Electric machine, corresponding power system and motor vehicle

Abstract

The present disclosure relates to an electric machine, a corresponding power system and a motor vehicle. The power system comprises an electric machine (10) and a control component (20). The electric machine (10) comprises a housing (101), a bracket (103) and a plurality of phase terminals (104). A stator (102) is assembled in the housing (101). The bracket (103) is connected to the housing (101). Each phase terminal (104) passes through a corresponding hole on the bracket (103) and comprises a first end (1041) and a second end (1042). The first end (1041) is connected to a terminal (1025) in the stator (102). The second end (1042) extends from the corresponding hole in a direction away from the housing (101). According to the embodiment of the present disclosure, the manufacturing and assembly tolerances of the phase terminals of the electric machine can be effectively controlled, the welding quality of the phase terminals is greatly improved, and the reliability of the electrical connection is ensured.

Description

Technical Field

[0001] Exemplary embodiments of this disclosure generally relate to the field of electrical machinery, and more particularly to an electric motor, a corresponding power system, and a motor vehicle. Background Technology

[0002] In power systems that include motors and control units, the clearance tolerance control between the phase pins of the motor and the phase pins of the control components is a key factor affecting system reliability. Since the soldering quality of the phase pins directly determines the stability and durability of electrical signal transmission, the precision requirements for the clearance tolerance are extremely stringent.

[0003] In existing technologies, the position of motor phase pins is affected by the accumulation of multiple tolerances. This can lead to problems such as poor soldering, increased contact resistance, and even connection failure. Therefore, there is an urgent need for a motor design that can effectively control assembly tolerances, suppress thermal deformation interference, and improve the consistency of phase pin positions. Utility Model Content

[0004] In order to overcome at least the problems existing in existing motors and / or other potential problems, exemplary embodiments of this disclosure propose an improved motor, a corresponding power system, and a motor vehicle.

[0005] In a first aspect, embodiments of this disclosure relate to an electric motor. The motor includes: a housing in which a stator is housed; a bracket connected to the housing; and a plurality of phase terminals, each phase terminal passing through a corresponding hole in the bracket and including: a first end connected to a terminal within the stator; and a second end extending from the corresponding hole in a direction away from the housing.

[0006] According to embodiments of this disclosure, the manufacturing and assembly tolerances of the phase terminals of the motor can be effectively controlled, greatly improving the welding quality of the phase terminals and ensuring the reliability of the electrical connection.

[0007] In some embodiments, the bracket includes: a plurality of sockets, each socket having a first hole and a second hole, wherein the first end of the phase terminal extends from the first hole and the second end of the phase terminal extends from the second hole.

[0008] In some embodiments, the bracket further includes a connecting rod configured to connect the plurality of sockets together.

[0009] In some embodiments, the bracket is connected to the bottom surface of the housing facing the external component.

[0010] In some embodiments, the bracket further includes a positioning post connected to a positioning hole on the bottom surface.

[0011] In some embodiments, the bracket and the plurality of phase terminals are integrally formed.

[0012] In some embodiments, the plurality of phase terminals may include two phase terminals or three phase terminals.

[0013] In a second aspect, embodiments of this disclosure relate to a power system. The power system includes a motor according to the first aspect; and a control component including a plurality of pins connected to corresponding phase terminals of the motor.

[0014] In some embodiments, the control component is a mechanical control component or an electronic control component.

[0015] In a third aspect, embodiments of this disclosure relate to a motor vehicle. The motor vehicle includes a power system according to the second aspect.

[0016] These and other aspects of this disclosure will become more apparent in the description of the following embodiments(s). Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A perspective view of a power system according to an exemplary embodiment of the present disclosure is shown.

[0019] Figure 2 A perspective view of an electric motor according to an exemplary embodiment of the present disclosure is shown.

[0020] Figure 3 A perspective view of a control component according to an exemplary embodiment of the present disclosure is shown.

[0021] Figure 4 A three-dimensional cross-sectional view of an electric motor according to an exemplary embodiment of the present disclosure is shown.

[0022] Figure 5 A perspective view of a stator within an electric motor according to an exemplary embodiment of the present disclosure is shown.

[0023] Figure 6 A perspective view of a phase terminal and bracket connected to an electric motor according to an exemplary embodiment of the present disclosure is shown.

