A copper bar and disc motor

Abstract

The application discloses a copper bar and a disc type motor, wherein the copper bar comprises a first connecting section, a middle section and a second connecting section, the middle section is located between the first connecting section and the second connecting section, the first connecting section is used for being connected with a lead-out wire of a winding of the disc type motor, and the second connecting section is used for being connected with a terminal of a wire harness of a controller. According to the scheme, the thickness of the middle section is reduced, the hardness of the middle section is reduced, the middle section can be bent, the bending direction of the middle section is from a side wall of a shell of the disc type motor to a top wall of the shell of the disc type motor, the second connecting section is located on the top wall of the shell of the disc type motor, the connection position of the second connecting section and the terminal of the wire harness of the controller is closer to an axis of the disc type motor, the copper bar occupies less space in the radial direction of the shell of the disc type motor compared with the prior art, and the compactness of the disc type motor is improved.

Description

Technical Field

[0001] This application relates to the field of disc motor technology, and particularly to a copper busbar and a disc motor. Background Technology

[0002] In related technologies, the lead wires of the windings of the disc motor are connected to the wiring harness of the controller via copper busbars. The copper busbars are relatively rigid and are arranged along the radial direction of the disc motor housing, which occupies a large amount of space in the radial direction of the disc motor housing and affects the compactness of the disc motor structure.

[0003] Therefore, how to improve the structural compactness of disc motors has become a technical problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0004] This application proposes a copper busbar to improve the structural compactness of a disc motor. This application also proposes a disc motor.

[0005] To achieve the above objectives, this application provides a copper busbar, including a first connecting segment, a middle segment, and a second connecting segment, wherein the two ends of the middle segment are respectively connected to the first connecting segment and the second connecting segment.

[0006] The first connecting segment is used to connect to the lead wire of the winding of the disc motor, and the first connecting segment is arranged along the axial direction of the disc motor.

[0007] The thickness of the intermediate section is less than the thickness of the first connecting section and / or the second connecting section, so that the intermediate section can be bent from the side wall of the disc motor to the top wall of the disc motor.

[0008] The second connecting segment is used to connect to the terminals of the controller's wiring harness, and one end of the second connecting segment used to connect to the terminals of the wiring harness is located on the top wall of the disc motor.

[0009] Preferably, in the above-mentioned copper busbar, the middle section is a middle section woven from soft copper wire.

[0010] Preferably, in the above-mentioned copper busbar, the middle section is welded to the first connecting section and the second connecting section.

[0011] Preferably, in the copper busbar described above, the first connecting segment includes a connecting segment and a transition segment, the width of the connecting segment is at least equal to the width of the lead wire, the width of the transition segment is greater than the width of the connecting segment, and the width of the transition segment does not exceed the width of the intermediate segment.

[0012] Preferably, in the copper busbar described above, the first connecting surface between the transition section and the intermediate section is a stepped surface or a smooth transition surface.

[0013] Preferably, in the copper busbar described above, the second connecting surface between the second connecting segment and the intermediate segment is a stepped surface or a smooth transition surface.

[0014] Preferably, in the above-mentioned copper busbar, the thickness of the first connecting segment and the thickness of the second connecting segment are equal;

[0015] Alternatively, the thickness of the second connecting segment is less than the thickness of the first connecting segment.

[0016] A disc motor includes a housing, a junction box, and copper busbars.

[0017] The top wall of the housing has a first opening.

[0018] The junction box is mounted on the top wall, and the junction box has a second opening communicating with the first opening.

[0019] The copper busbar is the copper busbar described in any of the above embodiments. The first connecting section of the copper busbar is connected to the lead wire of the winding inside the housing. The middle section of the copper busbar extends into the junction box through the first opening and the second opening. One end of the middle section connected to the second connecting section is bent toward the top wall so that the second connecting section fits against the bottom wall of the junction box.

[0020] Preferably, the above-described disc motor further includes an insulating component for pressing the terminals of the wiring harness of the second connecting section and the controller within the junction box.

[0021] The junction box is provided with studs on both sides of the copper busbar, and the insulating component is provided with screws corresponding to the positions of the studs. The insulating component is locked onto the junction box by the cooperation of the screws and the studs.

