A three-phase adapter

Abstract

The utility model discloses a three -phase adapter in the electric control field of new energy automobile, including copper row subassembly, insulating sleeve and insulating seat, and copper row subassembly is by three soft copper row respectively with three hard copper row welding arrangement and constitutes, and hard copper row includes the electric control connection department, the bending part and the welding part of integrally connected setting, and the electric control connection department is provided with error compensation subassembly, and the insulating seat includes the main casing for accommodating electric control connection department and bending part, the hollow cavity for accommodating error compensation subassembly, the boss of extending along the length direction of welding part and the sealing portion around the outside of main casing, and sealing portion is provided with the sealing groove recessed to the inside outside three welding portions, and is provided with the sealing ring in sealing groove, and the boss inner wall and welding portion outer wall between leave the interval for filling the sealant, and the insulating sleeve is sleeved in the outside of the connecting place of welding portion and soft copper row and extends to the outside of boss. The utility model adopts the copper row design of rigid and soft, has double -sealed protection, can isolate cooling oil.

Description

Technical Field

[0001] This utility model belongs to the field of new energy vehicle electronic control technology, and specifically relates to a three-phase adapter. Background Technology

[0002] In the electric motor drive system of new energy vehicles, the three-phase adapter serves as a key bridge connecting the motor windings and the output terminals of the electronic control system. Its performance directly affects the efficiency, reliability, and safety of the entire power system.

[0003] In pursuit of high power density and efficient heat dissipation, an increasing number of motors are adopting internal oil cooling technology, immersing core components such as the stator and rotor in a cooling oil environment. Three-phase adapters must penetrate the motor housing, connecting one end to the motor windings in the cooling oil environment and the other end to the electrical control system terminals in a dry and clean environment. Therefore, achieving absolute isolation between the motor-side cooling oil and the electrical control side, preventing cooling oil leakage into the electrical control system that could lead to short circuits, corrosion, and failure, has become the primary technical challenge in adapter design.

[0004] In the prior art, a three-phase copper busbar assembly and electric drive integrated system are disclosed, with publication number CN217159447U and application date of 2022-04-28. The assembly includes a three-phase copper busbar body and a base integrally formed with the three-phase copper busbar body. The base is used to connect to the housing of a motor controller, and a sealing structure is provided on the base for sealing connection with the wire passage holes on the housing. The three-phase copper busbar body includes a first connecting part located on the side of the base facing the housing and a second connecting part located on the side facing away from the housing. The sealing structure on the base provides a sealed connection between the base and the wire passage holes. The sealing structure includes a boss on the side of the base facing the housing and a sealing ring on the outer wall of the boss. Its shortcomings are: the motor and the electric control system are two independent assemblies, with unavoidable manufacturing and installation tolerances. The rigidly connected adapter lacks necessary tolerance capacity, and the single sealing ring design is prone to failure due to insufficient reliability under long-term vibration, thermal aging, and installation tolerances, making it difficult to achieve a durable and absolute seal. Utility Model Content

[0005] The purpose of this utility model is to provide a three-phase adapter that adopts a copper busbar design that combines rigidity and flexibility, and has double sealing protection to completely isolate the cooling oil.

[0006] The purpose of this utility model is achieved as follows: A three-phase adapter includes a copper busbar assembly, an insulating sleeve, and an insulating base. The copper busbar assembly is composed of three flexible copper busbars welded to three rigid copper busbars. The rigid copper busbars include an integrally connected electrical control connection part, a bending part, and a welding part. The electrical control connection part is provided with an error compensation component. The insulating base includes a main housing for accommodating the electrical control connection part and the bending part, a hollow cavity for accommodating the error compensation component, a boss extending along the length direction of the welding part, and a sealing part surrounding the outside of the main housing. The sealing part has an inwardly recessed sealing groove corresponding to the outside of the three welding parts. A sealing ring is provided in the sealing groove. A gap for filling sealant is left between the inner wall of the boss and the outer wall of the welding part. The insulating sleeve is sleeved on the outside of the connection between the welding part and the flexible copper busbar and extends to the outside of the boss.

