Large-span three-phase high-voltage power transmission module for electric vehicles

Abstract

The utility model discloses a large span three -phase high -voltage power transmission module of electric automobile. The power transmission module includes: the aluminium copper adapter line of multiple settings between automobile electric control assembly and electric drive assembly, and aluminium copper adapter line includes main lead line, end connection line and adapter, main lead line includes the aluminium conductor of aluminium profile of big length, and the both ends of aluminium conductor are formed two aluminium joints through flattening processing, the length of copper conductor of end connection line is far less than aluminium conductor, and the one outer end of copper conductor and aluminium joint are formed copper aluminium adapter end through ultrasonic welding, and its another outer end and copper wire ear fixed connection, and adapter fixed sleeve copper aluminium adapter end. The utility model discloses have low cost, and the main body strength is high and the end flexibility is high, and the installation is convenient and fixed, has good assembly compatibility, excellent installation tolerance compensation, is applicable to the effect of two end tolerance bigger and complex bending scene.

Description

Technical Field

[0001] This utility model relates to the field of power supply devices for new energy vehicles, and in particular to a large-span three-phase high-voltage power transmission module for electric vehicles. Background Technology

[0002] The rapid development of new energy heavy-duty vehicles, such as electric engineering vehicles, electric heavy trucks, and electric buses, has led to several drawbacks. Firstly, the electric drive and electronic control systems of these vehicles are located in different parts of the vehicle body, with a large span between them, resulting in very long power supply harnesses. This is especially true for heavy-duty vehicle manufacturers that often use multi-drive structures, requiring multiple long harnesses and incurring high costs due to the use of copper wire. Secondly, while copper wire is flexible, it has relatively poor strength. Long copper wires with large spans are prone to bending, requiring extensive external coverings for protection and a robust fixing structure, making installation complex and further increasing costs. Utility Model Content

[0003] To address one or more of the aforementioned problems, this utility model provides a large-span three-phase high-voltage power transmission module for electric vehicles.

[0004] According to one aspect of the present invention, the large-span three-phase high-voltage power transmission module for electric vehicles includes: multiple aluminum-copper adapter wires disposed between the vehicle's electronic control components and electric drive components, wherein the aluminum-copper adapter wires include a main wire, a terminal connection wire, and an adapter. The main conductor includes an aluminum conductor and a first sheath covering the aluminum conductor. The aluminum conductor is made of a long aluminum profile, and the two ends of the aluminum conductor extend out of the first sheath and are flattened to form two aluminum joints. The terminal connection includes a copper conductor and a second sheath covering the copper conductor. The length of the copper conductor is much shorter than that of the aluminum conductor. One end of the copper conductor and the aluminum connector are ultrasonically welded to form a copper-aluminum transition terminal, and the other end of the copper conductor is fixedly connected to the copper wire lug. The adapter includes an insulating mounting shell, a shielding cover, and an outer plastic shell, which are sequentially enclosed from the inside out. The sealing wire body is interference-fitted inside the two ports of the outer plastic shell, and the end caps are snapped onto the two ports. The copper-aluminum adapter end is fixedly fitted inside the mounting shell. The first sheath and the second sheath pass through the end caps on both sides and are interference-fitted to the sealing wire body.

[0005] In some embodiments, the aluminum-copper adapter cable includes a main conductor, a terminal connector, an adapter, and a copper lug. The two ends of the aluminum-copper adapter cable are aluminum connectors and copper lugs. The copper lugs are fixed to the motor terminals of the electric drive assembly by threaded fittings, and the other end, the aluminum connector, is fixed to the motor controller terminals of the electric control assembly by threaded fittings.

[0006] In some embodiments, the aluminum-copper adapter cable includes a main conductor, two terminal connecting wires, two adapters, and two copper wire lugs. The two aluminum connectors of the main conductor and the extended ends of the two terminal connecting wires are ultrasonically welded to form two copper-aluminum adapter ends. Each copper-aluminum adapter end is provided with an adapter. The copper wire lugs at both ends of the aluminum-copper adapter cable are respectively fixed to the motor of the electric drive assembly and the motor controller of the electric control assembly via threaded parts.

[0007] In some implementations, the electrical control assembly includes a motor controller, and the electric drive assembly includes multiple motors. The motor controller and each motor are connected via three aluminum-copper adapter cables to achieve three-phase high-voltage current transmission.