[0022] Preferably, in the above-mentioned disc motor, the junction box is provided with a waterproof connector, and the wiring harness extends into the junction box through the waterproof connector.

[0023] The copper busbar provided in this application embodiment is used to connect the lead wires of the windings of a disc motor to the wiring harness of a controller. It includes a first connecting section, an intermediate section, and a second connecting section, with the intermediate section located between the first and second connecting sections. The first connecting section is used to connect to the lead wires of the disc motor windings, and the second connecting section is used to connect to the terminals of the controller's wiring harness. This solution reduces the thickness of the intermediate section to decrease its rigidity, allowing it to be bent. The bending direction of the intermediate section is from the side wall of the disc motor housing to the top wall of the disc motor housing, so that the second connecting section is located on the top wall of the disc motor housing. This makes the connection position of the second connecting section and the terminals of the controller's wiring harness closer to the axis of the disc motor. Compared with the prior art, this reduces the space occupied by the copper busbar in the radial direction of the disc motor housing, contributing to a more compact structure of the disc motor.

[0024] This solution also discloses a disc motor, including a housing, a junction box, and a copper busbar, wherein the copper busbar is the same as described in any of the above solutions. Since the copper busbar has the aforementioned technical effects, the disc motor with this copper busbar also has the same technical effects, and will not be elaborated further here. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some examples or embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort, and this application can be applied to other similar scenarios based on the provided drawings. Unless obvious from the linguistic context or otherwise specified, the same reference numerals in the drawings represent the same structures or operations.

[0026] Figure 1 This is a schematic diagram of the copper busbar structure disclosed in the embodiments of this application;

[0027] Figure 2 This is a schematic diagram of the stator three-phase installation structure disclosed in the embodiments of this application;

[0028] Figure 3 This is a schematic diagram of the stator three-phase installation structure disclosed in the embodiments of this application.

[0029] The attached diagram is described below:

[0030] 1-First connecting section; 11-Connecting section; 12-Transition section; 2-Intermediate section; 3-Second connecting section; 4-Waterproof connector; 5-Housing; 6-Junction box; 61-Stud; 7-Screw; 8-Insulating component. Detailed Implementation

[0031] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are merely illustrative of the application and not intended to limit it. The described embodiments are only a part of the embodiments of the present application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without inventive effort are within the scope of protection of the present application.

[0032] It should be noted that, for ease of description, only the parts relevant to the application are shown in the accompanying drawings. Unless otherwise specified, the embodiments and features described in these embodiments can be arbitrarily combined, provided that the combined technical features are not contradictory. All feasible combinations of features are the technical content explicitly described herein. Any one of the multiple sub-features contained in the same statement can be applied independently, without necessarily being applied together with other sub-features.

[0033] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "a," and / or "the" are not specifically singular and may include the plural. Generally, the terms "comprising" and "including" only indicate the inclusion of expressly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements. An element defined by the phrase "comprising an..." does not exclude the presence of other identical elements in the process, method, product, or apparatus that includes the element.

[0034] In the description of the embodiments of this application, unless otherwise stated, " / " means "or", for example, A / B can mean A or B; "and / or" in this document is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Furthermore, in the description of the embodiments of this application, "multiple" refers to two or more.

[0035] Please see Figures 1-3 .

[0036] Some embodiments of this application disclose a copper busbar for connecting the leads of the windings of a disc motor to the wiring harness of a controller.

[0037] In this solution, the copper busbar includes a first connecting section 1, an intermediate section 2, and a second connecting section 3. The intermediate section 2 is located between the first connecting section 1 and the second connecting section 3. The first connecting section 1 is used to connect to the lead wire of the winding of the disc motor, and the second connecting section 3 is used to connect to the terminal of the wiring harness of the controller.

[0038] In this scheme, the thickness of the middle segment 2 is less than the thickness of the first connecting segment 1 and / or the second connecting segment 3. Specifically, the thickness of the middle segment 2 can be less than the thickness of the first connecting segment 1, or less than the thickness of the second connecting segment 3, or less than both the thickness of the first connecting segment 1 and the thickness of the second connecting segment 3. The thicknesses of the first connecting segment 1 and the second connecting segment 3 can be equal or unequal.

