An electrical connector assembly

Abstract

The utility model discloses an electric motor connector assembly, comprising: Busbar component and power connector, Busbar component includes the U-phase conducting row, V-phase conducting row and W-phase conducting row of laminated arrangement, and U-phase conducting row, V-phase conducting row and W-phase conducting row are all six one ring copper plate, and are fixed and insulated through the split type plastic piece, power connector includes three power terminals, is fixed and insulated through the insert injection molding piece respectively, and is connected U-phase conducting row, V-phase conducting row and W-phase conducting row. The electric motor connector assembly in the utility model, compact structure, and adopt six one ring copper plate's conducting row and split type plastic piece, greatly reduce the material cost, improve the connection reliability and assembly convenience, strengthen the structure stability and the mistake proofing ability, improve the electrical and thermal performance, improve the design flexibility and maintainability simultaneously.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and more specifically, to a motor connector assembly. Background Technology

[0002] Electro-hydraulic braking systems (EHB) are the core of modern vehicle braking systems, and their connector assemblies, as key components for the electrical connection of the motor, directly affect the reliability and cost of the motor. However, existing motor connector assemblies have complex structures, mainly employing integral injection molding with composite molds or split composite mold encapsulation, resulting in complex molds, low production efficiency, and high costs. The busbar assembly is composed of three semi-annular copper plates, using a large amount of copper with low material utilization, further increasing costs. Furthermore, its simple transition press-fit with the motor stator frame poses a risk of loosening. Simultaneously, existing busbar assemblies and power connectors use resistance welding or argon arc welding, requiring specialized welding equipment and involving complex processes. The sealing ring between the power connector and the valve block uses a serrated cylindrical structure, leading to high rubber mold costs. In addition, the existing motor connector assemblies have complex electrical connection methods, with each phase's four coils using a 2-series, 2-parallel connection, resulting in 12 wire ends needing to be connected for each of the 12 coils, leading to low efficiency and large layout space requirements. Therefore, there is an urgent need for a motor connector assembly that is simple in structure, low in cost, and reliable in connection. Utility Model Content

[0003] The purpose of this application is to overcome the shortcomings of the prior art and provide a motor connector assembly that is simple in structure, low in cost and reliable in connection, thereby reducing the cost of composite molds or eliminating the need for composite molds, improving production efficiency, and reducing the amount of copper used and the cost.

[0004] The specific technical solution is as follows: According to an embodiment of this application, a motor connector assembly is provided, including: a busbar assembly and a power connector; The Busbar assembly includes stacked U-phase conductive busbars, V-phase conductive busbars, and W-phase conductive busbars, and each of the U-phase conductive busbars, the V-phase conductive busbars, and the W-phase conductive busbars is a one-sixth annular copper plate, which is fixed and insulated by a split plastic component; The power connector includes three power terminals, which are fixed and insulated by insert injection molding parts, and are connected to the U-phase busbar, the V-phase busbar and the W-phase busbar.

[0005] In some embodiments of this application, it further includes: three wire-to-board connection terminals, the first ends of the three wire-to-board connection terminals being fixed to the U-phase busbar, the V-phase busbar and the W-phase busbar respectively by resistance welding, and the second ends being connected to the three power terminals respectively to form a plug-in engagement.

[0006] In some embodiments of this application, the wire-to-board connection terminal is a standard 250 series female terminal.

[0007] In some embodiments of this application, the Busbar assembly is interference-fitted with the motor stator frame, and the U-phase busbar, the V-phase busbar and the W-phase busbar are all provided with slots, and the motor stator frame is provided with a barb structure that engages with the three slots.

[0008] In some embodiments of this application, a sealing structure is provided at the interface between the power connector and the valve block.

[0009] In some embodiments of this application, the sealing structure is an O-ring, and an annular groove is provided on the outer wall of the insert injection molded part, and the O-ring is embedded in the annular groove.

