High voltage wire terminal for hybrid case

Abstract

The utility model discloses a high -tension line terminal seat for mixed hybrid box, including the terminal seat body of installation between mixed hybrid box motor casing and electric control casing, the connecting end of terminal seat body and electric control copper bar in electric control casing is provided with connecting assembly, and connecting assembly includes the sleeve of inside being equipped with the cavity and first connecting nut, and first connecting nut axial position limiting is established in the sleeve cavity and can float in horizontal direction in the sleeve cavity, the utility model discloses a horizontal floating connecting assembly can be set up, and the position deviation in the installation process is effectively compensated, solves the traditional terminal seat installation misplacement problem, has the advantage that improves the reliability of connection.

Description

Technical Field

[0001] This utility model belongs to the field of automotive hybrid system technology, and relates to a high-voltage wire terminal block for a hybrid gearbox. Background Technology

[0002] With the development of new energy technologies, hybrid transmissions have been widely used in the commercial vehicle sector, especially dual-motor hybrid transmissions. As one of the three core components of new energy vehicles, the performance of the motor drive system directly affects key driving performance aspects such as vehicle start-up, acceleration, and hill climbing. In oil-cooled hybrid transmission systems, the connection structure between the motor controller and the motor is particularly important, as it converts the electrical energy from the power battery into the electrical energy required to drive the motor, thereby achieving precise control over the vehicle's driving status.

[0003] Currently, the high-voltage wiring harness of hybrid transmissions has a significant technical defect: traditional wiring harnesses are made by injection molding a single piece of copper busbar after being riveted with ordinary nuts. During installation, they need to be bolted to the copper busbar of the power control brick on the electrical control housing. Due to the limited manufacturing precision of the injection molded parts and the long dimensional chain of the connection area, misalignment frequently occurs between the high-voltage wiring harness and the mounting holes of the power brick. This structural defect not only increases the assembly difficulty but may also cause unreliable connections, affecting the safe operation of the entire powertrain. The reliability issue of this connection structure is particularly prominent under the harsh operating conditions of commercial vehicles.

[0004] Therefore, it is necessary to improve the structure of the high-voltage line terminal block on the existing hybrid box to solve the problem of misalignment of the traditional terminal block and to improve the reliability of the connection. Utility Model Content

[0005] In view of this, the present invention provides a high-voltage line terminal block for a hybrid box, which has the advantages of solving the problem of misalignment during installation of traditional terminal blocks and improving connection reliability.

[0006] This utility model discloses a high-voltage line terminal block for a hybrid gearbox, including a terminal block body installed between the motor housing and the electrical control housing of the hybrid gearbox. The terminal block body is provided with a connecting assembly at the connection end with the electrical control copper busbar inside the electrical control housing. The connecting assembly includes a sleeve and a first connecting nut. The sleeve has a cavity. The first connecting nut is axially limited in the cavity of the sleeve and can float horizontally within the cavity of the sleeve.

[0007] Furthermore, the connecting assembly also includes a limiting ring disposed on the end of the sleeve and used to axially limit the first connecting nut.

[0008] Furthermore, the sleeve has a countersunk hole structure inside and includes a countersunk portion and a through hole portion, with the sleeve disposed at the countersunk portion.

[0009] Furthermore, the inner diameter of the limiting ring is smaller than the outer diameter of the first connecting nut but larger than the inner diameter of the first connecting nut.

[0010] Furthermore, the radial dimension of the countersunk portion is greater than the outer diameter of the first connecting bolt, and the radial dimension of the through hole portion is smaller than the inner diameter of the first connecting bolt.

[0011] Furthermore, a second connecting nut is pressed into the connection end between the terminal block body and the motor copper busbar inside the motor housing.

[0012] Furthermore, the terminal block body includes a terminal block copper busbar and a plastic layer for covering the terminal block copper busbar.

[0013] Furthermore, after the connecting component and the second connecting nut are respectively pressed onto the copper busbar of the terminal block, the entire terminal block body is formed by injection molding.

[0014] Furthermore, the plastic layer has an injection hole at the end near the motor housing.

[0015] Furthermore, the plastic layer is provided with weight-reducing holes at the end near the motor housing.

[0016] The beneficial effects of this utility model are:

[0017] This invention provides a high-voltage line terminal block for a hybrid box. By setting a horizontally floating connection component, it effectively compensates for positional deviations during installation, solves the problem of misalignment in traditional terminal blocks, and has the advantage of improving connection reliability. Attached Figure Description

[0018] Figure 1 This is a front structural diagram of the high-voltage line terminal block used in the hybrid box in this utility model;

[0019] Figure 2 for Figure 1 AA section view in the middle;

[0020] Figure 3 for Figure 2 Enlarged view of point B in the image;

[0021] Reference numerals in the attached drawings: 1. Terminal block body; 2. Connecting assembly; 3. Terminal block copper busbar; 4. Plastic layer; 5. Electrical control copper busbar connection end; 6. Motor copper busbar connection end; 7. Glue injection hole; 8. Weight reduction hole; 9. Sleeve; 10. First connecting nut; 11. Limiting ring; 12. Second connecting nut; 901. Sloping platform; 902. Through hole. Detailed Implementation

[0022] It should be noted that in the description of this specification, the terms "upper", "lower", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and 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.

