Busbar assembly, motor structure, electric power steering system, and vehicle

Abstract

The embodiments of the present application provide a busbar assembly, a motor structure, an electric power steering system, and a vehicle. The busbar assembly includes a plurality of phase copper bars and a plurality of neutral copper bars, the phase copper bars and the neutral copper bars are integrally injection molded to form a copper bar support frame, and a terminal support frame is provided on the base body, the plurality of phase copper bars have the same shape, the plurality of neutral copper bars have the same shape, the neutral copper bars include a neutral copper bar body extending in a radial direction, the phase copper bars include a phase copper bar body extending in an axial direction, and the projections of at least one phase copper bar body and at least one neutral copper bar body on an end face of the base body overlap.

Description

[Technical field]

[0001] This application claims priority to the Chinese patent application bearing application number "202210867515.6" and title "BUS BAR ASSEMBLY, MOTOR STRUCTURE, ELECTRIC POWER STEERING SYSTEM, AND VEHICLE", filed on July 22, 2022 with the State Intellectual Property Office of the People's Republic of China (SIPC), the Chinese patent application bearing application number "202221904223.7" and title "BUS BAR ASSEMBLY, MOTOR STRUCTURE, ELECTRIC POWER STEERING SYSTEM, AND VEHICLE", the Chinese patent application bearing application number "202210867171.9" and title "BUS BAR ASSEMBLY, MOTOR STRUCTURE, ELECTRIC POWER STEERING SYSTEM, AND VEHICLE", and the Chinese patent application bearing application number "202221899908.7" and title "BUS BAR ASSEMBLY, MOTOR STRUCTURE, ELECTRIC POWER STEERING SYSTEM, AND VEHICLE", all of which are incorporated herein by reference.

[0002] The present application relates to the technical field of motors, and more particularly to a busbar assembly, a motor structure, an electric power steering system, and a vehicle. [Background technology]

[0003] At present, with the rapid development of automobiles, especially new energy automobile technology, electric drive systems are gradually moving towards higher speed, smaller size, higher efficiency, etc. At the same time, vehicles have higher requirements for the cost and performance of electric drive systems, so motor assemblies are gradually developing towards smaller size, lighter weight, integration, etc. EPS (Electric Power Steering) brushless motors are becoming more and more popular due to their excellent advantages such as low noise, smooth operation, long life, and high power density. Summary of the Invention [Problem to be solved by the invention]

[0004] In the prior art, when producing busbars for conventional EPS motors, there are usually copper bars of various shapes in the same busbar, which requires designing separate dies for each type of copper bar, which increases production costs.

[0005] The present application aims to solve at least one of the technical problems existing in the prior art or related art. [Means for solving the problem]

[0006] In view of the above, a first embodiment of the present application provides a busbar assembly.

[0007] An embodiment of a second aspect of the present application provides a motor structure.

[0008] An embodiment of a third aspect of the present application provides an electric power steering system.

[0009] An embodiment of a fourth aspect of the present application provides a vehicle.

[0010] In order to achieve the above object, an embodiment of a first aspect of the present application provides a busbar assembly including a plurality of phase copper bars and a plurality of neutral copper bars, the phase copper bars and the neutral copper bars being integrally injection molded to form a copper bar support frame, the plurality of phase copper bars and the plurality of neutral copper bars including a base body arranged in the circumferential direction of the copper bar support frame, and a terminal support frame arranged on the base body and including a plurality of connection terminals connected to the phase copper bars, the plurality of phase copper bars have the same shape, the plurality of neutral copper bars have the same shape, the neutral copper bars include a neutral copper bar body extending in the radial direction of the base body, the phase copper bars include a phase copper bar body extending in the axial direction of the base body, and the projections of at least one phase copper bar body and at least one neutral copper bar body on the end face of the base body overlap.

[0011] In the above technical solution, the width direction of the phase copper bar body and the axial direction of the base body overlap, and the width direction is a direction perpendicular to the extension direction of the phase copper bar on the extension plane of the phase copper bar.

[0012] In the above technical solution, the plurality of neutral copper bars are circumferentially arranged around the axis of the base body, and the plurality of phase copper bars are rotationally symmetrical around the axis of the base body.

[0013] In the above technical proposal, the neutral copper bar specifically includes an arc-shaped neutral copper bar body, a plurality of transition bending portions provided radially outside the neutral copper bar body and formed by bending the neutral copper bar body along the axial direction, and a neutral hook portion connected to the transition bending portions.

[0014] In the above technical proposal, the phase copper bar body specifically includes a first copper bar portion, a second copper bar portion and a third copper bar portion which are located at different radial positions, the first copper bar portion and the second copper bar portion are connected via a first bent portion, and the second copper bar portion and the third copper bar portion are connected via a second bent portion.

