Busbar assembly and electric drive assembly system

Abstract

The present disclosure relates to a busbar assembly for a motor stator and an electric drive assembly system. The busbar assembly is arranged at an axial end of the stator, and includes: a base (3) comprising a base body (31) extending along a part of the circumference of the stator; a neutral busbar (4) arranged on the base body (31) and electrically connected with a neutral point lead-out wire (12) of a winding of the stator; and three-phase busbars (5) each arranged on the base body (31) and electrically connected with a three-phase lead-out wire (13) of the winding, wherein the busbar assembly (2) is located between an inner diameter (DI) and an outer diameter (D2) of the stator in a radial direction of the stator.

Description

[0001] BUSBAR ASSEMBLY AND ELECTRIC DRIVE ASSEMBLY SYSTEM

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to a busbar assembly for a motor stator and an electric drive assembly system.

[0004] BACKGROUND

[0005] The electric drive assembly system is an important part of a vehicle, and includes a motor, a gearbox assembly and a motor controller. The motor is a device that can realize electromechanical energy conversion, and generally includes a stator, a rotor, windings, and magnets, etc. A motor control module can control the motor. For example, the motor control module is an inverter. The motor control module is electrically connected with the stator of the motor through a busbar assembly, for example, to deliver alternating-current power to the stator. The arrangement of the busbar assembly affects the assembly of the motor, especially causing inconvenience when mounting the stator to the housing of the motor.

[0006] In addition, sensors for measuring the stator temperature are typically installed on a support of the busbar assembly, but these sensors are less accurate. Further, the connection between the above-mentioned sensors and external electrical components is complicated, which makes installation more difficult.

[0007] SUMMARY

[0008] The purpose of the present disclosure is to provide a busbar assembly for a motor stator and an electric drive assembly system. The busbar assembly is located between an outer diameter and an inner diameter of a stator in a radial direction, which does not affect the assembly of the motor. It is provided with a temperature sensor with high accuracy and simple connection, and has a flexible design that can meet different assembly requirements.

[0009] This purpose is achieved by the busbar assembly of the motor stator and the i electric drive assembly system including the busbar assembly according to the present disclosure described below.

[0010] The present disclosure relates to a busbar assembly for a motor stator. The busbar assembly is arranged at an axial end of the stator and comprises: a base comprising a base body extending along a part of the circumference of the stator; a neutral busbar arranged on the base body and electrically connected with a neutral point lead-out wire of a winding of the stator; and three-phase busbars each arranged on the base body and electrically connected with a three-phase lead-out wire of the winding. The busbar assembly is located between an inner diameter and an outer diameter of the stator in a radial direction of the stator.

[0011] In one embodiment, the neutral busbar is located outside the three-phase busbars in the radial direction of the stator.

[0012] In one embodiment, the neutral busbar and the three-phase busbars are arranged such that the neutral point lead-out wire and the three-phase lead-out wire are spaced apart in the radial direction of the stator.

[0013] In one embodiment, the busbar assembly further comprises a temperature sensor, and a sensing part of the temperature sensor is arranged on the neutral busbar.

[0014] In one embodiment, the busbar assembly further comprises a clamping member for the temperature sensor, and the clamping member is welded on the neutral busbar.

[0015] In one embodiment, the clamping member comprises a clamping body and a welding portion, the clamping body surrounds the sensing part, and the welding portion is welded on both sides of the neutral busbar.

[0016] In one embodiment, the base body comprises a temperature sensor interface.

[0017] In one embodiment, the temperature sensor interface is integrally formed with the base body.

[0018] In one embodiment, the neutral busbar is molded to the base body by an injection molding process.

[0019] In one embodiment, the busbar assembly further comprises a connecting pin electrically connected with a wiring portion of the temperature sensor, and a part of the connecting pin is located within the temperature sensor interface.

[0020] In one embodiment, the connecting pin is molded to the base body by an injection molding process.

[0021] In one embodiment, the three-phase busbars are arranged on the base body by means of a press fit.

[0022] In one embodiment, the base body comprises grooves, and the three-phase busbars are respectively inserted into corresponding grooves by means of a press fit.

[0023] In one embodiment, the three-phase busbars each comprises a bolt-shaped body and a wiring portion, the bolt-shaped body is inserted into a corresponding groove, and the wiring portion is electrically connected with a corresponding three- phase lead-out wire.

[0024] In one embodiment, the three-phase busbars each further comprises a bent connection portion between the bolt-shaped body and the wiring portion.

[0025] In one embodiment, the base body is provided with a lead-out wire insertion hole, and the lead-out wire insertion hole is arranged to taper in a direction away from the axial end of the stator.