[0010] In some embodiments of this application, the connection between the U-phase busbar, the V-phase busbar, the W-phase busbar and the motor stator coil is a delta connection. Each phase winding of the motor stator coil consists of four coils connected in series, and each phase winding has two wire ends, which are connected to the corresponding U-phase busbar, V-phase busbar or W-phase busbar.

[0011] In some embodiments of this application, the two wire ends connected to the V-phase busbar are located in the first stator slot, and the distance between the stator slot where the two wire ends connected to the other two phase busbars are located and the first stator slot does not exceed 3 slot pitches.

[0012] In some embodiments of this application, the split plastic component includes an upper support frame, a lower support frame, and an insulating plate. The Busbar assembly is fixed to the lower support frame, and the insulating plate is used to insulate each phase conductor from each other. The upper support frame is installed on the lower support frame, together forming three fixing grooves. The power terminal, which is encapsulated in the insert injection molded part, is fixed in the fixing groove.

[0013] In some embodiments of this application, the lower support frame includes a first horizontal portion and a first vertical portion connected to each other. The first horizontal portion is provided with a first mounting groove for fixing the U-phase conductive busbar, the V-phase conductive busbar, the W-phase conductive busbar, and the insulating plate. The first vertical portion is provided with three open slots. The first horizontal portion is provided with a second mounting groove connecting the open slots and the first mounting groove. The wire-to-plate connection terminal is disposed in the second mounting groove. A locking groove is provided at each end of the first horizontal portion. The upper support frame includes a second horizontal portion and a second vertical portion connected to each other. The second vertical portion includes three locking plates. A hook is provided at each end of the second horizontal portion. The two hooks are respectively locked into the corresponding locking grooves. The upper support frame is installed on the lower support frame, and the three locking plates abut against the corresponding open slots to form three fixing grooves.

[0014] The beneficial effects of the embodiments of this application are as follows: The busbar component in this motor connector assembly uses a one-sixth-circular copper plate, saving approximately two-thirds of the copper material. It also employs separate plastic parts and standard terminals, simplifying the mold structure and significantly reducing production costs. Furthermore, the busbar component utilizes both interference fit and barbed slot fixation to eliminate the risk of loosening. The power connector uses standard terminal plugging, ensuring reliable contact and easy assembly, resulting in a reliable and stable overall connection. The motor connector assembly uses a standard O-ring sealing structure, providing reliable sealing, low cost, easy assembly, and excellent sealing performance. The separate support frame and insulation plate design result in a compact structure, reliably ensuring insulation performance between phases and between phases and ground, providing excellent insulation. In addition, the coil wiring method is simplified, with fewer wire ends and clear wiring. Resistance welding is used with the busbar component, a mature process that ensures high assembly efficiency. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 An exploded view of a motor connector assembly provided in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a motor connector assembly provided in an embodiment of this application; Figure 3 Stator coil winding and wiring diagrams provided for embodiments of this application; Explanation of reference numerals in the attached drawings: 1 is the Busbar assembly, 2 is the power connector, 3 is the U-phase conductor bar, 4 is the V-phase conductor bar, 5 is the W-phase conductor bar, 6 is the power terminal, 7 is the insert injection molded part, 8 is the wire-to-board connection terminal, 9 is the slot, 10 is the O-ring seal, 11 is the upper support frame, 12 is the lower support frame, 13 is the insulating plate, 14 is the first horizontal part, 15 is the first vertical part, 16 is the opening slot, 17 is the locking slot, 18 is the second horizontal part, 19 is the second vertical part, 20 is the locking plate, and 21 is the hook. Detailed Implementation

[0017] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this utility model.

[0018] It should be noted that the terms "comprising" and "having," and any variations thereof, in the embodiments and accompanying drawings of this application are intended to cover non-exclusive inclusion. For example, it may include a series of structures, without being limited to the structures listed, but may optionally include structures not listed, or may optionally include other components inherent to these structures.