[0015] In the above technical proposal, a flat portion is provided at an end of the first copper bar portion away from the first bent portion, the flat portion extends radially, a mating hook portion is formed at an end of the flat portion away from the first copper bar portion, and the width direction of the flat portion is perpendicular to the axial direction of the base body.

[0016] In the above technical proposal, every three phase copper bars are distributed circumferentially around the axis and stacked, and of two adjacent phase copper bars, the planar portion of one phase copper bar covers the second copper bar portion of the other phase copper bar.

[0017] In the above technical proposal, in the three-phase copper bars that are stacked, the radial positions of the first copper bar portions of the three phase copper bars are the same, the radial positions of the second copper bar portions of the three phase copper bars are the same, and the radial positions of the third copper bar portions of the three phase copper bars are the same.

[0018] In the above technical solution, at least a portion of the three first copper bar portions is on a circle of the same radius, at least a portion of the three second copper bar portions is on a circle of the same radius, and at least a portion of the three third copper bar portions is on a circle of the same radius.

[0019] In the above technical proposal, the copper bar body is provided with a terminal connection portion extending in the axial direction, the connection terminal is electrically connected to the terminal connection portion, and the terminal connection portion is provided at a position between the flat portion and the first bent portion in the copper bar body.

[0020] In the above technical solution, each phase copper bar is provided with two phase hook portions extending radially outward, and the two phase hook portions are respectively provided on the plane portion and the third copper bar portion.

[0021] In the above technical solution, the two phase hook portions of each phase copper bar are both located radially outside the phase copper bar.

[0022] In the above technical proposal, the opening of the mating hook portion faces radially inward of the base body or faces one circumferential side of the base body.

[0023] In the above technical proposal, the openings of all mating hook portions are oriented in the same direction.

[0024] In the above technical solution, the copper bar is formed by bending a plate multiple times.

[0025] An embodiment of a second aspect of the present application provides a motor structure including a rotor structure, a stator structure arranged coaxially with the rotor structure, and a busbar assembly according to any one of the first aspects provided at one end of the stator structure and electrically connected to the stator structure.

[0026] An embodiment of the third aspect of the present application provides an electric power steering system, which includes the motor structure of the embodiment of the second aspect described above, so that the electric power steering system of the present application has all the beneficial effects of the motor structure according to any of the technical solutions described above.

[0027] An embodiment of a fourth aspect of the present application provides a vehicle including a vehicle body and a motor structure according to any one of the second aspects provided within the vehicle body, or an electric power steering system according to the third aspect provided within the vehicle body. Effect of the Invention

[0028] In the present application, all neutral copper bars have the same shape, and all phase copper bars also have the same shape, so that during production, only two types of molds are required to produce all phase copper bars and neutral copper bars, thereby significantly reducing the development and production costs of the molds required for production.

[0029] Additional aspects and advantages of the present application will be set forth in the description that follows, or may be learned by practice of the present application. [Brief description of the drawings]

[0030] [Figure 1] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present application; [Diagram 2] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present application; [Diagram 3] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present application; [Figure 4] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present application; [Diagram 5] 1A and 1B are schematic diagrams illustrating the structure of a terminal support frame and a connection terminal according to an embodiment of the present application. [Figure 6] FIG. 1 shows a schematic diagram of a laminated structure of multiple phase copper bars according to an embodiment of the present application. [Figure 7] FIG. 1 is a schematic diagram of a laminated structure of a copper bar according to an embodiment of the present application. [Figure 8] FIG. 2 shows a schematic diagram of the structure of multiple neutral copper bars according to an embodiment of the present application. [Figure 9] FIG. 2 shows a schematic diagram of the structure of a neutral copper bar according to an embodiment of the present application. [Figure 10] 1 is a schematic diagram showing a motor structure according to an embodiment of the present application; [Figure 11] 1 is a structural schematic diagram of an electric power steering system according to an embodiment of the present invention; [Figure 12] 1 is a schematic diagram showing the structure of a vehicle according to an embodiment of the present application; [Figure 13] 1 is a schematic diagram showing the structure of a vehicle according to an embodiment of the present application; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] In order to more clearly understand the above objects, features and advantages of the embodiments of the present application, the embodiments of the present application will be described in more detail with reference to the drawings and specific embodiments. Note that the embodiments of the present application and the features in the embodiments may be combined with each other unless they are inconsistent.

[0032] Although numerous specific details are set forth in the following description to facilitate a thorough understanding of the present application, the embodiments of the present application may be implemented in other ways than those described herein, and therefore the scope of protection of the present application is not limited to the specific embodiments disclosed below.

[0033] Hereinafter, several embodiments of the present invention will be described with reference to FIGS.