[0039] This solution reduces the thickness of the middle section 2, thereby lowering its rigidity and allowing it to be bent. For example... Figure 1 As shown, the bending direction of the middle section 2 is from the side wall of the disc motor housing 5 to the top wall of the disc motor housing 5, so that the second connecting section 3 is located on the top wall of the disc motor housing 5, and the connection position of the second connecting section 3 and the terminal of the controller wiring harness is closer to the axis of the disc motor. Compared with the prior art, the space occupied by the copper busbar in the radial direction of the disc motor housing 5 is reduced, which helps to improve the structural compactness of the disc motor.

[0040] To further optimize the above technical solution, the first connecting section 1 is set along the axial direction of the disc motor, or in other words, the first connecting section 1 is set close to the side wall of the disc motor. Correspondingly, the middle section 2 can be bent along the side wall and top wall of the housing 5 to further reduce the space occupied by the first connecting section 1 in the radial direction of the housing 5.

[0041] It should be noted that the first connecting segment 1, the middle segment 2, and the second connecting segment 3 are arranged sequentially along the length of the copper busbar. The copper busbar as a whole has a plate-like structure. The dimensions of the first connecting segment 1, the middle segment 2, and the second connecting segment 3 along the plane perpendicular to the plate-like structure are their respective thicknesses.

[0042] This solution reduces the hardness of the intermediate section 2 relative to the first connecting section 1 and the second connecting section 3 by reducing the thickness of the intermediate section 2, making the intermediate section 2 bendable. Preferably, the intermediate section 2 can be bent manually by the operator. The reduced thickness of the intermediate section 2 relative to the first connecting section 1 and the second connecting section 3 also reduces the weight of the copper busbar and lowers the production cost of the copper busbar.

[0043] Furthermore, by reducing the thickness of the middle section 2 of the copper busbar, while ensuring current load capacity, the intermediate hardness of the copper busbar can be reduced, thus improving its flexibility. This method is relatively simple and has low processing difficulty. The cross-sectional area of ​​the middle section 2 is not less than the minimum cross-sectional area required for current load capacity.

[0044] In some embodiments, the middle section 2 is a thinner copper plate-like structure. In this case, the middle section 2, the first connecting section 1, and the second connecting section 3 can be separate structures or integrated structures.

[0045] In an embodiment where the middle section 2 is a separate structure from the first connecting section 1 and the second connecting section 3, the middle section 2 is welded to the first connecting section 1 and the second connecting section 3.

[0046] In other embodiments, the intermediate section 2 is a braided section of soft copper wire. The overall rigidity of the braided soft copper wire intermediate section 2 is relatively low, allowing it to be bent along the housing 5 of the disc motor with low bending difficulty. The braided soft copper wire intermediate section 2 is preferably connected to the first connecting section 1 and the second connecting section 3 by welding. In embodiments where the intermediate section 2 is braided soft copper wire, the thickness of the intermediate section 2 is thinner than the thickness of the first connecting section 1 and the second connecting section 3.

[0047] The middle section 2 is made of copper, which achieves low resistance without increasing the cost of the copper busbar.

[0048] The middle section 2 can be made of the same material as the first connecting section 1 and the second connecting section 3, or it can be made of a different material.

[0049] Since the width of the winding lead wire is smaller than the width of the copper busbar (where the widths of both the lead wire and the copper busbar are dimensions along the plane of the copper busbar), to reduce the difficulty of connecting the lead wire to the copper busbar, this solution includes a connecting portion 11 and a transition portion 12 in the first connecting section 1. The transition portion 12 connects to the intermediate section 2, and the connecting portion 11 connects to the winding lead wire. Optionally, the width of the transition portion 12 is greater than the width of the connecting portion 11, the width of the transition portion 12 does not exceed the width of the intermediate section 2, and the width of the connecting portion 11 is at least equal to the width of the lead wire.

[0050] The first connecting section 1 can be designed as a T-shape or an L-shape. Optionally, the connecting part 11 and the transition part 12 have the same thickness.