[0019] This application discloses a motor connector assembly. Detailed descriptions follow.

[0020] Figure 1 – Figure 2 An embodiment of a motor connector assembly according to this application is shown. Figure 1 and Figure 2 As shown, the motor connector assembly includes a busbar assembly 1 and a power connector 2. The busbar assembly 1 is used inside the motor to efficiently deliver high current (three-phase power) from the power input to the terminals of the stator windings with minimal loss, impedance, and inductance, achieving power distribution and transmission. The power connector 2 is used to provide a reliable, safe, and separable connection between the external wiring harness of the motor and the internal circuitry of the motor (i.e., the busbar assembly 1), providing a separable electrical interface.

[0021] This application employs a simple assembly process and structure. Specifically, the Busbar assembly 1 is the core conductive part, comprising a stacked U-phase conductive bus 3, a V-phase conductive bus 4, and a W-phase conductive bus 5. These three conductive buses are all annular copper plates with an arc length corresponding to a central angle of approximately 60°, formed by stamping, greatly saving copper material. Furthermore, the three conductive buses in the Busbar assembly 1 are fixed and insulated from each other by separate plastic parts. The power connector 2 includes three power terminals 6, namely three long strip copper plates (U, V, and W) stamped from copper plates, which are fixed and insulated by insert injection molding parts 7, and connect to the U-phase conductive bus 3, V-phase conductive bus 4, and W-phase conductive bus 5. Further, a sealing structure is provided at the interface between the power connector 2 and the valve block to achieve a sealed connection. In the specific implementation, the sealing structure is an O-ring seal 10, which has low rubber mold and unit cost.

[0022] In some embodiments, the motor connector assembly further includes three wire-to-board connection terminals 8. The first ends of the three wire-to-board connection terminals 8 are respectively fixed to the U-phase busbar 3, the V-phase busbar 4, and the W-phase busbar 5 by resistance welding, and the second ends are respectively connected to the three power terminals 6 to form a plug-in engagement.

[0023] In other embodiments, the split plastic component includes an upper support frame 11, a lower support frame 12, and an insulating plate 13. The Busbar assembly 1 is fixed to the lower support frame 12, and the insulating plate 13 ensures that the phase conductors are insulated from each other. The upper support frame 11 is mounted on the lower support frame 12, together forming three fixing slots. The power terminal 6, encapsulated within the insert injection molded part 7, is fixed within the fixing slots. In a specific implementation, the lower support frame 12 includes a first horizontal portion 14 and a first vertical portion 15 connected to each other. The first horizontal portion 14 has a first mounting slot for sequentially stacking and fixing the W-phase conductor 5, V-phase conductor 4, insulating plate 13, and U-phase conductor 3. The first vertical portion 15 has three opening slots 16, and the first horizontal portion 14 has a second mounting slot connecting the opening slots 16 and the first mounting slot, for accommodating the wire-to-plate connection terminal 8, which is disposed within the second mounting slot. The wire-to-plate connection terminal 8 is preferably a standard 250 series female terminal, one end of which is firmly connected to the corresponding conductive busbar (3, 4, 5) by resistance welding. The upper support frame 11 includes a second horizontal part 18 and a second vertical part 19 connected to each other. A locking groove 17 is provided at each end of the first horizontal part 14, and correspondingly, a hook 21 is provided at each end of the second horizontal part 18 for locking into the locking grooves 17 at both ends of the first horizontal part 14 of the lower support frame 12. The second vertical part 19 includes three locking plates 20. When the upper support frame 11 is installed on the lower support frame 12 by the cooperation of the hooks 21 and the locking grooves 17, the three locking plates 20 abut against the corresponding opening grooves 16, thereby forming three stable fixing grooves together with the lower support frame 12.