[0034] As shown in FIG. 1 , the busbar assembly 100 of this embodiment includes a base body 102 and a terminal support frame 108. The base body 102 includes a phase copper bar 104, a neutral copper bar 106, and a copper bar support frame 1022. The copper bar support frame 1022 is formed when the phase copper bar 104 and the neutral copper bar 106 are injection molded. After the injection molding is completed, the copper bar support frame serves as a plastic case for the phase copper bar and the neutral copper bar, and exerts the effect of integral fixing and insulation. A plurality of copper bars are provided, specifically including the phase copper bar 104 and the neutral copper bar 106 arranged in the circumferential direction. The terminal support frame 108 is mainly provided on the base body 102. The terminal support frame includes a plurality of connecting terminals 1082 that can be easily connected to an external power supply or controller, thereby realizing the control of the motor connected to the busbar assembly 100.

[0035] However, for all copper bars, in this application, the shapes of all neutral copper bars 106 are the same, and the shapes of all phase copper bars 104 are also the same, so that during production, only two types of dies are designed to realize the production of all phase copper bars 104 and neutral copper bars 106. It can be understood that one type of die is used for all phase copper bars 104, and another type of die is used for all neutral copper bars 106. The assembly can be realized only by arranging the neutral copper bars 106 individually and arranging the phase copper bars 104 in a shifted stacked manner, thereby greatly reducing the development and production costs of the dies required for production.

[0036] When attaching the two types of copper bars to the copper bar support frame 1022, there needs to be some overlap in the axial direction.

[0037] However, in the present application, the main structure of the phase copper bar 104 is the phase copper bar body 1041, and the arrangement direction of the phase copper bar body 1041 is restricted so that it is arranged vertically within the base body 102, that is, the width direction of the phase copper bar body 1041 overlaps with the axial direction of the base body 102. In addition, the width direction is further defined, and the structure of the phase copper bar 104 is plate-shaped, the extension plane of the phase copper bar 104 is a plane perpendicular to the thickness direction, and the width direction is perpendicular to the extension direction of the phase copper bar 104.

[0038] In addition, since the shapes of the multiple phase copper bars 104 and the neutral point copper bar 106 are the same and the resistance of each copper bar is equal, the imbalance rate between each resistance can be effectively reduced, and the NVH (i.e., noise, vibration and harshness) risk in an automobile structure of a motor using the bus bar assembly 100 can be reduced.

[0039] Additionally, the phase copper bar 104 and the neutral copper bar 106 are electrically conductive and typically in direct contact.

[0040] After the installation of the phase copper bar 104 and the neutral copper bar 106 on the base body 102 is completed, that is, after the phase copper bar and the neutral copper bar are integrally injection molded to form a copper bar support frame, the entire copper bar support frame, the phase copper bar and the neutral copper bar are combined together to facilitate installation.

[0041] In addition, each phase copper bar 104 is connected to the end of at least one stator winding, and a number of connection terminals are further provided on the terminal support frame. After the multiple stator windings are joined together, electrical connection with an external structure can be realized through the connection terminals.

[0042] Furthermore, the base body 102 itself is annular in shape, which more closely matches the shape of the end faces of typical stator structures.

[0043] By restricting the arrangement of the neutral copper bar 106 and the phase copper bar 104, the main structure of the neutral copper bar 106 is the neutral copper bar body 1062, the extension direction is the radial direction, and the main structure of the phase copper bar 104 is the phase copper bar body 1041, the extension direction is the axial direction, and by adopting a mutually perpendicular arrangement form, the axial and radial dimensions of the copper bar can be reduced to the maximum. In other words, the phase copper bar body is vertically arranged in the base body, and the neutral copper bar body is horizontally arranged in the base body.

[0044] In addition, the terminal support frame mainly includes a bracket body 1084 and three connecting terminals 1082, and the multiple connecting terminals 1082 are fixed to the bracket body 1084, and then injection molding is performed to finally form the terminal support frame. In addition, the phase copper bars 104 and the connecting terminals 1082 are electrically conductive, so that the terminal support frame is electrically connected to the three phase copper bars 104 at the same time, thereby realizing a modularized conductive relationship.

[0045] The extension direction of the phase copper bar 104 and the neutral point copper bar 106 is the length direction of the copper bar, and the width direction is the lateral dimension of the copper bar; that is, the plane formed by the extension direction and width direction of the copper bar is the extension plane, and the direction perpendicular to the extension plane is the thickness direction. When multiple connection terminals 1082 are used, three connection terminals 1082 can be grouped into a set, with each set corresponding to one terminal support frame, i.e., each terminal support frame includes three connection terminals, thereby adapted for connection and conduction of a three-phase circuit.

[0046] 8, when multiple neutral copper bars 106 are selected, they are arranged around the axis of the base body 102 to utilize their circumferential positions, thereby realizing a current path in combination with the phase copper bars 104 that are rotationally symmetric around the axis. The number of neutral copper bars 106 may be an odd number or an even number.