[0007] When this utility model is in use, the sealing ring of the sealing part fits tightly with the housing, forming a main sealing barrier that blocks the cooling oil in the motor cavity over a large area. At the same time, the sealant filled in the boss forms a secondary barrier, completely blocking any possible oil vapor from penetrating and ensuring that the electrical control side is dry. The insulating seat and the insulating sleeve work together to provide reliable phase-to-phase and phase-to-ground insulation for the entire conductive circuit, while the soft copper busbar and error compensation component effectively absorb vibration and compensate for tolerances, ensuring the long-term safety and stability of the electrical connection under harsh working conditions. Compared with the prior art, the beneficial effects of this utility model are as follows: the hard copper busbar provides structural strength, ensuring stable connection and support with the terminals of the electrical control system; the soft copper busbar provides flexibility and vibration resistance, which can compensate for installation tolerances and slight displacement and vibration generated during motor operation, avoiding stress transmission to the welding point or electrical control system, and improving the reliability of the system; the insulating sleeve tightly wraps the welding point, soft copper busbar and boss, which not only provides a certain degree of environmental sealing to protect the welding point from direct contact with cooling oil, but also provides additional insulation protection to prevent short circuits between the three phases or due to contact with the housing, and also plays a mechanical protection role for the welding part.

[0008] As a further improvement of this utility model, the error compensation component includes a bolt, an elastic washer, and a floating nut, wherein the bolt passes through the elastic washer and the electrical control connection and is threadedly connected to the floating nut.

[0009] As a further improvement of this utility model, the floating nut is a cuboid structure with a circular through hole along its own axis. The inner wall of the circular through hole is provided with an internal thread. The center of the hollow cavity is a rectangular through hole. There are gaps between the outer wall of the floating nut and the inner wall of the rectangular through hole. The diagonal length of the floating nut is greater than the length of the short side of the rectangular through hole.

[0010] As a further improvement of this utility model, the electrical control connection part is provided with a fixing hole that allows a bolt to pass through, and the diameter of the fixing hole is larger than the diameter of the circular through hole.

[0011] As a further improvement of this utility model, the hollow cavity includes a horizontal support plate. The upper side of the horizontal support plate is provided with a fixing groove for accommodating the end of the electrical control connection part and two partition plates symmetrically distributed on both sides of the electrical control connection part. The lower side is provided with a receiving cylinder for allowing the floating nut to move in the horizontal direction. The rectangular through hole penetrates the horizontal support plate and the receiving cylinder.

[0012] As a further improvement of this utility model, the bottom of the receiving cylinder is provided with a sealing stepped hole and a number of rivets for fixed connection with the sealing cover. The sealing cover is provided with an installation hole for the rivets to pass through and a sealing frustum that is interference-fitted with the sealing stepped hole.

[0013] As a further improvement of this utility model, a plurality of mounting ears are provided around the sealing part, and through-hole inserts are provided in the mounting ears.

[0014] As a further improvement of this utility model, the sealing ring has an H-shaped cross-section and multiple protrusions that abut against the sealing groove are provided on both the inner and outer walls.

[0015] As a further improvement of this utility model, the three hard copper busbars are respectively a U-phase hard copper busbar, a V-phase hard copper busbar, and a W-phase hard copper busbar. The bending portion of the U-phase hard copper busbar includes a vertical bending section one and a vertical bending section two. The bending portion of the V-phase hard copper busbar includes a vertical bending section three and a vertical bending section four. The bending portion of the W-phase hard copper busbar includes a horizontal bending section and a vertical bending section five. The vertical bending section one and the vertical bending section three are arranged parallel to each other at intervals. The vertical bending sections two and four are arranged parallel to the vertical bending section five at intervals and are located above the horizontal bending section.