[0008] In some implementations, the electric vehicle is an electric engineering vehicle or a heavy-duty truck, with the electronic control components located near the driver's cab and the electric drive components located near the drive shaft. Several parallel aluminum-copper adapter cables are fixed to the chassis.

[0009] In some implementations, an aluminum-copper adapter cable is fitted with a flange at one end and an insulating end cap at the other end. The flange is threaded to the housing of the electronic control assembly, and multiple insulating end caps are snapped into an integrated base, which is fixedly connected to the electric drive assembly.

[0010] In some embodiments, the aluminum conductor is an aluminum rod or aluminum bar, and the outer wall of the aluminum conductor is also covered with an insulating layer, and a shielding layer is provided between the insulating layer and the first sheath; the terminal connection is a shielded copper wire.

[0011] In some implementations, the copper wire at one end is evenly spread out and ultrasonically welded to the upper surface of the aluminum connector, and the copper wire at the other end is evenly spread out and ultrasonically welded to the upper surface of the aluminum connector.

[0012] In some embodiments, the upper ring of the copper pad is fitted into the connection through hole of the aluminum connector, and the horizontal piece of the copper pad is attached to the wiring terminal of the motor controller; the surface of the copper wire lug is tin-plated.

[0013] In some embodiments, the mounting shell and the shielding cover are both separate upper and lower structures, and the two separate parts are fixed into one piece by a snap-fit ​​structure. The shielding cover is fitted and snapped onto the outside of the mounting shell, and the outer plastic shell is fitted and snapped onto the outside of the shielding cover. The outer walls of the two ports of the shielding cover are provided with outer pressure rings, and the inner walls of the two ports and the sheath are provided with inner pressure sleeves.

[0014] The advantages of this long-span three-phase high-voltage power transmission module for electric vehicles are as follows: First, the new power transmission module mainly uses aluminum wire, requiring only a small amount of copper wire. The cost of aluminum wire is significantly lower than that of copper wire, especially in scenarios with multiple long-distance transmissions, greatly saving costs. Second, the main conductor is made of aluminum profile, which has significantly higher strength than copper wire, greatly simplifying the external protective covering and reducing fixing requirements, making installation simpler and faster, and further reducing costs. Third, the terminal connection with copper conductors at one or both ends gives the aluminum-copper adapter cable good flexibility, providing good assembly compatibility and excellent installation tolerance compensation in scenarios with large tolerances at both ends and complex bends. Fourth, the copper-aluminum adapter cable is formed by ultrasonic welding, resulting in high connection strength, fast welding speed, and almost no damage to the conductor material. Fifth, the adapter has an insulating mounting shell, a shielding cover, and an outer plastic shell, which can ensure that the copper-aluminum adapter is well fixed, safely shielded, and has a good service life. Attached Figure Description

[0015] Figure 1 This is a three-dimensional schematic diagram of the large-span three-phase high-voltage power transmission module for an electric vehicle according to Embodiment 1 of this utility model. Figure 2 for Figure 1 A three-dimensional schematic diagram of the aluminum-copper adapter cable shown. Figure 3 This is a three-dimensional schematic diagram of the large-span three-phase high-voltage power transmission module for electric vehicles according to Embodiment 2 of this utility model. Figure 4 for Figure 3 A three-dimensional schematic diagram of the aluminum-copper adapter cable shown. Figure 5 for Figure 1 and Figure 3 A three-dimensional schematic diagram of the adapter shown; Figure 6 for Figure 5 A cross-sectional schematic diagram of the adapter shown; Figure 7 for Figure 5 A three-dimensional exploded view of the adapter shown; Aluminum-copper adapter cable 00, copper-aluminum adapter terminal 001; Main conductor 1, aluminum conductor 10, first sheath 11, aluminum connector 12, shielding layer 13, insulation layer 14; Terminal connection 2, copper conductor 20, second sheath 21, extended end 22; Adapter 3, mounting housing 31, shielding cover 32, outer plastic shell 33, sealing body 34, end cap 35, outer pressure ring 36, shielding inner pressure sleeve 37; 4. Copper wire lug; 5. Flange seat; 6. Insulating end cap; 7. Copper gasket; 8. Integrated base; Electronic control components 01; electric drive components 02; drive shaft 03; driver's cab 04; chassis 05. Detailed Implementation