[0047] Generally, the number of neutral copper bars 106 is even and rotationally symmetric.

[0048] As shown in FIG. 1 , the busbar assembly 100 of this embodiment includes a base body 102 and a terminal support frame 108. The base body 102 includes a phase copper bar 104, a neutral copper bar 106, and a copper bar support frame 1022. The copper bar support frame 1022 is formed when the phase copper bar 104 and the neutral copper bar 106 are injection molded. After the injection molding is completed, the copper bar support frame serves as a plastic case for the phase copper bar and the neutral copper bar, and exerts the effect of integral fixing and insulation. A plurality of copper bars are provided, specifically including the phase copper bar 104 and the neutral copper bar 106 arranged in the circumferential direction. The terminal support frame 108 is mainly provided on the base body 102. The terminal support frame includes a plurality of connecting terminals 1082 that can be easily connected to an external power supply or controller, thereby realizing the control of the motor connected to the busbar assembly 100.

[0049] As shown in FIG. 9, the neutral copper bar 106 mainly includes a neutral copper bar body 1062 and a plurality of transition bends 1064, in which the neutral copper bar body 1062 extends radially, and the transition bends 1064 are formed by bending along the axis on the radial outer side of the neutral copper bar body 1062, i.e., bending upward from the outside, and a neutral hook portion 1066 is provided on the transition bend 1064, which provides a welding position for the winding under the action of the neutral hook portion 1066, thereby realizing electrical continuity.

[0050] Furthermore, by restricting each neutral hook portion 1066 and restricting it to be positioned radially outward, the welding operation during winding is facilitated, operation space is provided, and the presence or absence of welding leaks or winding leaks can be easily observed.

[0051] According to some of the above structures, one plate-shaped substrate can be used and can be formed through multiple punching and bending processes, thereby improving the yield and reducing the material loss rate.

[0052] 7, the phase copper bar body 1041 mainly includes three parts, a first copper bar part 1042, a second copper bar part 1044 and a third copper bar part 1046, which are offset in the radial direction, and the three copper bar parts are connected in sequence, and the offset between two adjacent copper bar parts is realized by the bent part. Specifically, the first copper bar part 1042 and the second copper bar part 1044 are connected through the first bent part 1043, and the second copper bar part 1044 and the third copper bar part 1046 are connected through the second bent part 1045. Under the action of the first bent part 1043 and the second bent part 1045, the first copper bar part 1042, the second copper bar part 1044 and the third copper bar part 1046 are offset in the radial direction, so that when multiple phase copper bars 104 are stacked, there is no mutual interference in position, thereby realizing a normal joint conduction effect.

[0053] Furthermore, the radial position of the first copper bar portion 1042 is at the outermost position, and the radial position of the third copper bar portion 1046 is at the innermost position. Alternatively, the radial position of the first copper bar portion 1042 is at the inner side, and the radial position of the third copper bar portion 1046 is at the outer side.

[0054] The radial positions of the first copper bar portion 1042, the second copper bar portion 1044 and the third copper bar portion 1046 vary monotonically.

[0055] When multiple phase copper bars 104 are selected, the phase copper bars 104 are stacked in groups of three, and when installed, the flat portion 1050 of one of two adjacent phase copper bars 104 covers the second copper bar portion 1044 of the other. That is, for the three phase copper bars 104, the order in the circumferential direction is phase copper bar 1, phase copper bar 2, and phase copper bar 3, with the flat portion of phase copper bar 1 covering the second copper bar portion 1044 of phase copper bar 2, and the flat portion of phase copper bar 2 covering the second copper bar portion 1044 of phase copper bar 3.

[0056] Furthermore, for phase copper bar 1, phase copper bar 2 and phase copper bar 3, the radial positions of the three first copper bar parts are the same, that is, the three first copper bar parts 1042 are on the same circumferential surface; similarly, the radial positions of the three second copper bar parts 1044 are also the same, and the radial positions of the three third copper bar parts 1046 are also the same, that is, after the stacking arrangement, the radial positions of the first copper bar part 1042, the second copper bar part 1044 and the third copper bar part 1046 are unified, making the overall structure more regular and ensuring the balance of the overall structure of the bus bar.

[0057] By adjusting the arrangement of the second copper bar portion 1044 of the phase copper bar 104 and the arrangement of the neutral copper bar body 1062 of the neutral copper bar 106, the phase copper bar 104 and the neutral copper bar 106 are arranged vertically, the second copper bar portion 1044 is located in the middle position of the phase copper bar 104, and the neutral copper bar body 1062 functions as the main structure of the neutral copper bar 106. By arranging both vertically, injection molding is facilitated.