[0024] In this embodiment, the Busbar assembly 1 and the power connector 2 are connected using a standard 250 series female terminal. Since it is a standard part, it can be used in large quantities, so the cost is low. In addition, the Busbar assembly 1 and the standard 250 series female terminal are connected by resistance welding, which is a mature process and has low cost. The power connector 2 and the standard 250 series female terminal are connected by a simple plug-in method, which has high production efficiency and low cost.

[0025] The power connector 2 consists of three power terminals 6 encapsulated within an insert injection molded part 7 using an insert injection molding process. The insert injection molded part 7, encapsulating the power terminals 6, is installed in a fixing groove formed by an upper support frame 11 and a lower support frame 12. The inner end of the power terminal 6 forms a plug-in fit with the other end of the wire-to-plate connection terminal 8 to achieve electrical connection. An annular groove is formed on the outer wall of the insert injection molded part 7, into which an O-ring seal 10 is embedded. When the assembly is installed on the valve block, the O-ring seal 10 is compressed, achieving a reliable static radial seal.

[0026] The entire Busbar assembly 1 is installed with the motor stator frame via its lower support frame 12 using an interference fit. Simultaneously, slots 9 are provided on the U-phase conductor bus 3, V-phase conductor bus 4, and W-phase conductor bus 5. The motor stator frame has a resilient hook structure that engages with the three slots 9. During assembly, pressure is applied to ensure an interference fit between the Busbar assembly 1 and the motor stator frame. Simultaneously, the resilient hook structure deforms and engages in the slots 9, forming a double safety mechanism to prevent loosening and achieving bidirectional locking.

[0027] In terms of electrical connection, the U-phase busbar 3, V-phase busbar 4, and W-phase busbar 5 are connected to the motor stator coils in a delta configuration. Each phase winding of the motor stator coil consists of four coils connected in series, and each phase winding has two wire ends. These two wire ends are connected to the corresponding U-phase busbar 3, V-phase busbar 4, or W-phase busbar 5. Furthermore, the two wire ends connected to the V-phase busbar 4 are located in the first stator slot, and the distance between the stator slot containing the two wire ends connected to the other two phase busbars and the first stator slot does not exceed three slot pitches. That is, the motor stator coils and Busbar assembly 1 are connected in a delta configuration. Each phase winding consists of all four coils connected in series, with only two wire ends led out. The two wire ends of the V-phase are located in the same stator slot, while the wire ends of the U-phase and W-phase are respectively arranged in slots no more than three slot pitches to the left and right of the slot containing the V-phase wire end. This design allows the other four wire ends to be easily fixed and routed to adjacent positions on the left and right sides of the V-phase, such as... Figure 3 As shown, the coil utilizes the motor stator frame structure and employs an external wiring method, which improves its insulation and high-voltage withstand capability. These six wire ends are ultimately connected to the U, V, and W phase busbars (3, 4, 5) via resistance welding. This wiring method is simple and compact, improving insulation reliability.

[0028] In summary, this application discloses a motor connector assembly. The busbar component uses a one-sixth annular copper plate, saving approximately two-thirds of the copper material. It also employs separate plastic parts and standard terminals, resulting in a simple mold structure and significantly reduced production costs. Furthermore, the busbar component utilizes both interference fit and barbed slot fixing methods to completely eliminate the risk of loosening. The power connector uses standard terminal plugging, ensuring reliable contact and easy assembly, resulting in a reliable and stable overall connection. This motor connector assembly uses a standard O-ring sealing structure, providing reliable sealing, low cost, easy assembly, and excellent sealing performance. The separate support frame and insulation plate design result in a compact structure, reliably ensuring insulation performance between phases and between phases and ground, providing good insulation. In addition, the coil wiring method is simplified, with fewer wire ends and clear wiring. Resistance welding is used with the busbar component, a mature process with high assembly efficiency.