[0024] In the accompanying drawings, the same reference numerals denote the same or corresponding parts. Detailed Implementation

[0025] The principles of this disclosure will be described in conjunction with exemplary embodiments. These embodiments are only for illustration and to help those skilled in the art understand and implement this disclosure, and do not constitute a limitation on its scope. This disclosure can be implemented in various ways other than those described. In the following description and claims, the meanings of technical terms not otherwise defined are consistent with the common understanding of those skilled in the art to which this disclosure pertains. The expressions "an embodiment," "exemplary embodiment," etc., in this disclosure mean that the relevant embodiment may include specific features, structures, or characteristics, but not every embodiment necessarily includes them, and these expressions do not necessarily refer to the same embodiment. At the same time, those skilled in the art should know that specific features, structures, or characteristics described in connection with a certain embodiment can be applied in other embodiments (whether or not explicitly described). Although terms such as “first” and “second” can be used to describe elements, elements are not limited by these terms; they are only used to distinguish different elements. “And / or” covers any and all combinations of the listed terms. The terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments. The singular forms “a,” “an,” and “the” also include the plural forms unless explicitly indicated in the context. Words such as “comprising,” “including,” and “having” indicate the presence of the stated features, elements, components, etc., but do not exclude the presence or addition of one or more other features, elements, components, etc., and combinations thereof.

[0026] As mentioned above, the welding quality of phase pins directly affects the reliability and performance of the entire power system, thus requiring extremely high control over the gap tolerance. In existing technologies, the position of motor phase pins is affected by various factors, including but not limited to assembly tolerances between the housing and stator, thermal deformation caused by heat shrinking processes, and the positioning errors of the phase pins themselves in the control components. These factors collectively make it difficult to control the gap between phase pins within the ideal range, thereby affecting welding quality and product yield.

[0027] Especially during the heat shrinking process, the high-temperature environment can cause deformation of the motor phase pins, further exacerbating the instability of the gap. Existing assembly processes are complex, involving multiple tolerances, making it difficult to achieve high-precision pin alignment.

[0028] To address at least the aforementioned problems, embodiments of this disclosure provide a powertrain system for a motor vehicle. Reference is made below. Figures 1 to 6 The specific structure of the power system according to embodiments of the present disclosure will be described.

[0029] Figure 1 A perspective view of a power system according to an exemplary embodiment of the present disclosure is shown. Figure 1The power system 1 shown can be installed on various types of motor vehicles, such as motorcycles, cars, etc., and the embodiments disclosed herein do not particularly limit this.

[0030] like Figure 1 As shown, the entire power system 1 is generally composed of two main parts: a motor 10 and a control unit 20. The motor 10, as the core of the power system, is used to convert electrical energy into mechanical energy; while the control unit 20 is connected to the motor 10 both mechanically and electrically, and is used to precisely control and regulate the entire power system 1. In some embodiments, the control unit 20 can be a mechanical control unit (MCU). In other embodiments, the control unit 20 can also be an electronic control unit (ECU). The embodiments of this application do not particularly limit this. The two key components, the control unit 20 and the motor 10, are electrically connected through phase terminals, and the quality of this connection directly affects the performance and reliability of the entire system. In practical applications, this connection needs to withstand various harsh environmental conditions, including high temperature, vibration, and humidity changes, thus placing extremely high demands on the reliability of the connection.

[0031] Figure 2 and Figure 3 Perspective views of a motor 10 and a control component 20 in a power system 1 according to exemplary embodiments of the present disclosure are shown respectively. Figure 2 As shown, the motor 10 includes a housing 101, which is a robust outer shell die-cast from a metal such as aluminum alloy, possessing excellent casting properties and mechanical strength. Alternatively, in other embodiments, materials other than aluminum alloy may be used for the housing 101, as long as the material can achieve the intended function. Specific materials are not limited to the embodiments of this disclosure. The housing 101 not only provides structural support but also serves a heat dissipation function. The outer surface of the housing 101 is designed with heat dissipation fins 1010, which are configured to provide heat dissipation for the motor 10, effectively dissipating heat generated inside the housing 101 to the external environment.

[0032] like Figure 2 As shown, the housing 101 of the motor 10 has a bottom surface 1011, which faces the control component 20. Multiple phase terminals 104 extend from one side of the bottom surface 1011. The number of phase terminals 104 is typically three, corresponding to the U, V, and W phases of a three-phase motor.