[0058] For each phase copper bar 104, two phase hook portions 1052 are provided, and the phase hook portions 1052 are provided on the first copper bar portion 1042 and the third copper bar portion 1046 and extend outward so that the windings can be easily welded to the phase hook portions 1052.

[0059] In one specific embodiment, the axial positions of the neutral hook portion 1066 and the mating hook portion 1052 are limited, specifically, limited between the upper and lower surfaces of the base body 102, that is, the projections of the two hook portions onto the peripheral surface of the base body 102 are within the base body 102, so that the hook portions do not exceed the range of the base body 102 in the axial direction, and unnecessary dimensions in the axial direction can be reduced.

[0060] Furthermore, the heights of the hook portions of the two copper bars are the same, that is, the axial positions of the neutral hook portion 1066 and the phase hook portion 1052 are kept the same. When winding welding is performed, the winding welding process of the entire busbar can be realized without adjusting the axial welding position, which greatly improves production efficiency.

[0061] As shown in Figures 4, 5 and 6, the busbar assembly 100 of this embodiment includes a base body 102 and a terminal support frame 108. The base body 102 includes a phase copper bar 104, a neutral copper bar 106 and a copper bar support frame 1022. The copper bar support frame 1022 is formed when the phase copper bar 104 and the neutral copper bar 106 are injection molded. After the injection molding is completed, the copper bar support frame serves as a plastic case for the phase copper bar and the neutral copper bar, and exerts the effects of integral fixing and insulation. A plurality of copper bars are provided, specifically including the phase copper bar 104 and the neutral copper bar 106 arranged in the circumferential direction. The terminal support frame 108 is mainly provided on the base body 102. The terminal support frame includes a plurality of connecting terminals 1082 that can be easily connected to an external power supply or controller, thereby realizing the control of the motor connected to the busbar assembly 100.

[0062] As shown in FIG. 9, the neutral copper bar 106 mainly includes a neutral copper bar body 1062 and a plurality of transition bends 1064, in which the neutral copper bar body 1062 extends radially, and the transition bends 1064 are formed by bending along the axis on the radially outer side of the neutral copper bar body 1062, i.e., bending upward from the outside, and a neutral hook portion 1066 is provided on the transition bend 1064, which provides a welding position for the winding under the action of the neutral hook portion 1066, thereby realizing electrical continuity.

[0063] As shown in Fig. 7, the phase copper bar 104 mainly includes three parts, a first copper bar part 1042, a second copper bar part 1044 and a third copper bar part 1046, which are offset in the radial direction, and the three copper bar parts are connected in sequence, and the offset between two adjacent copper bar parts is realized by the bent part. Specifically, the first copper bar part 1042 and the second copper bar part 1044 are connected through the first bent part 1043, and the second copper bar part 1044 and the third copper bar part 1046 are connected through the second bent part 1045. Under the action of the first bent part 1043 and the second bent part 1045, the first copper bar part 1042, the second copper bar part 1044 and the third copper bar part 1046 are offset in the radial direction, so that when multiple phase copper bars 104 are stacked, there is no mutual interference in position, thereby realizing a normal joint conduction effect.

[0064] In addition, as shown in FIG. 2, a neutral pin hole 1068 is provided on the neutral copper bar body 1062, which fixes the neutral copper bar 106 on the injection molding tooling during installation, thereby exerting the functions of injection molding and fixing. After the injection molding is completed, the phase copper bar 104 and the neutral copper bar 106 can be removed together with the copper bar support frame 1022, which facilitates the subsequent assembly with the base body 102 and the terminal.

[0065] In addition, under the action of the neutral pin hole 1068, the radial width of the neutral point copper bar body 1062 becomes shorter, and the corresponding cross-sectional area also becomes smaller. At this time, a radial protrusion 1070 can be provided on the radially inner side, thereby ensuring that the cross-sectional area through which the current flows is consistent with the position of the neutral pin hole, thereby avoiding large local resistance and serious heat generation during operation, and improving the stability of product use.

[0066] By providing a terminal connection portion 1048 on the first copper bar portion 1042, the connection of the terminal support frame is realized by the terminal connection portion 1048, and an electrical signal in the phase copper bar 104 is transmitted to the connection terminal via the terminal connection portion 1048 to realize control or power supply.

[0067] The terminal support frame is provided with three terminal connections 1048 .

[0068] After the three phase copper bars 104 are stacked, a terminal support frame is directly provided on the three terminal connection portions 1048, so that electrical signals in the three phase copper bars 104 are transmitted to the three connection terminals.

[0069] With regard to the first copper bar portion 1042, a radially extending flat portion 1050 is provided at the end of the first copper bar portion 1042 remote from the first bent portion 1043, and the flat portion 1050 is connected to the first copper bar portion 1042, i.e., the width direction of the first copper bar portion 1042 extends in the axial direction, while the flat portion 1050 extends in the lateral direction, i.e., the width direction extends in the radial direction, i.e., the width direction of the flat portion 1050 is perpendicular to the axial direction, and a phase hook portion 1052 is provided at the other end of the flat portion 1050, i.e., the end remote from the first copper bar portion 1042, so that the winding can be easily welded to the phase hook portion 1052.