[0016] The present invention will now be described in further detail with reference to the accompanying drawings. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to the directions in the accompanying drawings, while the terms "inner" and "outer" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0017] Figures 1 to 7 The diagram schematically illustrates a large-span three-phase high-voltage power transmission module for an electric vehicle according to one embodiment of the present invention. As shown, the large-span three-phase high-voltage power transmission module for the electric vehicle includes: multiple aluminum-copper adapter wires 00 disposed between the vehicle's electronic control assembly 01 and electric drive assembly 02, wherein each aluminum-copper adapter wire 00 includes a main conductor 1, a terminal connection 2, and an adapter 3; The main conductor 1 includes an aluminum conductor 10 and a first sheath 11 covering the aluminum conductor 10. The aluminum conductor 10 is made of a long aluminum profile. Preferably, the aluminum conductor 10 is an aluminum rod or aluminum busbar. Furthermore, the outer wall of the aluminum conductor 10 is also covered with an insulation layer 14, and a shielding layer 13 is provided between the insulation layer 14 and the first sheath 11. This configuration provides the main conductor with good shielding and safety. The two ends of the aluminum conductor 10 extend beyond the first sheath 11 and are flattened to form two aluminum connectors 12; these aluminum connectors are easy to process.

[0018] The terminal connector 2 includes a copper conductor 20 and a second sheath 21 covering the copper conductor 20. The terminal connector 2 is preferably a shielded copper wire. The copper conductor 20 is much shorter than the aluminum conductor 10. One extended end 22 of the copper conductor 20 and the aluminum connector 12 are ultrasonically welded to form a copper-aluminum transition terminal 001, and the other extended end 22 is fixedly connected to a copper wire lug 4. Further, the copper wires of one extended end 22 are evenly spread and ultrasonically welded to the upper surface of the aluminum connector 12, and the copper wires of the other extended end 22 are also evenly spread and ultrasonically welded to the upper surface of the aluminum connector 12. The beneficial effect of this welding arrangement is that it further ensures the weld strength and transmission safety.

[0019] The adapter 3 includes an insulating mounting shell 31, a shielding cover 32, and an outer plastic shell 33, which are sequentially enclosed from the inside to the outside. The outer plastic shell 33 has an interference fit on the sealing wire body 34 at both ends and an end cap 35 snapped onto the outside of both ends. The copper-aluminum adapter end 001 is fixedly fitted inside the mounting shell 31. The first sheath 11 and the second sheath 21 pass through the end caps 35 on both sides and are interference-fitted to the sealing wire body 34.

[0020] Preferred, such as Figure 1 and 2The first embodiment shown includes an aluminum-copper adapter cable 00 comprising a main conductor 1, two end connectors 2, two adapters 3, and two copper wire lugs 4. The two aluminum connectors 12 of the main conductor 1 and the extended ends 101 of the two end connectors 2 are ultrasonically welded to form two copper-aluminum adapter ends 001. Each of the two copper-aluminum adapter ends 001 is equipped with an adapter 3. The copper wire lugs 4 at both ends of the aluminum-copper adapter cable 00 are respectively fixed to the motor terminals of the electric drive assembly 02 and the motor controller terminals of the electric control assembly 01 via threaded fittings. Its advantages are: this design provides good flexibility at both ends, making it suitable for demanding applications.

[0021] Preferred, such as Figure 3 and 4 The second embodiment shown includes an aluminum-copper adapter cable 00, which includes a main line 1, a terminal connection line 2, an adapter 3, and a copper wire lug 4. The two ends of the aluminum-copper adapter cable 00 are aluminum connectors 12 and copper wire lug 4. The copper wire lug 4 is fixed to the motor terminal of the electric drive assembly 02 by a threaded component, and the other end, the aluminum connector 12, is fixed to the motor controller terminal of the electric control assembly 01 by a threaded component.