[0033] Correspondingly, refer to Figure 3The control component 20 has multiple corresponding pins 204 inside. The number and distance of the multiple pins 204 of the control component 20 are matched with the number of phase terminals 104 of the motor 10, thereby achieving a secure connection between the two. It is understood that the number of phase terminals 104 and pins 204 can be adjusted according to the actual scenario, and such adjustments also fall within the protection scope of this disclosure.

[0034] Figure 4 A three-dimensional cross-sectional view of an electric motor 10 according to an exemplary embodiment of the present disclosure is shown. Figure 5 It shows Figure 4 A perspective view of the stator 102 of the motor 10. (See figure) Figure 4 As shown, a stator 102 is housed inside the housing 101, and precision copper wire windings are wound on the stator 102. When current flows through these windings, a strong rotating magnetic field is generated to ensure the stable operation of the motor 10. Figure 4 and Figure 5 As shown, the stator 102 is provided with a terminal 1025, which is electrically connected to the pin 204 of the control component 20 through a phase terminal 104 provided on the bracket 103, thereby ultimately realizing the electrical connection between the motor 10 and the control component 20.

[0035] The following is for reference. Figure 6 To describe bracket 103. For example... Figure 6 As shown, the bracket 103 includes multiple sockets 106. The number of sockets 106 corresponds to the number of phase terminals 104. Although three sockets 106 are shown in the figure, this is merely illustrative and can be adjusted according to the actual scenario, such as two, four, or even more. Figure 6 As shown, each socket 106 is provided with a first hole 1051 and a second hole 1052, through which the phase terminal 104 can pass, thereby forming a first end 1041 and a second end 1042 respectively. Figure 6 As shown, the first end 1041 of the phase terminal 104 protrudes from the first hole 1051 of the socket 106, and the second end 1042 of the phase terminal 104 protrudes from the second hole 1052 of the socket 106. (Return to Reference) Figure 4 The first end 1041 of the phase terminal 104 is connected to the terminal 1025 inside the stator 102, while the second end 1042 of the phase terminal 104 extends from the corresponding hole in a direction away from the housing 101. When the bracket 103 is mounted on the bottom surface 1011 of the housing 101 of the motor 10 and the motor 10 is assembled with the control component 20, the second end 1042 of the phase terminal 104 can be connected to the pin 204 of the control component 20, thereby realizing the electrical connection between the motor 10 and the control component 20.

[0036] The bracket 103 can be a plastic part, and it can be injection molded integrally with the phase terminal 104. During manufacturing, the phase terminal 104 is first placed in a predetermined position in the mold, then molten plastic material is injected, and after cooling, it forms a single unit. This process ensures the positional accuracy of each pin, greatly reduces assembly errors, and ensures a firm connection between the bracket 103 and the phase terminal 104. The bracket 103 can be fixedly connected to the bottom surface 1011 of the motor housing 101.

[0037] In existing designs, there are no support brackets or phase terminals connected to them; instead, the stator terminals connect directly to the pins of the control components. This necessitates making the stator terminals very long. Since the assembly between the stator and the housing involves a heat-shrink process, the high temperatures during this process cause changes in the shape of the terminals. The longer the component (e.g., the terminal), the more pronounced the deformation during heat shrinking. This makes it difficult to control the tolerances between the stator terminals and the pins of the control components, reducing the alignment between them. This leads to problems such as poor contact, increased contact resistance, and even connection failure, severely impacting the overall performance and yield of the power system.

[0038] According to embodiments of this disclosure, the bracket 103 and the bottom surface 1011 of the housing 101 of the motor 10 can be fixedly connected. Furthermore, since the bracket 103 and the phase terminal 104 are integrally formed, only a portion of the phase terminal 104 may deform during the heat-shrink process. Compared to existing designs, the length of the deformed component is significantly reduced, minimizing misalignment during heat shrinking and greatly improving the assembly accuracy of the phase terminal. This effectively solves the problem of controlling the position of motor phase pins, improving product reliability and consistency. This design is not only suitable for current application needs but also provides a reliable technical foundation for future high-performance motor designs.