[0070] Furthermore, by providing the phase hook portion 1052 at the other end of the flat portion 1050, that is, the end portion remote from the terminal connection portion 1048, the winding can be easily welded to the phase hook portion 1052.

[0071] It will be appreciated that the mating hook portion 1052 may be formed by extending and bending the flat portion 1050, or may be formed by connecting separate members.

[0072] Based on any of the above embodiments, when multiple connection terminals 1082 are used, three connection terminals 1082 can be grouped into a set, and each set corresponds to one terminal support frame 108, that is, the three connection terminals 1082 are provided on one terminal support frame 108, thereby being adapted for conduction of a three-phase circuit.

[0073] After the connection terminals 1082 are provided on the terminal support frame 108, they can be integrally formed by injection molding, facilitating attachment and assembly.

[0074] Furthermore, as shown in Figures 2 and 3, the copper bar support frame 1022 is provided with a first positioning hole 1182 at a position opposite to the phase copper bar 104, and a second positioning hole 1184 at a position opposite to the neutral copper bar 106. During installation, the phase copper bar 104 and the neutral copper bar 106 are fixed to the injection molding tooling, thereby exerting the effects of injection molding and fixing. After the injection molding is completed, the phase copper bar 104 and the neutral copper bar 106 can be removed together with the copper bar support frame 1022, which facilitates the subsequent assembly with the base body 102 and the terminal.

[0075] In addition, as shown in FIG. 2, the base body 102 is provided with a weight reduction groove 120, which can reduce the material and the weight of the base body 102; and the circumferential weight reduction groove 120 can keep the wall thickness almost the same, thereby ensuring the yield after injection molding.

[0076] 4, the terminal support frame 108 mainly includes a bracket body 1084 and three connecting terminals 1082, and the terminal support frame 108 can be formed by integrally injection molding the three connecting terminals 1082 with the bracket body 1084. The phase copper bars 104 and the connecting terminals 1082 are electrically conductive, so that the terminal support frame 108 is electrically connected to the three phase copper bars 104 at the same time, thereby realizing a modular conductive relationship.

[0077] Furthermore, by providing the third positioning hole 1088 in the bracket body 1084, the assembly of the terminal support frame 108 is realized by fitting the terminal positioning protrusion 1222 shown in FIG.

[0078] Furthermore, as shown in FIG. 4, reinforcing ribs 1090 are provided in the circumferential direction of the connection terminal, which not only improves the strength but also improves the stability of the terminal assembly, making it possible to prevent deformation or displacement during assembly.

[0079] Furthermore, the extending direction of the connection terminal is restricted to the axial direction, so that the connection terminal is provided in the bracket body and then connected to an external power source or a circuit board in the axial direction. Also, one end of the connection terminal extends in the axial direction, and the other end extends inward in the radial direction and is then bent laterally. After bending, the terminal connection portion 1048 of the copper bar 104 is welded, thereby establishing a conductive relationship.

[0080] 10, the motor structure 200 according to the present embodiment includes a rotor structure 202 and a stator structure 204 that are coaxially arranged, and the rotor structure 202 is arranged inside the stator structure 204 to form a motor structure 200 with a stator on the outside and a rotor on the inside, in which a changed magnetic field is generated under the action of the inner stator structure 204, thereby rotating and driving the rotor structure 202. In addition, a busbar assembly is arranged at one end of the stator structure, and the busbar assembly is electrically connected to the stator structure, thereby realizing control of the stator structure.

[0081] Furthermore, since the motor structure 200 includes any of the embodiments of the busbar assembly 100 described above, it has the beneficial effects of any of the busbar assemblies 100 of the first aspect, and a duplicated description will be omitted here.

[0082] As shown in FIG. 11, this embodiment provides an electric power steering system 400 and includes the motor structure 200 in any of the possible embodiments described above, so that the electric power steering system 400 of this embodiment has all the beneficial effects of the motor structure 200 in the above embodiments.

[0083] The electric power steering system 400 (abbreviated as EPS: Electric Power Steering) is an electric power steering system that directly relies on the motor structure 200 to provide auxiliary torque power. Compared with the conventional hydraulic power steering system HPS (Hydraulic Power Steering), the EPS system has a simple structure, is flexible to assemble, and can not only save energy but also protect the environment. Most models of modern vehicles are basically equipped with EPS systems.

[0084] The electric power steering system 400 includes various possible embodiments. One of the various possible embodiments will be specifically described below. Specifically, in one possible embodiment, the EPS system includes an electric power steering system and an assist torque mechanism that generates an assist torque. The assist torque assists the steering torque of the electric power steering system that is generated by the driver operating the steering wheel. The assist torque reduces the driver's operating burden.