[0022] This electric vehicle's long-span three-phase high-voltage power transmission module uses a new type of aluminum-copper adapter cable 00. Its main power transmission component is a long aluminum main conductor 1, with shorter copper end connections 2 only at the electric drive end or both ends. Connectors 3 are used at the connection points. The advantages are: First, the new power transmission module primarily uses aluminum wire, requiring only a small amount of copper wire. Aluminum wire is significantly cheaper than copper wire, especially in scenarios with multiple long-distance connections, greatly saving costs. Second, the main conductor 1 is made of aluminum profiles, which are significantly stronger than copper wires, greatly simplifying the external protective covering and reducing fixing requirements, simplifying and speeding up installation, and further reducing costs. Thirdly, the connection wire 2 with copper conductor 20 at one or both ends gives the aluminum-copper adapter wire 00 good flexibility, making it suitable for applications with large tolerances at both ends and complex bends, with good assembly compatibility and excellent installation tolerance compensation; fourthly, the copper-aluminum adapter end 001 in the middle of the aluminum-copper adapter wire 00 is formed by ultrasonic welding, resulting in high connection strength, fast welding speed, and almost no damage to the wire material; fifthly, the adapter 3 has an insulating mounting shell 31, a shielding cover 32, and an outer plastic shell 33, which can ensure that the copper-aluminum adapter end 001 is well fixed, safely shielded, and has a good service life.

[0023] Preferably, in the two embodiments described above, the electrical control component 01 includes a motor controller, and the electric drive component 02 includes multiple motors. The motor controller and each motor are connected in phase via three aluminum-copper adapter cables 00 to achieve three-phase high-voltage current transmission. The advantages are: a large number of wiring harnesses and a new power supply module further reduce costs.

[0024] Furthermore, in the two embodiments described above, the electric vehicle is an electric engineering vehicle or a heavy-duty truck. The electronic control component 01 is located near the vehicle's driver's cab 04, and the electric drive component 02 is located near the vehicle's drive shaft 03. Several parallel aluminum-copper adapter cables 00 are fixed to the chassis 05, and the length of the aluminum-copper adapter cables 00 is greater than or equal to 5 meters. The beneficial effect is that the long wiring harness and the new power supply module further reduce costs.

[0025] Furthermore, in the two embodiments described above, one end of the aluminum-copper adapter cable 00 is fitted with a flange seat 5 and the other end with an insulating end cap 6. The flange seat 5 is threaded to the housing of the electronic control component 01, and multiple insulating end caps 6 are snapped into an integrated base 8, which is fixedly connected to the electric drive component 02. Preferably, the main conductor 1 of the aluminum-copper adapter cable 00 is externally sheathed with a braided layer and fixed with tape to form a protective tube. Several protective tubes are fixedly connected to the chassis 05 through integrated clamps. The advantages are: the fixing structure is simple, easy to install, and low in cost.

[0026] Preferably, the first sheath 11 and the second sheath 21 are rubber sheaths.

[0027] Preferably, the upper ring of the copper pad 7 is fitted onto the connection through hole of the aluminum connector 12, and the horizontal piece of the copper pad 7 is fitted onto the wiring terminal of the motor controller. The beneficial effect is that the copper pad 7 has superior high-voltage connection performance.

[0028] Preferably, the surface of the copper wire lug 4 is tin-plated. The beneficial effects are: this arrangement significantly reduces corrosion and improves long-term conductivity.

[0029] Furthermore, such as Figures 5 to 7 As shown, the mounting shell 31 and the shielding cover 32 are both upper and lower split structures, and the two splits are fixed into one piece by a snap-fit ​​structure. The shielding cover 32 covers and snaps onto the outside of the mounting shell 31, and the outer plastic shell 33 covers and snaps onto the outside of the shielding cover 32. The shielding cover 32 has an outer pressure ring 36 on the outer wall of both ports and an inner pressure sleeve 37 between the inner wall of both ports and the sheath. Its advantages are: this configuration is easy to install and provides good shielding performance.

[0030] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A large-span three-phase high-voltage power transmission module for electric vehicles, characterized in that, Includes: multiple aluminum-copper adapter cables (00) disposed between the automotive electronic control assembly (01) and the electric drive assembly (02), wherein the aluminum-copper adapter cables (00) include a main line (1), a terminal connection line (2) and an adapter (3); The main conductor (1) includes an aluminum conductor (10) and a first sheath (11) covering the aluminum conductor (10). The aluminum conductor (10) is made of a long aluminum profile. The two ends of the aluminum conductor (10) extend out of the first sheath (11) and are flattened to form two aluminum connectors (12). The terminal connection (2) includes a copper conductor (20) and a second sheath (21) covering the copper conductor (20). The length of the copper conductor (20) is much smaller than that of the aluminum conductor (10). One of the extended ends (22) of the copper conductor (20) and the aluminum connector (12) are ultrasonically welded to form a copper-aluminum transition end (001), and its other extended end (22) is fixedly connected to a copper wire lug (4). The adapter (3) includes an insulating mounting shell (31), a shielding cover (32) and an outer plastic shell (33) that are wrapped from the inside to the outside. The outer plastic shell (33) has an interference fit on the sealing wire body (34) at both ends and an end cap (35) on the outside of both ends. The copper-aluminum adapter end (001) is fixedly fitted inside the mounting shell (31). The first sheath (11) and the second sheath (21) respectively pass through the end caps (35) on both sides and are interference-fitted to the sealing wire body (34).