[0023] like Figures 1 to 3 As shown, an embodiment of this utility model discloses a high-voltage line terminal block for a hybrid gearbox, including a terminal block body 1 installed between the motor housing and the electrical control housing of the hybrid gearbox. The terminal block body 1 is provided with a connecting component 2 at the connection end of the electrical control copper busbar in the electrical control housing. The connecting component 2 includes a sleeve 9 and a first connecting nut 10. The sleeve is provided with a cavity. The first connecting nut 10 is axially limited and disposed in the cavity of the sleeve 9 and can float horizontally in the cavity of the sleeve 9. The sleeve 9 can be made of metal or high-strength engineering plastic, with the metal sleeve 9 preferably made of copper alloy or stainless steel to balance conductivity and strength. The cross-sectional shape of the cavity is set to square or other polygonal shapes, and the outer contour of the first connecting nut 10 is set to match the cross-sectional shape of the cavity. Its outer diameter is fitted with the cavity of the sleeve 9 with a clearance controlled within the range of 0.5-1mm to achieve effective floating. In order to prevent the first connecting nut 10 from rotating in the cavity when tightening, this solution designs both the cross-sectional shape of the cavity and the outer contour of the first connecting nut 10 to be square. Axial limiting can be achieved by the step inside the sleeve 9 or by welding a limiting block. This technical solution effectively solves the problem of misalignment between the high-voltage terminal block and the power brick of the hybrid box through a floating connection structure. When the installation position of the terminal block body 1 is deviated due to the injection molding process, the first connecting nut 10 can be finely adjusted in horizontal position within the cavity of the sleeve 9, thereby compensating for dimensional errors in the manufacturing and assembly process. Compared with the existing technology that uses fixed nuts for riveting, this solution significantly reduces the requirements for the machining accuracy of parts, making the connection between the high-voltage terminal block and the power brick more reliable; the floating design of the connecting component 2 improves the assembly success rate and reduces installation stress without affecting the conductivity.

[0024] In this embodiment, the connecting assembly 2 further includes a limiting ring 11 disposed on the end of the sleeve 9 and used to axially limit the first connecting nut 10; the inner diameter of the limiting ring 11 is smaller than the outer diameter of the first connecting nut 10 but larger than the inner diameter of the first connecting nut 10; combined with Figure 3As shown, the inner diameter of the limiting ring 11 is smaller than the outer diameter of the first connecting nut 10 but larger than the inner diameter of the first connecting nut 10, to ensure that the connecting bolt can pass through the connecting assembly 2 normally when connected to the electrical control copper busbar, and to limit the axial movement of the first connecting nut 10. The limiting ring 11 can be fixed to the end of the sleeve 9 by welding. This technical solution effectively limits the axial displacement of the first connecting nut 10 by setting the limiting ring 11 at the end of the sleeve 9, while allowing it to float horizontally within the cavity of the sleeve 9 to compensate for the positional deviation during installation. This solves the problem of misalignment caused by insufficient manufacturing precision when connecting the high-voltage line terminal block and the power brick.

[0025] In this embodiment, the sleeve 9 has a countersunk hole structure and includes a countersunk portion 901 and a through hole portion 902. The sleeve 9 is disposed at the countersunk portion 901; combined with Figure 3 As shown, the countersunk hole structure refers to a stepped structure inside the sleeve 9, consisting of a countersunk portion 901 with a larger diameter and a through hole portion 902 with a smaller diameter. The countersunk portion 901 is used to accommodate the first connecting nut 10, and the through hole portion 902 is used for connecting bolts to the first connecting nut 10 via threads. The depth of the countersunk portion 901 can be slightly greater than the thickness of the first connecting nut 10, allowing the nut to float horizontally within the countersunk portion 901. This technical solution, by adopting the countersunk hole structure, can effectively solve the positioning problem during the assembly of the connecting component 2, and the countersunk portion 901 provides a precise installation position for the first connecting nut 10.

[0026] In this embodiment, the radial dimension of the countersunk portion 901 is larger than the outer diameter of the first connecting nut 10, and the radial dimension of the through hole portion 902 is smaller than the inner diameter of the first connecting nut 10. The inner diameter of the limiting ring 11 must meet two conditions: first, it must be smaller than the maximum outer diameter of the first connecting nut 10 to ensure that the limiting ring 11 can effectively prevent the nut from falling out of the sleeve 9; second, it must be larger than the minimum inner diameter of the nut to ensure that the nut maintains necessary floating space within the cavity of the sleeve 9. This technical solution, by precisely controlling the dimensional relationship between the limiting ring 11 and the nut, ensures the axial limiting function while retaining the horizontal floating compensation capability of the connecting assembly 2.