[0039] Furthermore, the embodiments of this disclosure also bring about manufacturing economics. Although some innovative designs are employed, the overall manufacturing cost is kept within a reasonable range. The one-piece molding production process improves production efficiency and reduces labor costs.

[0040] like Figure 6 As shown, to enhance the overall structural strength of the bracket 103, the bracket 103 may further include a connecting rod 107, which is configured to connect multiple sockets 106 together. By connecting these sockets 106 together via the connecting rod 107, a single integral structure is formed. The connecting rod 107 has a rounded transition to avoid stress concentration and improve the overall structural reliability. The cross-sectional shape of the connecting rod 107 can be circular, rectangular, or other suitable shapes, which can be determined according to actual needs.

[0041] Continue to refer to Figure 6 As shown, the bracket 103 may also be provided with one or more positioning posts 1035, which can be connected to positioning holes (not shown) on the bottom surface 1011 of the housing 101, thereby achieving precise positioning of the bracket 103.

[0042] like Figure 6 As shown, the sockets 106 can be arranged in a straight line, so that the phase terminals 104 extending from the sockets 106 are also arranged in a straight line. This arrangement ensures sufficient phase terminal gaps and facilitates accurate docking of the phase terminals 104 with the pins 204 of the control component 20.

[0043] Furthermore, the power system 1 disclosed herein has good maintainability. When it is necessary to replace or repair the control component 20, the connection with the motor 10 can be disconnected relatively easily. The design of the bracket 103 also facilitates the inspection and maintenance of the phase terminals 104.

[0044] Embodiments of this disclosure also provide a power system 1, which includes the control component 20 and the motor 10 described above. Because the design of this disclosure is applicable not only to three-phase motors but also to other multi-phase motors, its versatility allows it to be widely used in various types of power systems.

[0045] Embodiments of this disclosure also provide a motor vehicle including the aforementioned powertrain system 1. The powertrain system 1 can be used to drive various vehicle systems, such as air suspension systems, power steering systems, etc. Due to the innovative design of this disclosure, the reliability and performance of the motor vehicle are significantly improved.

[0046] In summary, the embodiments of this disclosure effectively solve the problem of difficult-to-control tolerance accuracy of motor phase pins by proposing a design in which the bracket and phase terminals are integrally formed, thereby improving the reliability of the product's electrical connection. This design is not only suitable for current application needs but also provides a technical foundation for the design of future higher-performance motors.

[0047] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above description is only a specific embodiment of this utility model and is not intended to limit the scope of protection of this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.

Claims

1. A motor (10), characterized in that, include: The housing (101) contains the stator (102). A bracket (103) is connected to the housing (101). as well as A plurality of phase terminals (104), each phase terminal (104) passing through a corresponding hole on the bracket (103), and comprising: The first end (1041) is connected to the terminal (1025) inside the stator (102); as well as The second end (1042) extends from the corresponding hole in a direction away from the housing (101).

2. The motor (10) according to claim 1, characterized in that, The support (103) includes: Multiple sockets (106), each socket (106) is provided with a first hole (1051) and a second hole (1052). The first end (1041) of the phase terminal (104) extends from the first hole (1051), and the second end (1042) of the phase terminal (104) extends from the second hole (1052).

3. The motor (10) according to claim 2, characterized in that, The bracket (103) also includes a connecting rod (107) configured to connect the plurality of sockets (106) together.

4. The motor (10) according to claim 1, characterized in that, The bracket (103) is connected to the bottom surface (1011) of the housing (101) facing the external component.

5. The motor (10) according to claim 4, characterized in that, The bracket (103) also includes a positioning post (1035), which is connected to a positioning hole on the bottom surface (1011).

6. The motor (10) according to any one of claims 1 to 5, characterized in that, The bracket (103) and the plurality of phase terminals (104) are integrally formed.

7. The motor (10) according to any one of claims 1 to 5, characterized in that, The plurality of phase terminals (104) includes two phase terminals (104) or three phase terminals (104).

8. A power system (1), characterized in that, include: The motor (10) according to any one of claims 1 to 7; as well as The control unit (20) includes a plurality of pins (204) connected to corresponding phase terminals (104) of the motor (10).

9. The power system (1) according to claim 8, characterized in that, The control component (20) is a mechanical control component or an electronic control component.

10. A motor vehicle, characterized in that, Includes the power system (1) according to claim 8 or 9.

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