[0026] In one embodiment, the base further comprises a plurality of axial pillars, and the axial pillars are arranged between the base body and the axial end of the stator.

[0027] The present disclosure further relates to an electric drive assembly system. The electric drive assembly system comprises the busbar assembly as described above and a motor.

[0028] The advantages of the technical solutions of the present disclosure are as follows: the busbar assembly is located between the outer diameter and the inner diameter of the stator in the radial direction, which simplifies the assembly of the motor and makes the assembly process more flexible; the temperature sensor is arranged on the neutral busbar, so that the temperature of the stator can be measured more accurately, and the measurement speed is improved; the temperature sensor interface is used so that the electrical connection between the external electrical component and the temperature sensor is simpler, the overall system assembly is easier, and the reliability and transmission efficiency of signal transmission can be ensured; the structure of the busbar assembly is simpler and more compact, and the busbar assembly has a flexible design that can meet different assembly requirements.

[0029] BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1 is a partial schematic diagram of an electric drive assembly system according to an embodiment of the present disclosure;

[0031] FIG. 2 is a schematic diagram of a motor stator of an electric drive assembly system and a busbar assembly of the motor stator according to an embodiment of the present disclosure;

[0032] FIG. 3 is a schematic diagram of a busbar assembly of a motor stator according to an embodiment of the present disclosure in one direction;

[0033] FIG. 4 is a schematic diagram of a busbar assembly of a motor stator according to an embodiment of the present disclosure in another direction;

[0034] FIG. 5 is an exploded schematic diagram of a busbar assembly of a motor stator according to an embodiment of the present disclosure;

[0035] FIG. 6 is a schematic diagram showing the installation of a temperature sensor of a busbar assembly of a motor stator according to an embodiment of the present disclosure; and

[0036] FIG. 7 is a schematic diagram of a temperature sensor interface of a busbar assembly of a motor stator according to an embodiment of the present disclosure.

[0037] DETAILED DESCRIPTION

[0038] In order to make the purpose, technical solution and advantages of the embodiments of the present disclosure clearer, the technical solution of the embodiments of the present disclosure will be described clearly and completely below in conjunction with the accompanying drawings of the embodiments of the present disclosure.

[0039] Unless otherwise defined, technical terms or scientific terms used herein shall have the common meanings understood by those skilled in the art. Similar words such as “first” and “second” used in the description and claims of the patent application do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, similar words such as "one", "a” or “the” do not indicate a quantity limit, but rather indicate the existence of at least one. Similar words such as "comprise" or "include" mean that the components or objects appearing before the word cover the components or objects and their equivalents listed after the word, without excluding other components or objects.

[0040] As shown in FIG. 1, the electric drive assembly system according to the present disclosure may include a motor and a busbar assembly 2 for a motor stator 1. The busbar assembly 2 is arranged at an axial end 11 of the stator 1 and is used to electrically connect the stator to, for example, an inverter. The motor may be a new energy high-voltage drive motor, such as a permanent magnet synchronous motor or a permanent magnet synchronous flat wire motor.

[0041] As shown in FIG. 3 to FIG. 5, the busbar assembly 2 may include a base 3, a neutral busbar 4 and three-phase busbars 5. As shown in FIG. 2 and FIG. 4, the base 3 may include a base body 31 extending along a part of the circumference of the stator 1. The neutral busbar 4 is arranged on the base body 31 and electrically connected with a neutral point lead-out wire 12 of a winding of the stator 1, for example, by means of welding. The three-phase busbars 5 are U, V, W three-phase busbars. The three-phase busbars 5 are each arranged on the base body 31 and electrically connected with a three-phase lead-out wire 13 of the winding of the stator 1, for example, by means of welding. As shown in FIG. 2, the busbar assembly 2 is located between an inner diameter DI and an outer diameter D2 of the stator 1 in a radial direction of the stator 1. Through this arrangement, the stator equipped with the busbar assembly may be installed on the housing of the motor from either the driving side or the non-driving side of the motor, or a rotor may be installed from the driving side or the non-driving side of the motor, which simplifies the assembly of the motor and makes the assembly process more flexible.

[0042] As shown in FIG. 3 and FIG. 4, the neutral busbar 4 is located outside the three-phase busbars 5 in the radial direction of the stator 1. As shown in FIG. 2, the neutral busbar 4 and the three-phase busbars 5 are arranged such that the neutral point lead-out wire 12 and the three-phase lead-out wire 13 are spaced apart in the radial direction of the stator 1. Through this arrangement, it can be ensured that the insulating electrical gap between the neutral point lead-out wire 12 and the three- phase lead-out wire 13 meets the requirements.