[0029] It will be understood by those skilled in the art that the accompanying drawings are merely schematic diagrams of one embodiment, and the components shown in the drawings are not necessarily essential for implementing this invention. It should also be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0030] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances. Furthermore, in the description of the embodiments of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0031] Finally, it should be noted that the above-described embodiments are merely specific implementations of this utility model, used to illustrate the technical solution of this utility model, and not to limit it. The protection scope of this utility model is not limited thereto. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some of the technical features, within the technical scope disclosed in this utility model. These modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model, and should all be covered within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the protection scope described in the claims.

Claims

1. A motor connector assembly, characterized in that, include: Busbar components and power connectors; The Busbar assembly includes stacked U-phase conductive busbars, V-phase conductive busbars, and W-phase conductive busbars, and each of the U-phase conductive busbars, the V-phase conductive busbars, and the W-phase conductive busbars is a one-sixth annular copper plate, which is fixed and insulated by a split plastic component; The power connector includes three power terminals, which are fixed and insulated by insert injection molding parts, and are connected to the U-phase busbar, the V-phase busbar and the W-phase busbar.

2. The motor connector assembly according to claim 1, characterized in that, Also includes: The three wire-to-board connection terminals have their first ends fixed to the U-phase busbar, the V-phase busbar, and the W-phase busbar respectively by resistance welding, and their second ends respectively forming a plug-in connection with the three power terminals.

3. The motor connector assembly according to claim 2, characterized in that, The wire-to-board connection terminal is a standard 250 series female terminal.

4. The motor connector assembly according to claim 1, characterized in that, The Busbar assembly is interference-fitted with the motor stator frame, and the U-phase conductor bus, the V-phase conductor bus, and the W-phase conductor bus are all provided with slots. The motor stator frame is provided with a barb structure that engages with the three slots.

5. The motor connector assembly according to claim 1, characterized in that, A sealing structure is provided at the interface between the power connector and the valve block.

6. The motor connector assembly according to claim 5, characterized in that, The sealing structure is an O-ring, and an annular groove is provided on the outer wall of the insert injection molded part, and the O-ring is embedded in the annular groove.

7. The motor connector assembly according to claim 1, characterized in that, The connection between the U-phase busbar, the V-phase busbar, the W-phase busbar and the motor stator coil adopts a delta connection. Each phase winding of the motor stator coil consists of 4 coils connected in series, and each phase winding has two wire ends, which are connected to the corresponding U-phase busbar, V-phase busbar or W-phase busbar.

8. The motor connector assembly according to claim 7, characterized in that, The two wire ends connected to the V-phase busbar are located in the first stator slot, and the stator slots where the two wire ends connected to the other two phase busbars are located are no more than 3 slot pitches apart from the first stator slot.

9. The motor connector assembly according to claim 2, characterized in that, The split plastic component includes an upper support frame, a lower support frame, and an insulating plate. The Busbar assembly is fixed on the lower support frame, and the insulating plate is used to insulate each phase conductor from each other. The upper support frame is installed on the lower support frame, together forming three fixing slots. The power terminal, which is encapsulated in the insert injection molded part, is fixed in the fixing slot.

10. The motor connector assembly according to claim 9, characterized in that, The lower support frame includes a first horizontal part and a first vertical part connected to each other. The first horizontal part is provided with a first mounting groove for fixing the U-phase conductive busbar, the V-phase conductive busbar, the W-phase conductive busbar, and the insulating plate. The first vertical part is provided with three open slots. The first horizontal part is provided with a second mounting groove connecting the open slots and the first mounting groove. The wire-to-plate connection terminal is disposed in the second mounting groove. A locking groove is provided at each end of the first horizontal part. The upper support frame includes a second horizontal part and a second vertical part connected to each other. The second vertical part includes three locking plates. A hook is provided at each end of the second horizontal part. The two hooks are respectively locked into the corresponding locking grooves. The upper support frame is installed on the lower support frame, and the three locking plates abut against the corresponding open slots to form three fixing grooves.

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