[0085] Specifically, the electric power steering system 400 includes a steering wheel 411, a steering shaft 412, a universal coupling 413, a rotating shaft 414, a rack-and-pinion mechanism 415, a rack shaft 416, and wheels 417 for left and right steering.

[0086] The assist torque mechanism includes a steering torque sensor 421, an automobile electronic control unit 422, a motor, and a reduction gear mechanism 423. Specifically, the steering torque sensor 421 detects the steering torque of the electric power steering system. The control unit 422 generates a drive signal in response to a detection signal of the steering torque sensor 421. The motor generates an assist torque corresponding to the steering torque in response to the drive signal. The motor transmits the generated assist torque to the electric power steering system via the reduction gear mechanism 423.

[0087] As shown in FIG. 12, the vehicle 300 of this embodiment includes a vehicle body 302 and a motor structure 200 provided in the vehicle body 302, and the vehicle body 302 mainly provides a certain protective effect for the motor structure 200. Since the motor structure 200 is provided in the vehicle body 302, the vehicle 300 has the beneficial effects of any of the motor structures of the embodiments of the second aspect described above, and a duplicated description will not be repeated here.

[0088] The motor structure of the vehicle may be the main drive structure of an electric vehicle or the like, or it may be the drive structure for other equipment within the vehicle, such as a fan.

[0089] Of course, as shown in FIG. 13, the motor structure 200 can drive an electric power steering system 400 to realize steering of the vehicle 300.

[0090] According to the busbar assembly, motor structure, electric power steering system, and vehicle of the present application, all neutral copper bars have the same shape, and all phase copper bars also have the same shape, so that during production, only two types of molds are required to produce all phase copper bars and neutral copper bars, thereby significantly reducing the development and production costs of the molds required for production.

[0091] In this application, the terms "first", "second" and "third" are used for descriptive purposes only and are not to be understood as indicating or implying relative importance. The term "plurality" means two or more unless otherwise expressly limited. Terms such as "attach", "couple", "connect", "fixed" and the like should be understood in a broad sense, for example, "connection" may be a fixed connection, a detachable connection, or an integral connection. "Connect" may be a direct connection or an indirect connection via an intermediate medium. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific situation.

[0092] In the description of this application, the orientations or positional relationships indicated by terms such as "upper", "lower", "left", "right", "front", "rear", etc. are based on the orientations or positional relationships shown in the drawings, and are merely for the purpose of facilitating and simplifying the description of this application, and should not be understood as indicating or implying that the devices or units referred to have a specific direction or must be constructed and operated in a specific orientation. Therefore, they should not be understood as limiting this application.

[0093] In the description herein, reference to a term such as "one embodiment," "some embodiments," or "particular embodiment" means that a particular feature, structure, material, or characteristic described with reference to that embodiment or example is included in at least one embodiment or example of the present application. Illustrative references of such terms herein do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0094] The above is only a preferred embodiment of the present application, and does not limit the present application. Those skilled in the art may have various modifications and changes to the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application. [Explanation of symbols]

[0095] The correspondence between the reference characters and the names of the members in FIGS.

[0096] 100 Busbar Assembly 102 Base body 1022 Copper bar support frame 104 Phase Copper Bar 1041 Phase copper bar body 1042 First copper bar section 1043 First bending part 1044 Second copper bar section 1045 Second bending part 1046 3rd Copper Bar Section 1048 Terminal connection 1050 Plane part 1052 mating hook part 106 Neutral copper bar 1062 Neutral copper bar body 1064 Transition bend 1066 Neutral hook part 1068 Neutral pin hole 1070 Radial projection 108 Terminal support frame 1082 Connection terminal 1084 Bracket body 1088 3rd positioning hole 1090 Reinforcement rib 1182 First positioning hole 1184 Second positioning hole 120 Reduction groove 1222 Terminal positioning protrusion 200 Motor Structure 202 Rotor Structure 204 Stator Structure 300 vehicles 302 Body 400 Electric Power Steering System 411 Handle 412 Steering shaft 413 Universal Coupling 414 Rotating Shaft 415 Rack and pinion mechanism 416 Rack shaft 417 Wheels 421 Steering torque sensor 422 Control Unit 423 Reduction mechanism

Claims

1. A base body including a plurality of phase copper bars and a plurality of neutral copper bars, the phase copper bars and the neutral copper bars being integrally injection molded to form a copper bar support frame, the phase copper bars and the neutral copper bars being arranged in a circumferential direction of the copper bar support frame; A terminal support frame is provided on the base body and includes a plurality of connection terminals connected to the phase copper bars; The shapes of the plurality of phase copper bars are the same, the shapes of the plurality of neutral copper bars are the same, the neutral copper bar includes a neutral copper bar body extending in the radial direction of the base body, the phase copper bar includes a phase copper bar body extending in the axial direction of the base body, and the projections of at least one of the phase copper bar body and at least one of the neutral copper bar body on the end surface of the base body overlap; Busbar assembly.