[0043] As shown in FIG. 4, the busbar assembly 2 further includes a temperature sensor 6, such as a thermal sensor. A sensing part 61 of the temperature sensor 6 is arranged on the neutral busbar 4 for sensing the temperature of the neutral busbar 4. Considering that the temperature at the neutral busbar is the highest, the temperature sensor of the present disclosure can measure the temperature of the busbar assembly or the stator more accurately. As shown in FIG. 4, the busbar assembly 2 further includes a clamping member 7 for the temperature sensor 6, and the clamping member 7 can be welded on the neutral busbar 4. In this way, the temperature sensor 6 is integrated with the neutral busbar 4. As shown in FIG. 6, the clamping member 7 includes a clamping body 71 and a welding portion 72. The clamping body 71 surrounds the sensing part 61 of the temperature sensor 6, and the welding portion 72 is welded on both sides of the neutral busbar 4, for example, by means of resistance welding, etc. For example, the clamping member 7 may be made of copper. Of course, other metals are also possible. The clamping body 71 may have a generally annular form surrounding the sensing part 61 of the temperature sensor 6. The welding portion 72 is a plate-shaped structure extending from the clamping body 71. The above arrangement makes the contact area between the sensing part of the temperature sensor and the neutral busbar larger, and thus, the speed of sensing the temperature can be improved. In addition, the temperature sensor is fixed by means of welding so that the heat conduction efficiency is higher.

[0044] As shown in FIG. 3 and FIG. 4, the base body 31 includes a temperature sensor interface 33. The temperature sensor interface 33 can be integrally formed with the base body 31. In addition, as shown in FIG. 7, the electrical connection between the external electrical component and the temperature sensor 6 can be achieved by inserting the external electrical component into the temperature sensor interface 33 through a connector. Therefore, the connection manner is simpler and the overall system assembly is easier. In addition, since the connector is embedded in the temperature sensor interface 33, the reliability of signal transmission can be ensured and the transmission efficiency, especially the efficiency of the electric drive assembly system, is improved.

[0045] The neutral busbar 4 is molded to the base body 31 by an injection molding process. In addition, as shown in FIG. 5, the busbar assembly 2 further includes a connecting pin 8 that is electrically connected with the wiring portion of the temperature sensor 6. The above-mentioned wiring portion is a part other than the sensing part 61 of the temperature sensor 6, and may be an electric wire or the like. The wiring portion of the temperature sensor 6 can be squeezed into an opening of the connecting pin 8 in such a way as to achieve the electrical connection between the two. In addition, the connection between the two can be reinforced by means of welding, such as TIG welding. As shown in FIG. 3, a part of the connecting pin 8 is located in the temperature sensor interface 33. The connecting pin 8 can be molded to the base body 31 by an injection molding process. After this, the connecting pin 8 can be protected by filling the temperature sensor interface 33 with glue. The injection molding process allows the base body 31, the neutral busbar 4 and the connecting pin 8 to be formed into one body. The use of the injection molding process makes the structure of the busbar assembly more compact.

[0046] The three-phase busbars 5 are arranged on the base body 31 by means of a press fit. Specifically, after the base 3, the neutral busbar 4 and the connecting pin 8 are integrated together by an injection molding process, the three-phase busbars 5 are installed on the base body 31 by means of a press fit. As shown in FIG. 5, the base body 31 includes grooves 34, and the three-phase busbars 5 are inserted into the corresponding grooves 34 by means of a press fit, respectively. The press fit together with the above-mentioned injection molding process ensures that the structure of the busbar assembly is simple and compact, especially causing the busbar assembly not to exceed the outer diameter and inner diameter of the stator in the radial direction of the stator.

[0047] As shown in FIG. 5, the three-phase busbars 5 each includes a bolt-shaped body 51 and a wiring portion 52. The bolt-shaped body 51 can be inserted into a corresponding groove 34, for example, by means of a press fit, to achieve a stable electrical connection between the two. In this way, an electrical connector of an inverter can be inserted into the bolt-shaped body 51 to achieve an electrical connection, so that the overall assembly is more integrated. As shown in FIG. 2, the wiring portion 52 is electrically connected with a corresponding three-phase lead-out wire 13. In addition, the three-phase busbars 5 each further includes a bent connection portion 53 between the bolt-shaped body 51 and the wiring portion 52. By arranging the bent connection portion, the overall structure of the busbar assembly can be made more compact, and the sheet metal process and subsequent welding process can also be optimized.

[0048] As shown in FIG. 3, the base body 31 is provided with a lead-out wire insertion hole 35, and the lead-out wire insertion hole is arranged to taper in a direction away from the axial end 11 of the stator 1. In this manner, it is not only possible to locate the lead-out wire in the radial direction, but it is also possible to make it easier to insert the lead-out wire into the lead-out wire insertion hole from the bottom of the base body 31. After the lead-out wire passes through the lead-out wire insertion hole 35, the electrical connection between the lead-out wire and the corresponding neutral busbar and three-phase busbar can be achieved by means of welding.