[0051] Since the width of the connecting part 11 is smaller than the width of the transition part 12 and also smaller than the width of the middle section 2, the hardness of the connecting part 11 is smaller than that of the transition part 12. The connecting part 11 can also be bent appropriately, which can reduce the overall hardness of the copper busbar to a certain extent.

[0052] The width of the connecting part 11 is smaller than the width of the transition part 12 and the intermediate section 2. The current load borne by the connecting part 11 is large. After passing through the wider transition part 12 and the intermediate section 2, the current load becomes smaller. This design can improve the current carrying capacity.

[0053] The first connection surface between the transition section 12 and the intermediate section 2 is a stepped surface or a smooth transition surface.

[0054] In an embodiment where the first connecting surface between the transition section 12 and the intermediate section 2 is a stepped surface, the height of the stepped surface is half the thickness difference between the transition section 12 and the intermediate section 2. This embodiment can reduce the processing difficulty.

[0055] In an embodiment where the first connection surface between the transition section 12 and the intermediate section 2 is a smooth transition surface, the smooth transition surface is a sloped surface or an arc-shaped surface. This embodiment can reduce resistance.

[0056] Preferably, the first connection surface between the transition portion 12 and the intermediate section 2 is a smooth transition surface.

[0057] The second connecting surface between the second connecting segment 3 and the middle segment 2 is a stepped surface or a smooth transition surface.

[0058] In an embodiment where the second connecting surface between the second connecting segment 3 and the intermediate segment 2 is a stepped surface, the height of the stepped surface is half the thickness difference between the second connecting segment 3 and the intermediate segment 2. This embodiment can reduce the processing difficulty.

[0059] In an embodiment where the second connecting surface between the second connecting segment 3 and the intermediate segment 2 is a smooth transition surface, the smooth transition surface is a sloped surface or an arc-shaped surface. This embodiment can reduce resistance.

[0060] The thicknesses of the first connecting segment 1 and the second connecting segment 3 may be equal or unequal, but the thicknesses of both the first connecting segment 1 and the second connecting segment 3 are greater than that of the middle segment 2.

[0061] In an embodiment where the thickness of the first connecting segment 1 is not equal to the thickness of the second connecting segment 3, since the width of the connecting portion 11 of the first connecting segment 1 is narrow, in order to ensure that the connecting portion 11 of the first connecting segment 1 can withstand the working current, the thickness of the second connecting segment 3 may be less than the thickness of the first connecting segment 1.

[0062] The second connecting section 3 is used to connect to the terminals of the controller's wiring harness. To ensure the connection strength between the copper busbar, the second connecting section 3, and the terminals of the wiring harness, the thickness of the second connecting section 3 does not need to be adjusted in this design. The width of the second connecting section 3 is approximately the same as the width of the copper lugs of the controller's wiring harness terminals. The second connecting section 3 has mounting holes for connecting to the terminals of the controller's wiring harness.

[0063] This solution also discloses a disc motor, such as Figure 2 and Figure 3 As shown, it includes a housing 5, a junction box 6, and a copper busbar, wherein the copper busbar is the copper busbar described in any of the above schemes.

[0064] Since the copper busbar has the above-mentioned technical effects, the disc motor with the copper busbar also has the same technical effects, which will not be elaborated here.

[0065] In some embodiments, a winding is provided inside the housing 5, and the top wall of the housing 5 has a first opening. A junction box 6 is installed on the top wall of the housing 5. The junction box 6 has a second opening that corresponds to and communicates with the first opening. The first connecting section 1 of the copper busbar is connected to the lead wire of the winding through the second opening and the first opening in sequence. The middle section 2 of the copper busbar extends into the junction box 6 through the first opening and the second opening. After being bent along the side wall and top wall of the housing 5, the second connecting section 3 of the copper busbar is located on one side of the axial direction of the housing 5 and close to the center of the housing 5. The second connecting section 3 of the copper busbar is in contact with the bottom wall of the junction box 6.

[0066] The free end of the second connecting section 3 of the copper busbar and the terminal of the controller's wiring harness are pressed together in the junction box 6 by the insulating part 8.