[0027] In this embodiment, a second connecting nut 12 is pressed into the connection end between the terminal block body 1 and the motor copper busbar inside the motor housing. Figure 2 As shown, the second connecting nut 12 is fixed to the connection end between the terminal block body 1 and the motor copper busbar by a crimping process, and is used to screw the terminal block copper busbar 3 to the motor copper busbar on the motor housing. This is existing technology and will not be described in detail here.

[0028] In this embodiment, the terminal block body 1 includes a terminal block copper busbar 3 and a plastic layer 4 for covering the terminal block copper busbar 3; after the connecting assembly 2 and the second connecting nut 12 are respectively pressed onto the terminal block copper busbar 3, the terminal block body 1 is integrally injection molded. Figure 2 As shown, the copper busbar 3 of the terminal block serves as a conductive component, connecting the motor copper busbar and the electronic control copper busbar to ensure circuit continuity. The plastic layer 4 is coated on the outside of the copper busbar 3 through injection molding, ensuring both insulation performance and structural strength. This technical solution effectively solves the problem of installation hole deviation caused by injection molding deformation in traditional methods by using a process sequence of pressing followed by injection molding. The pressing process ensures accurate positioning of the connector and the copper busbar, and the metal parts have formed a stable structure during subsequent injection molding, avoiding the impact of plastic shrinkage on the installation position. The sleeve 9 has knurling on its outer wall for sol-gel fixation during injection molding, while also preventing the sleeve 9 from rotating when tightening the first connecting nut 10 later.

[0029] In this embodiment, the plastic layer 4 has an injection hole 7 at its end near the motor housing; combined with Figure 1 As shown, due to the uneven shrinkage of the plastic layer 4 after injection molding, there may be some gaps between it and the copper busbar 3 of the terminal block. Therefore, the glue injection hole 7 is provided so that after injection molding, sealant can be injected into the plastic layer 4 and the terminal block body 1 to fill the gaps and ensure a tight fit between the plastic layer 4 and the copper busbar 3 of the terminal block.

[0030] In this embodiment, the plastic layer 4 is further provided with a weight-reduction hole 8 at the end near the motor housing; combined with Figure 1 As shown, by setting weight-reducing holes 8 in the plastic layer 4, the overall weight of the terminal block body 1 is effectively reduced while maintaining the necessary structural strength.

[0031] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the spirit and scope of the technical solutions of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A high-voltage line terminal block for a hybrid box, characterized in that: The device includes a terminal block body installed between the motor housing and the electrical control housing of the hybrid gearbox. The terminal block body is provided with a connection assembly at the connection end with the electrical control copper busbar inside the electrical control housing. The connection assembly includes a sleeve and a first connecting nut. The sleeve has a cavity. The first connecting nut is axially limited and disposed in the cavity of the sleeve and can float horizontally within the cavity of the sleeve.

2. The high-voltage line terminal block for a hybrid box according to claim 1, characterized in that: The connecting assembly further includes a limiting ring disposed on the end of the sleeve and used to axially limit the first connecting nut.

3. The high-voltage line terminal block for a hybrid box according to claim 1, characterized in that: The sleeve has a countersunk hole structure inside and includes a countersunk portion and a through hole portion. The sleeve is disposed at the countersunk portion.

4. The high-voltage line terminal block for a hybrid box according to claim 2, characterized in that: The inner diameter of the limiting ring is smaller than the outer diameter of the first connecting nut but larger than the inner diameter of the first connecting nut.

5. The high-voltage line terminal block for a hybrid box according to claim 3, characterized in that: The radial dimension of the countersunk portion is greater than the outer diameter of the first connecting bolt, and the radial dimension of the through hole portion is smaller than the inner diameter of the first connecting bolt.

6. The high-voltage line terminal block for a hybrid box according to claim 1, characterized in that: A second connecting nut is pressed into the connection end between the terminal block body and the motor copper busbar inside the motor housing.

7. The high-voltage line terminal block for a hybrid box according to claim 6, characterized in that: The terminal block body includes a terminal block copper busbar and a plastic layer for covering the terminal block copper busbar.

8. The high-voltage line terminal block for a hybrid box according to claim 7, characterized in that: The connecting component and the second connecting nut are respectively pressed onto the copper busbar of the terminal block, and then integrally injection molded to form the terminal block body.

9. The high-voltage line terminal block for a hybrid box according to claim 7, characterized in that: The plastic layer has an injection hole at the end near the motor housing.

10. The high-voltage line terminal block for a hybrid box according to claim 7, characterized in that: The plastic layer also has weight-reducing holes at the end near the motor housing.

Images