[0049] As shown in FIG. 1 and FIG. 4, the base 3 further includes a plurality of axial pillars 32. The axial pillars are arranged between the base body 31 and the axial end 11 of the stator 1. The number of axial pillars 32 may be at least three, but the present disclosure does not limit the number thereof. By adjusting the length of the axial pillar 32, namely, the size of the axial pillar 32 in the axial direction of the motor, the busbar assembly can be positioned in the axial direction, so that the busbar assembly has a flexible design that can meet different assembly requirements.

[0050] It should be understood that the structures described above and shown in the attached drawings are only examples of the present disclosure, which can be replaced by other structures exhibiting the same or similar functions for acquiring the desired final result. In addition, it should be understood that the embodiments described above and shown in the atached drawings should be deemed to merely constitute non-restrictive examples of the present disclosure, and it can be modified in various manners within the scope of patent claims.

Claims

CLAIMS1. A busbar assembly (2) for a motor stator (1), wherein the busbar assembly (2) is arranged at an axial end (11) of the stator and comprises: a base (3) comprising a base body (31) extending along a part of a circumference of the stator; a neutral busbar (4) arranged on the base body (31) and electrically connected with a neutral point lead-out wire (12) of a winding of the stator; and three-phase busbars (5) each arranged on the base body (31) and electrically connected with a three-phase lead-out wire (13) of the winding, wherein the busbar assembly (2) is located between an inner diameter (DI) and an outer diameter (D2) of the stator in a radial direction of the stator.

2. The busbar assembly according to claim 1, wherein the neutral busbar (4) is located outside the three-phase busbars (5) in the radial direction of the stator.

3. The busbar assembly according to claim 1 , wherein the neutral busbar (4) and the three-phase busbars (5) are arranged such that the neutral point lead-out wire (12) and the three-phase lead-out wire (13) are spaced apart in the radial direction of the stator.

4. The busbar assembly according to claim 1, wherein the busbar assembly (2) further comprises a temperature sensor (6), and a sensing part (61) of the temperature sensor is arranged on the neutral busbar (4).

5. The busbar assembly according to claim 4, wherein the busbar assembly (2) further comprises a clamping member (7) for the temperature sensor (6), the clamping member is welded on the neutral busbar (4).

6. The busbar assembly according to claim 5, wherein the clamping member (7) comprises a clamping body (71) and a welding portion (72), the clamping body (71) surrounds the sensing part (61), and the welding portion (72) is welded on both sides of the neutral busbar (4).

7. The busbar assembly according to claim 4, wherein the base body (31) comprises a temperature sensor interface (33).

8. The busbar assembly according to claim 7, wherein the temperature sensor interface (33) is integrally formed with the base body (31).

9. The busbar assembly according to claim 8, wherein the neutral busbar (4) is molded to the base body (31) by an injection molding process.

10. The busbar assembly according to claim 7, wherein the busbar assembly (2) further comprises a connecting pin (8) electrically connected with a wiring portion of the temperature sensor (6), and a part of the connecting pin is located within the temperature sensor interface (33).

11. The busbar assembly according to claim 10, wherein the connecting pin (8) is molded to the base body (31) by an injection molding process.

12. The busbar assembly according to any one of claims 1 to 11, wherein the three-phase busbars (5) are arranged on the base body (31) by means of a press fit.

13. The busbar assembly according to claim 12, wherein the base body (31) comprises grooves (34), and the three-phase busbars (5) are respectively inserted into corresponding grooves (34) by means of a press fit.

14. The busbar assembly according to claim 13, wherein the three-phase busbars (5) each comprises a bolt-shaped body (51) and a wiring portion (52), the bolt-shaped body (51) is inserted into a corresponding groove (34), and the wiring portion (52) is electrically connected with a corresponding three-phase lead-out wire (13).

15. The busbar assembly according to claim 14, wherein the three-phase busbars (5) each further comprises a bent connection portion (53) between the boltshaped body (51) and the wiring portion (52).

16. The busbar assembly according to any one of claims 1 to 11, wherein the base body (31) is provided with a lead-out wire insertion hole (35), and the lead- out wire insertion hole is arranged to taper in a direction away from the axial end (11) of the stator.

17. The busbar assembly according to claim 16, wherein the base (3) further comprises a plurality of axial pillars (32), the axial pillars are arranged between the base body (31) and the axial end (11) of the stator.

18. An electric drive assembly system, wherein the electric drive assemblysystem comprises the busbar assembly (2) according to any one of claims 1 to 17 and a motor.

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