[0016] As a further improvement of this utility model, the soft copper busbar is formed by stacking multiple copper foils, and the two ends are welded by polymer diffusion welding to form a hardened part one and a hardened part two respectively. There is an arc-shaped flexible part between the hardened part one and the hardened part two. The end of the insulating sleeve extends to the outside of the arc-shaped flexible part. A groove is opened on the end face of the hardened part one, and a part that matches and engages with the shape of the groove is provided on the end face of the welded part. An elliptical hole is opened on the hardened part two. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0018] Figure 2 This is a top view of the present invention.

[0019] Figure 3 for Figure 2 Sectional view at point AA.

[0020] Figure 4This is a three-dimensional structural diagram of the copper busbar assembly in this utility model.

[0021] Among them, 1 is a hard copper busbar, 101 is an electrical control connection part, 101a is a fixing hole, 102 is a vertical bending section one, 103 is a vertical bending section two, 104 is a vertical bending section three, 105 is a vertical bending section four, 106 is a horizontal bending section, 107 is a vertical bending section five, 108 is a welding part, 2 is a soft copper busbar, 201 is a hardened part one, 202 is a hardened part two, 203 is an arc-shaped flexible part, 3 is an insulating sleeve, 4 is a main shell, 5 is a hollow cavity, 501 is a horizontal support plate, 501a is a fixing groove, 502 is a partition plate, 503 is a receiving cylinder, 503a is a rectangular through hole, 503b is a sealing stepped hole, 503c is a rivet, 504 is a sealing cover, 6 is a rectangular through hole, 7 is a boss, 8 is a sealing part, 9 is a bolt, 10 is an elastic washer, 11 is a floating nut, 1101 is a circular through hole, 12 is a sealing ring, 13 is a sealant, and 14 is a through hole insert. Detailed Implementation

[0022] like Figure 1-4 As shown, a three-phase adapter includes a copper busbar assembly, an insulating sleeve 3, and an insulating base. The copper busbar assembly is composed of three flexible copper busbars 2 welded to three rigid copper busbars 1. The rigid copper busbar 1 includes an integrally connected electrical control connection part 101, a bending part, and a welding part 108. The electrical control connection part 101 is provided with an error compensation component. The insulating base includes a main housing 4 for accommodating the electrical control connection part 101 and the bending part, a hollow cavity 5 for accommodating the error compensation component, and a section along the length of the welding part 108. The boss 7 extends outward and the sealing part 8 surrounds the outside of the main housing 4. The sealing part 8 is provided with an inwardly recessed sealing groove on the outside of the three welded parts 108. A sealing ring 12 is provided in the sealing groove. The sealing ring 12 has an H-shaped cross section and multiple protrusions that abut against the sealing groove are provided on both the inner and outer walls. A gap is left between the inner wall of the boss 7 and the outer wall of the welded part 108 for filling with sealant 13. The insulating sleeve 3 is sleeved on the outside of the connection between the welded part 108 and the soft copper busbar 2 and extends to the outside of the boss 7.

[0023] In this embodiment, the error compensation component includes a bolt 9, an elastic washer 10, and a floating nut 11. A fixing hole 101a is provided on the electrical control connection part 101. The bolt 9 passes through the elastic washer 10 and the fixing hole 101a and is threadedly connected to the floating nut 11. The floating nut 11 has a cuboid structure with a circular through hole 1101 along its own axis. Internal threads are provided on the inner wall of the circular through hole 1101. A rectangular through hole 503a is located at the center of the hollow cavity 5. Gaps are left between the outer wall of the floating nut 11 and the inner wall of the rectangular through hole 503a, and the diagonal length of the floating nut 11 is greater than the length of the shorter side of the rectangular through hole 503a. The radial clearance allows the floating nut 11 to translate and rotate slightly in the XY plane, compensating for installation position deviations. The diagonal restriction constrains the movement range of the floating nut 11 within the rectangular through hole 503a, preventing it from completely dislodging and ensuring connection stability. At the same time, the size of the clearance determines the amount of compensation, allowing precise control of the allowable installation deviation range during design to avoid excessive loosening. The diameter of the fixing hole 101a is larger than the diameter of the circular through hole 1101, providing the bolt 9 with an additional "degree of freedom of swing," thereby ensuring that the self-aligning function of the floating nut 11 can be fully realized and eliminating assembly stress.

