A new busbar assembly for a gearbox motor of a new energy power automobile

Abstract

The application relates to the technical field of automobile gearbox motors, and discloses a novel busbar assembly for a gearbox motor of a new energy power automobile, which comprises three groups of terminals, the inner sides of the three groups of terminals are respectively welded with corresponding soft copper bars, one side of each of the three groups of terminals is sequentially provided with a U-shaped wrapping structure and a copper enameled wire, and the side, away from the U-shaped wrapping structure, of the three groups of copper enameled wires is provided with a plastic shell; three groups of protective grooves are formed in the outer wall of the plastic shell; the three groups of terminals, the soft copper bars, the U-shaped wrapping structure and the copper enameled wires are independently arranged and integrated, the installation adaptability and the anti-vibration reliability are improved, the soft copper bars provide flexible buffering, effectively absorb the gearbox operation vibration, avoid stress concentration caused by rigid connection, the U-shaped wrapping structure wraps the soft copper bar to prevent vibration fracture, the protective grooves in the outer wall of the plastic shell form space constraints on the vibrating copper enameled wire, the space constraints allow slight deformation to compensate for the tolerance and limit the amplitude to prevent peripheral interference, simplify the component layout, meet the span requirement, and reduce the cost.

Description

Technical Field

[0001] This application relates to the field of automotive transmission motor technology, specifically a novel busbar assembly for transmission motors in new energy vehicles. Background Technology

[0002] In hybrid vehicle transmissions, the drive motor needs to introduce high-voltage electricity from an external connector to the internal stator windings via a bus assembly. This assembly typically includes a high-voltage connector that interfaces with the outside and three-phase conductors (usually a raised pin structure) that connect to the stator windings.

[0003] Currently, its installation is poor: the connection end face between the high-voltage connector and the gearbox housing, and the mating end of the three-phase conductor and the stator winding rise pin have strict dimensional tolerances and assembly tolerances. Even small deviations in the axial and radial directions can lead to installation difficulties, generate assembly stress, or even make installation impossible. Vibration reliability is also poor: the gearbox working environment is full of vibration. The traditional long strip rigid busbar has a low natural frequency and is prone to resonance with the excitation frequency of the engine or motor, leading to metal fatigue fracture. Although using long soft connections can alleviate vibration, it is costly, occupies a lot of space, and may swing and interfere with the surroundings under vibration. The contradiction between cost and performance leads to the use of full-section or long-section soft connections to solve the vibration problem, which drastically increases material costs (such as laminated busbars) and processing costs.

[0004] Therefore, an integrated busbar assembly that combines large span, excellent installability, high vibration resistance, and low cost is proposed. Utility Model Content

[0005] The purpose of this application is to provide a novel busbar assembly for a transmission motor in a new energy vehicle, which solves the problems mentioned in the background art: poor installation performance: the connection end face between the high-voltage connector and the transmission housing, and the raised pin connection end between the three-phase conductor and the stator winding have strict dimensional and assembly tolerances. Even small deviations in the axial and radial directions can lead to installation difficulties, assembly stress, or even failure to install. Poor vibration reliability: the transmission working environment is full of vibration. Traditional long strip rigid busbars have low natural frequencies and are prone to resonance with the excitation frequency of the engine or motor, leading to metal fatigue fracture. While using long flexible connections can alleviate vibration, they are costly, occupy a lot of space, and may swing and interfere with the surrounding environment under vibration. The contradiction between cost and performance leads to the problem that using full or long flexible connections to solve the vibration problem results in a sharp increase in material costs (such as laminated busbars) and processing costs.

[0006] To solve the above-mentioned technical problems, this utility model is achieved through the following technical solution: This application provides a novel busbar assembly for a transmission motor of a new energy vehicle, comprising three sets of terminals. The inner sides of the three sets of terminals are respectively welded with corresponding soft copper busbars, and each set of terminals has a U-shaped wrapping structure and copper enameled wire arranged sequentially on one side. The side of the three sets of copper enameled wires away from the U-shaped wrapping structure is provided with a plastic shell, and the outer wall of the plastic shell is provided with three sets of protective grooves.