2. The plurality of neutral copper bars are circumferentially arranged around the axis of the base body, and the plurality of phase copper bars are rotationally symmetric around the axis of the base body. The busbar assembly of claim 1 .

3. Specifically, the neutral copper bar is The neutral point copper bar body having an arc shape; A plurality of transition bends are provided radially outward of the neutral copper bar body and are formed by bending the neutral copper bar body along the axial direction; a neutral hook portion connected to the transition fold portion, The busbar assembly according to claim 1 or 2.

4. The copper bar body is specifically The copper bar includes a first copper bar portion, a second copper bar portion, and a third copper bar portion that are different in radial position, the first copper bar portion and the second copper bar portion are connected via a first bent portion, and the second copper bar portion and the third copper bar portion are connected via a second bent portion. The busbar assembly according to claim 3 .

5. A flat portion is provided at an end of the first copper bar portion away from the first bent portion, the flat portion extends in a radial direction, and a mating hook portion is formed at an end of the flat portion away from the first copper bar portion, The width direction of the planar portion is perpendicular to the axial direction of the base body. The busbar assembly according to claim 4 .

6. The phase copper bars are distributed in a circumferential direction around the axis and stacked in threes, and of two adjacent phase copper bars, a planar portion of one of the phase copper bars covers a second copper bar portion of the other phase copper bar. The busbar assembly according to claim 5 .

7. In the three phase copper bars provided in a stacked manner, the radial positions of the first copper bar portions of the three phase copper bars are the same, the radial positions of the second copper bar portions of the three phase copper bars are the same, and the radial positions of the third copper bar portions of the three phase copper bars are the same. The busbar assembly according to claim 6.

8. At least a portion of the three first copper bar portions is on a circle of the same radius, at least a portion of the three second copper bar portions is on a circle of the same radius, and at least a portion of the three third copper bar portions is on a circle of the same radius. The busbar assembly of claim 7.

9. Each of the phase copper bars is provided with two phase hook portions extending radially outward, and the two phase hook portions are provided on the planar portion and the third copper bar portion, respectively. A busbar assembly according to any one of claims 5 to 8.

10. The two phase hook portions of each of the phase copper bars are both located radially outward of the phase copper bar; or The opening of the mating hook portion faces the radially inward direction of the base body, or faces one circumferential side of the base body, or The neutral hook portion and the phase hook portion are located at the same height in the axial direction, or The projection of the neutral hook portion and the mating hook portion on the peripheral surface of the base body is within the base body, or The orientation of the openings of the phase hook portion and the neutral hook portion is the same; or The projections of the phase hook portion and the neutral hook portion on the end surface of the base body do not overlap. The busbar assembly of claim 9.

11. The first copper bar portion is provided with a terminal connection portion extending in an axial direction, the connection terminal is electrically connected to the terminal connection portion, and the terminal connection portion is provided at a position between the flat portion and the first bent portion in the first copper bar portion. A busbar assembly according to any one of claims 5 to 10.

12. A first positioning hole is provided in the copper bar support frame corresponding to the phase copper bar; A second positioning hole is provided in the copper bar support frame corresponding to the neutral point copper bar. A busbar assembly according to any one of claims 1 to 11.

13. A weight reduction groove is provided in the copper bar support frame along the circumferential direction of the base body; A busbar assembly according to any one of claims 1 to 12.

14. The copper bar support frame is provided with a terminal positioning protrusion, the terminal support frame includes a bracket body, and a third positioning hole is provided in the bracket body; or a reinforcing rib provided on one circumferential side of the connection terminal; or One end of the connection terminal extends outward in the axial direction, and the other end extends inward in the radial direction and is then bent to one side in the circumferential direction, and the other end of the connection terminal is welded to the terminal connection portion of the phase copper bar; A busbar assembly according to any one of claims 1 to 13.

15. The width direction of the phase copper bar body overlaps with the axial direction of the base body, and the width direction is a direction perpendicular to the extension direction of the phase copper bar on the extension plane of the phase copper bar; A busbar assembly according to any one of claims 1 to 14.

16. A rotor structure; a stator structure disposed coaxially with the rotor structure; and a busbar assembly according to any one of claims 1 to 15 provided at one end of the stator structure. Motor structure.

17. The motor structure according to claim 16, Electric power steering system.

18. The car body and A motor structure according to claim 16, which is provided in the vehicle body; and the electric power steering system according to claim 17 provided in the vehicle body. vehicle.

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