound around the surface 1134 of the winding frame 113. The engagement between the protrusion P2 on the winding frame 113 and the through hole T of the plastic part 115 does not affect the winding of the stator winding 112.

[0110] In one embodiment, the surface 1133 of the winding frame 113 is in contact with the surface of the plastic part 115 facing the winding frame 113. This increases the stress points between the plastic part 115 and the winding frame 113, further reducing the risk of breakage failure at the weld points of the multiple busbars 114 and the stator winding 112. Furthermore, the contact between the surface 1133 of the winding frame 113 and the surface of the plastic part 115 facing the winding frame 113 indicates that the winding frame 113 and the plastic part 115 are properly assembled, simplifying the assembly process of the winding frame 113 and the plastic part 115.

[0111] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A drive motor, characterized in that, The stator core of the drive motor is used to house the winding frame, which isolates the stator core from the stator windings. A plastic component encloses multiple busbars, which transmit the received three-phase AC power to the stator windings. The plastic component and the winding frame are distributed along the axial direction of the drive motor, wherein: The surface of the winding frame facing the plastic part includes a plurality of protrusions, and the plastic part includes a plurality of through holes, each of the through holes being used to engage one of the protrusions.

2. The drive motor according to claim 1, characterized in that, Each of the protrusions is for passing through one of the through holes, and each of the through holes is for engaging a portion of the protrusion that protrudes from the plastic part.

3. The drive motor according to claim 2, characterized in that, The diameter of each segment of the protrusion is greater than the diameter of each through hole.

4. The drive motor according to claim 2 or 3, characterized in that, The diameter of each of the protrusions not exposed on the other side of the plastic part is smaller than the diameter of each of the through holes.

5. The drive motor according to claim 1, characterized in that, The plurality of protrusions are evenly distributed along the circumference of the drive motor, and the plurality of through holes are not evenly spaced along the circumference of the drive motor, wherein: The plurality of protrusions are divided into two groups, and the plurality of through holes are used to engage one group of the protrusions and to avoid the other group of the protrusions.

6. The drive motor according to claim 5, characterized in that, The outer peripheral surface of the plastic part includes multiple fixed ends, each fixed end including a through hole, and the multiple fixed ends are spaced unequally along the circumferential direction of the drive motor, wherein: Two of the fixed ends with a large gap between them are used to avoid the other set of protrusions.

7. The drive motor according to claim 6, characterized in that, Two of the fixed ends with a large gap among the plurality of fixed ends are also used to avoid the stator winding being electrically connected to one end of the busbar.

8. The drive motor according to any one of claims 5 to 7, characterized in that, The number of the other set of protrusions is less than the number of the first set of protrusions, and the other set of protrusions is evenly distributed along the circumference of the drive motor.

9. The drive motor according to claim 1, characterized in that, The plurality of through holes are divided into two groups, the number of through holes in one group is less than the number of through holes in the other group, and the diameter of the through holes in the one group is less than the diameter of the through holes in the other group.

10. The drive motor according to claim 9, characterized in that, The diameter of the first set of through holes is equal to the diameter of the protrusion passing through the first set of through holes, and the diameter of the second set of through holes is greater than the diameter of the protrusion passing through the second set of through holes.

11. The drive motor according to any one of claims 1 to 3, 5 to 7, 9 or 10, characterized in that, Along the axial direction of the drive motor, the distance between one end of each busbar electrically connected to the stator winding and the surface is greater than the length of each protrusion.

12. The drive motor according to any one of claims 1 to 3, 5 to 7, 9 or 10, characterized in that, The surface of the winding frame protrudes from the surface of the stator winding wound around the winding frame along the axial direction of the drive motor.

13. The drive motor according to any one of claims 1 to 3, 5 to 7, 9 or 10, characterized in that, The surface of the winding frame is in contact with the surface of the plastic part facing the winding frame.

14. A powertrain, characterized in that, The powertrain includes a reducer and a drive motor as described in any one of claims 1 to 13, wherein the motor shaft of the drive motor is used for transmission connection to the input shaft of the reducer.

15. An electric vehicle, characterized in that, The electric vehicle includes wheels, a transmission mechanism, and a powertrain as described in claim 14, the powertrain being used to drive the wheels via the transmission mechanism.

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