2. The high-voltage power transmission module according to claim 1, characterized in that, The aluminum-copper adapter cable (00) includes a main line (1), a terminal connection line (2), an adapter (3), and a copper wire lug (4). The two ends of the aluminum-copper adapter cable (00) are aluminum connectors (12) and copper wire lugs (4). The copper wire lug (4) and the motor terminal of the electric drive assembly (02) are fixed by threaded parts. The other end, the aluminum connector (12), and the motor controller terminal of the electric control assembly (01) are fixed by threaded parts.

3. The high-voltage power transmission module according to claim 1, characterized in that, The aluminum-copper adapter cable (00) includes a main conductor (1), two end connectors (2), two adapters (3) and two copper wire lugs (4). The two aluminum connectors (12) of the main conductor (1) and the extended ends (101) of the two end connectors (2) are ultrasonically welded to form two copper-aluminum adapter ends (001). Each of the two copper-aluminum adapter ends (001) is provided with an adapter (3). The copper wire lugs (4) at both ends of the aluminum-copper adapter cable (00) are fixed to the motor of the electric drive assembly (02) and the motor controller of the electric control assembly (01) respectively by threaded parts.

4. The high-voltage power transmission module according to claim 2 or 3, characterized in that, The electrical control component (01) includes a motor controller, and the electric drive component (02) includes multiple motors. The motor controller and each motor are connected by three aluminum-copper adapter cables (00) to realize the transmission of three-phase high-voltage current.

5. The high-voltage power transmission module according to claim 4, characterized in that, The electric vehicle is an electric engineering vehicle or a heavy truck. The electronic control component (01) is located near the vehicle driver's cab (04), the electric drive component (02) is located near the vehicle drive shaft (03), and several parallel aluminum-copper adapter cables (00) are fixed on the chassis (05).

6. The high-voltage power transmission module according to claim 5, characterized in that, An aluminum-copper adapter cable (00) is fitted with a flange seat (5) at one end and an insulating end cap (6) at the other end. The flange seat (5) is threaded to the housing of the electrical control assembly (01). Multiple insulating end caps (6) are snapped into an integrated base (8). The integrated base (8) is fixedly connected to the electric drive assembly (02).

7. The high-voltage power transmission module according to claim 1, characterized in that, The aluminum conductor (10) is an aluminum rod or aluminum bar, and the outer wall of the aluminum conductor (10) is also covered with an insulating layer (14). A shielding layer (13) is also provided between the insulating layer (14) and the first sheath (11); the terminal connection (2) is a shielded copper wire.

8. The high-voltage power transmission module according to claim 7, characterized in that, The copper wire of one of the extended ends (22) is evenly spread out and ultrasonically welded to the upper surface of the aluminum connector (12), and the copper wire of the other extended end (22) is evenly spread out and ultrasonically welded to the upper surface of the aluminum connector (12).

9. The high-voltage power transmission module according to claim 8, characterized in that, The upper ring of the copper pad (7) is sleeved at the connection through hole of the aluminum connector (12), and the horizontal piece of the copper pad (7) is attached to the wiring terminal of the motor controller; the surface of the copper wire lug (4) is tin-plated.

10. The high-voltage power transmission module according to claim 1, characterized in that, The mounting shell (31) and the shielding cover (32) are both upper and lower split structures, and the two splits are fixed into one by a snap-fit ​​structure. The shielding cover (32) covers and snaps onto the outside of the mounting shell (31), and the outer plastic shell (33) covers and snaps onto the outside of the shielding cover (32). The shield (32) has an outer pressure ring (36) on the outer wall of both ports and an inner pressure sleeve (37) between the inner wall of both ports and the sheath.

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