[0067] The second connecting section 3 of the copper busbar has mounting holes corresponding to the terminal positions of the controller's wiring harness. The terminals of the controller's wiring harness and the second connecting section 3 of the copper busbar are locked in the junction box 6 by bolts, while the insulating component 8 is further locked to the junction box 6 by bolts.

[0068] In some embodiments, the insulating member 8 is provided with screws 7, and the junction box 6 is provided with studs 61 corresponding to the positions of the screws 7. The insulating member 8 is locked onto the junction box 6 by the screws 7 and nuts.

[0069] A copper busbar is provided between two adjacent studs 61, and the studs 61 limit the copper busbar; a limiting protrusion is provided on the insulating part 8 to limit the wiring harness of the controller.

[0070] Optionally, a waterproof connector 4 is provided on the junction box 6, through which the terminals of the controller's wiring harness extend into the junction box 6.

[0071] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed, and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. The scope of this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the above-described application concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A copper busbar, characterized in that, It includes a first connecting segment (1), a middle segment (2), and a second connecting segment (3), wherein the two ends of the middle segment (2) are respectively connected to the first connecting segment (1) and the second connecting segment (3). The first connecting segment (1) is used to connect with the lead wire of the winding of the disc motor, and the first connecting segment (1) is arranged along the axial direction of the disc motor. The thickness of the intermediate section (2) is less than the thickness of the first connecting section (1) and / or the second connecting section (3), so that the intermediate section (2) can be bent from the side wall of the disc motor to the top wall of the disc motor. The second connecting segment (3) is used to connect to the terminal of the controller's wiring harness, and one end of the second connecting segment (3) used to connect to the terminal of the wiring harness is located on the top wall of the disc motor.

2. The copper busbar according to claim 1, characterized in that, The middle section (2) is a middle section (2) woven from soft copper wire.

3. The copper busbar according to claim 1 or 2, characterized in that, The intermediate segment (2) is welded to the first connecting segment (1) and the second connecting segment (3).

4. The copper busbar according to claim 1, characterized in that, The first connecting segment (1) includes a connecting part (11) and a transition part (12). The width of the connecting part (11) is at least equal to the width of the lead wire, the width of the transition part (12) is greater than the width of the connecting part (11), and the width of the transition part (12) does not exceed the width of the intermediate segment (2).

5. The copper busbar according to claim 4, characterized in that, The first connection surface between the transition section (12) and the intermediate section (2) is a stepped surface or a smooth transition surface.

6. The copper busbar according to claim 1, 2, 4 or 5, characterized in that, The second connecting surface between the second connecting segment (3) and the middle segment (2) is a stepped surface or a smooth transition surface.

7. The copper busbar according to claim 6, characterized in that, The first connecting segment (1) and the second connecting segment (3) have the same thickness; Alternatively, the thickness of the second connecting segment (3) is less than the thickness of the first connecting segment (1).

8. A disc motor, characterized in that, Includes housing (5), junction box (6), and copper busbar. The top wall of the housing (5) has a first opening. The junction box (6) is installed on the top wall, and the junction box (6) has a second opening communicating with the first opening. The copper busbar is the copper busbar according to any one of claims 1-7. The first connecting section (1) of the copper busbar is connected to the lead wire of the winding inside the housing (5). The middle section (2) of the copper busbar extends into the junction box (6) through the first opening and the second opening. The end of the middle section (2) connected to the second connecting section (3) is bent toward the top wall so that the second connecting section (3) fits against the bottom wall of the junction box (6).

9. The disc motor according to claim 8, characterized in that, It also includes an insulating component (8) for clamping the terminals of the second connecting section (3) and the controller's wiring harness within the junction box (6). The junction box (6) is provided with studs (61) on both sides of the copper busbar. The insulating part (8) is provided with screws (7) corresponding to the positions of the studs (61). The insulating part (8) is locked onto the junction box (6) by the cooperation of the screws (7) and the studs (61).

10. The disc motor according to claim 8, characterized in that, The junction box (6) is provided with a waterproof connector (4), and the wire harness extends into the junction box (6) through the waterproof connector (4).

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