[0007] By adopting the above technical solution, through the integrated design of three independently arranged terminals, soft copper busbars, U-shaped wrapping structure and copper enameled wire, the installation adaptability and vibration resistance reliability are significantly improved. Among them, the soft copper busbar provides flexible buffer, effectively absorbs the vibration of the gearbox operation, and avoids stress concentration of rigid connection. The U-shaped wrapping structure wraps the soft copper busbar to prevent vibration breakage. The groove on the outer wall of the plastic shell forms a spatial constraint on the vibration envelope wire, which allows for slight deformation to compensate for tolerances, limits the amplitude to prevent peripheral interference, simplifies the component layout, meets the span requirements, and reduces costs.

[0008] Optionally, the three sets of terminals are respectively welded to the corresponding soft copper busbars.

[0009] By adopting the above technical solution, the soft copper busbar can play a role in providing a flexible connection to the terminals. The soft copper busbar has the ability to absorb vibration energy through deformation, avoid stress concentration at rigid connections, and improve vibration resistance and fatigue durability.

[0010] Optionally, the three sets of soft copper busbars are respectively welded to the corresponding U-shaped wrapping sheet, and the three sets of copper enameled wires are slidably inserted into the corresponding U-shaped wrapping structure and welded together.

[0011] By adopting the above technical solution, the U-shaped wrapping structure can be connected by a soft copper busbar, which can play a role in the flexible connection between the U-shaped wrapping structure and the terminal. The copper enameled wire is formed by bending process, and its flexibility can realize the adaptive compensation of assembly tolerance, reduce the installation difficulty and improve the fault tolerance. The copper enameled wire is inserted into the corresponding U-shaped wrapping structure and welded, which can enhance the stability of electrical connection.

[0012] Optionally, the inner corners of the inner walls of the three sets of U-shaped wrapping structures on the side away from the terminals are rounded.

[0013] By adopting the above technical solution, the inner corners of the inner wall on the side away from the terminal of the U-shaped wrapping structure are rounded, which facilitates the insertion of copper enameled wires.

[0014] Optionally, the plastic shell is a square mold formed by injection molding, and the three sets of copper enameled wires are arranged inside the plastic shell.

[0015] By adopting the above technical solution, the cost is reduced and an insulating support function is provided by using a plastic shell as a square mold formed by injection molding.

[0016] Compared with the prior art, the beneficial effects of the technical solution of this application are as follows: The technical solution of this application significantly improves installation adaptability and vibration resistance reliability through the integrated design of three independently arranged terminals, soft copper busbars, U-shaped wrapping structure and copper enameled wire. Among them, the soft copper busbar provides flexible buffer, effectively absorbs the vibration of the gearbox operation, and avoids stress concentration of rigid connection. The U-shaped wrapping structure wraps the soft copper busbar to prevent vibration breakage. The groove on the outer wall of the plastic shell forms a spatial constraint on the vibration envelope wire, which allows for small deformation to compensate for tolerances, limits the amplitude to prevent peripheral interference, simplifies component layout, meets span requirements, and reduces costs. Attached Figure Description

[0017] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is an axial view schematic diagram of a novel busbar assembly for a transmission motor of a new energy vehicle according to this application; Figure 2 This is a partial enlarged plastic view of a novel busbar assembly for a transmission motor in a new energy vehicle according to this application; Figure 3 This is an enlarged view of the U-shaped wrapping structure of a novel busbar assembly for a transmission motor of a new energy vehicle according to this application.

[0018] In the diagram: 1. Terminal; 2. Soft copper busbar; 3. Copper enameled wire; 4. Plastic shell; 5. Protective groove; 6. U-shaped wrapping structure; 7. Rounded corners. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0020] Please see Figure 1-3 This application provides a technical solution: a novel busbar assembly for a transmission motor of a new energy vehicle, comprising three sets of terminals 1, with corresponding soft copper busbars 2 welded to the inner side of the three sets of terminals 1, and U-shaped wrapping structures 6 and copper enameled wires 3 arranged sequentially on one side of each of the three sets of terminals 1, and a plastic shell 4 arranged on the side of the three sets of copper enameled wires 3 away from the U-shaped wrapping structure 6, and three sets of protective grooves 5 opened on the outer wall of the plastic shell 4; In the technical solution of this application, the installation adaptability and vibration resistance reliability are significantly improved by integrating three independently arranged terminals 1, soft copper busbars 2, U-shaped wrapping structures 6 and copper enameled wires 3. Among them, the soft copper busbars 2 provide flexible buffering, effectively absorbing the vibration of the gearbox operation and avoiding stress concentration of rigid connections. The U-shaped wrapping structure 6 wraps the soft copper busbars 2 to prevent vibration breakage. The outer wall groove of the plastic shell 4 forms a spatial constraint on the vibration wrapping wire, which allows for slight deformation to compensate for tolerances and limits the amplitude to prevent peripheral interference, simplifies the component layout, meets the span requirements, and reduces costs.