[0024] The hollow cavity 5 includes a horizontal support plate 501. The upper side of the horizontal support plate 501 is provided with a fixing groove 501a for accommodating the end of the electrical control connection part 101 and two partition plates 502 symmetrically distributed on both sides of the electrical control connection part 101. The lower side is provided with a receiving cylinder 503 for allowing the floating nut 11 to move horizontally. A rectangular through hole 503a penetrates the horizontal support plate 501 and the receiving cylinder 503. The bottom of the receiving cylinder 503 is provided with a sealing stepped hole 503b and two rivets 503c for fixed connection with the sealing cover 504. The sealing cover 504 is provided with a mounting hole for the rivets 503c to pass through and a sealing frustum that is interference-fitted with the sealing stepped hole 503b. The sealing part 8 is provided with four mounting ears around its perimeter, and a through-hole insert 14 is provided in the mounting ears.

[0025] The three hard copper busbars 1 are the U-phase hard copper busbar, the V-phase hard copper busbar, and the W-phase hard copper busbar. The bending section of the U-phase hard copper busbar includes a vertical bending section 102 and a vertical bending section 2 103. The bending section of the V-phase hard copper busbar includes a vertical bending section 3 104 and a vertical bending section 4 105. The bending section of the W-phase hard copper busbar includes a horizontal bending section 106 and a vertical bending section 5 107. The vertical bending section 102 and the vertical bending section 3 104 are arranged parallel to each other at intervals. The vertical bending sections 2 103 and 4 105 are arranged parallel to the vertical bending section 5 107 at intervals, and are located above the horizontal bending section 106.

[0026] The soft copper busbar 2 is made of multiple copper foils stacked together. The two ends are welded by polymer diffusion welding to form a hardened part 1 201 and a hardened part 202 respectively. Between the hardened part 1 201 and the hardened part 202 is an arc-shaped flexible part 203. The end of the insulating sleeve 3 extends to the outside of the arc-shaped flexible part 203. The end face of the hardened part 1 201 is provided with a groove. The end face of the welding part 108 is provided with a part that matches and engages with the shape of the groove. The hardened part 202 is provided with an elliptical hole.

[0027] The advantages of this utility model are as follows: The inner and outer lips of the H-shaped cross section face the inner and outer sides of the mounting surface, forming two independent sealing defense lines. The inner lip is compressed outward under the action of cooling oil pressure, tightly fitting the inner wall of the sealing groove and preventing the cooling oil from leaking outward. The outer lip is compressed inward under the action of external environmental pressure, filling the gap between the outer wall of the sealing groove and the mounting surface, preventing external pollutants from entering or gas from the electrical control side from leaking. When the sealing ring 12 is compressed, the multiple protrusions on the inner and outer walls preferentially contact the inner and outer walls of the sealing groove, forming a "point-to-surface" contact rather than an overall surface contact. On the one hand, the multiple protrusions can disperse the compressive stress and avoid microscopic unevenness of the mounting surface. On the other hand, the elastic deformation of the protrusions can actively fill the gap between the sealing groove and the mounting surface. Compared with the O-ring with planar contact, it significantly improves the sealing adaptability to non-ideal interfaces and ensures zero leakage.

[0028] This utility model is not limited to the above embodiments. Based on the technical solutions disclosed in this utility model, those skilled in the art can make some substitutions and modifications to some of the technical features without creative labor, and these substitutions and modifications are all within the protection scope of this utility model.