[0021] In the technical solution of this application, such as Figure 1 and Figure 2 As shown, the plastic shell 4 is a square mold formed by injection molding, and three sets of copper enameled wires 3 are set inside the plastic shell 4. By making the plastic shell 4 a square mold formed by injection molding, the cost is reduced and insulation support function is provided.

[0022] In the technical solution of this application, such as Figure 1 As shown, the three sets of terminals 1 are welded to the corresponding flexible copper busbars 2. The flexible copper busbars 2 provide a flexible connection to the terminals 1 and have the ability to absorb vibration energy through deformation, avoiding stress concentration at rigid connections and improving vibration resistance and fatigue durability. The three sets of flexible copper busbars 2 are welded to the corresponding U-shaped wrapping sheets, and the three sets of copper enameled wires 3 are slidably inserted into the corresponding U-shaped wrapping structure 6 and welded together. The connection between the flexible copper busbars 2 and the U-shaped wrapping structure 6 provides a flexible connection between the U-shaped wrapping structure 6 and the terminals 1. The copper enameled wires 3 are formed by bending, utilizing their flexibility to achieve adaptive compensation of assembly tolerances, reducing installation difficulty and improving fault tolerance. The insertion and welding of the copper enameled wires 3 into the corresponding U-shaped wrapping structure 6 enhances the stability of the electrical connection. The inner corners of the inner walls of the three U-shaped wrapping structures 6 away from the terminals 1 are rounded 7, which facilitates the insertion of the copper enameled wires 3.

[0023] In use, the flexible copper busbar 2 serves as the core vibration compensation unit of the busbar assembly. This flexible connection effectively absorbs and buffers high-frequency vibrations and low-frequency swaying generated by the operation of the motor and gearbox, avoiding stress concentration at rigid connections. This endows the entire assembly with excellent high vibration resistance and long-term fatigue durability. The copper enameled wire 3 uses low-cost enameled copper wire that is bent into shape, significantly reducing material costs. Its inherent flexibility allows for slight adaptive deformation during assembly, thereby compensating for axial and radial assembly tolerances and greatly improving the ease of installation and fault tolerance of the assembly. The groove 5 is a square protective groove 5 integrally molded by injection molding of the injection shell. The protective groove 5 confines the vibrating envelope wire within a precise geometric space. Through clearance fit, without restricting its minor necessary deformation, it effectively limits its maximum amplitude during vibration, prevents interference with surrounding components, and ensures the controllability and reliability of vibration. The U-shaped wrapping structure 6 wraps around a set of copper enameled wires 3, improving welding strength. The rounded corner structure 7 serves as an effective guide slope, which can smoothly guide the components and mating parts during assembly, avoiding interference and jamming caused by sharp edges, and significantly improving assemblability.

Claims

1. A novel busbar assembly for a transmission motor in a new energy vehicle, characterized in that: It includes three sets of terminals (1), and the inner sides of the three sets of terminals (1) are respectively welded with corresponding soft copper busbars (2), and a U-shaped wrapping structure (6) and copper enameled wire (3) are respectively arranged on one side. A plastic shell (4) is arranged on the side of the three sets of copper enameled wires (3) away from the U-shaped wrapping structure (6), and three sets of protective grooves (5) are opened on the outer wall of the plastic shell (4).

2. A novel busbar assembly for a transmission motor of a new energy vehicle according to claim 1, characterized in that, The three sets of terminals (1) are respectively welded to the corresponding soft copper busbars (2).

3. A novel busbar assembly for a transmission motor of a new energy vehicle according to claim 1, characterized in that, The three sets of soft copper busbars (2) are respectively welded to the corresponding U-shaped wrapping sheet, and the three sets of copper enameled wires (3) are slidably inserted into the corresponding U-shaped wrapping structure (6) and welded together.

4. A novel busbar assembly for a transmission motor of a new energy vehicle according to claim 1, characterized in that, The inner corners of the inner wall of the three sets of U-shaped wrapping structures (6) on the side away from the terminal (1) are rounded (7).

5. A novel busbar assembly for a transmission motor of a new energy vehicle according to claim 1, characterized in that, The plastic shell (4) is a square mold formed by injection molding, and the three sets of copper enameled wires (3) are arranged inside the plastic shell (4).

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