Claims

1. A three-phase adapter, characterized in that, The device includes a copper busbar assembly, an insulating sleeve, and an insulating base. The copper busbar assembly is composed of three flexible copper busbars welded to three rigid copper busbars. The rigid copper busbars include an integrally connected electrical control connection part, a bending part, and a welding part. The electrical control connection part is equipped with an error compensation component. The insulating base includes a main housing for accommodating the electrical control connection part and the bending part, a hollow cavity for accommodating the error compensation component, a boss extending along the length of the welding part, and a sealing part surrounding the outside of the main housing. The sealing part has inwardly recessed sealing grooves corresponding to the outer sides of the three welding parts, and sealing rings are provided in the sealing grooves. A gap for filling sealant is left between the inner wall of the boss and the outer wall of the welding part. The insulating sleeve is fitted over the outside of the connection between the welding part and the flexible copper busbar and extends to the outside of the boss.

2. A three-phase adapter according to claim 1, characterized in that, The error compensation component includes a bolt, an elastic washer, and a floating nut. The bolt passes through the elastic washer and the electrical control connection and is threadedly connected to the floating nut.

3. A three-phase adapter according to claim 2, characterized in that, The floating nut has a cuboid structure with a circular through hole along its own axis. The inner wall of the circular through hole has an internal thread. The center of the hollow cavity has a rectangular through hole. There are gaps between the outer wall of the floating nut and the inner wall of the rectangular through hole. The diagonal length of the floating nut is greater than the length of the short side of the rectangular through hole.

4. A three-phase adapter according to claim 2, characterized in that, The electrical control connection part has a fixing hole that allows a bolt to pass through, and the diameter of the fixing hole is larger than the diameter of the circular through hole.

5. A three-phase adapter according to claim 3, characterized in that, The hollow cavity includes a horizontal support plate. The upper side of the horizontal support plate is provided with a fixing groove for accommodating the end of the electrical control connection part and two partition plates symmetrically distributed on both sides of the electrical control connection part. The lower side is provided with a receiving cylinder for allowing the floating nut to move in the horizontal direction. The rectangular through hole penetrates the horizontal support plate and the receiving cylinder.

6. A three-phase adapter according to claim 5, characterized in that, The bottom of the receiving cylinder is provided with a sealing stepped hole and several rivets for fixed connection with the sealing cover. The sealing cover is provided with an installation hole for the rivets to pass through and a sealing frustum that is interference-fitted with the sealing stepped hole.

7. A three-phase adapter according to claim 1, characterized in that, The sealing part is provided with several mounting ears around its perimeter, and a through-hole insert is provided inside the mounting ears.

8. A three-phase adapter according to claim 1, characterized in that, The sealing ring has an H-shaped cross-section and multiple protrusions on both its inner and outer walls that abut against the sealing groove.

9. A three-phase adapter according to claim 1, characterized in that, The three hard copper busbars are U-phase hard copper busbar, V-phase hard copper busbar, and W-phase hard copper busbar. The bending portion of the U-phase hard copper busbar includes a vertical bending section one and a vertical bending section two. The bending portion of the V-phase hard copper busbar includes a vertical bending section three and a vertical bending section four. The bending portion of the W-phase hard copper busbar includes a horizontal bending section and a vertical bending section five. The vertical bending section one and the vertical bending section three are arranged parallel to each other at intervals. The vertical bending sections two and four are arranged parallel to the vertical bending section five at intervals and are located above the horizontal bending section.

10. A three-phase adapter according to claim 1, characterized in that, The soft copper busbar is made of multiple stacked copper foils, and the two ends are welded by polymer diffusion welding to form a hardened part one and a hardened part two respectively. There is an arc-shaped flexible part between the hardened part one and the hardened part two. The end of the insulating sleeve extends to the outside of the arc-shaped flexible part. A groove is opened on the end face of the hardened part one, and a part that matches and engages with the groove is provided on the end face of the welded part. An elliptical hole is opened on the hardened part two.

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