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 "Busbar assembly, motor structure, electric power steering system, and vehicle," filed with the State Intellectual Property Administration of China on July 22, 2022, the Chinese patent application bearing application number "202221904223.7" and title "Busbar assembly, motor structure, electric power steering system, and vehicle," the Chinese patent application bearing application number "202210867171.9" and title "Busbar assembly, motor structure, electric power steering system, and vehicle," and the Chinese patent application bearing application number "202221899908.7" and title "Busbar 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 busbar assemblies, motor structures, electric power steering systems, and vehicles. [Background technology]

[0003] Currently, with the rapid development of automobiles, especially new energy automobile technology, electric drive systems are gradually moving in the direction of higher speed, smaller size, and higher efficiency. At the same time, vehicles are placing higher requirements on the cost and performance of electric drive systems, so motor assemblies are gradually developing in the direction of smaller size, lighter weight, and integration. EPS (Electric Power Steering) brushless motors are becoming increasingly 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 bus bars for conventional EPS motors, there are usually copper bars of various shapes within the same bus bar, which requires designing individual molds for each type of copper bar, increasing 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 circumstances, an embodiment of a first aspect 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 circumferentially around 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 having the same shape, the plurality of neutral copper bars having the same shape, the neutral copper bars including a neutral copper bar body extending radially of the base body, the phase copper bars including a phase copper bar body extending axially 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 solution, the neutral copper bar specifically includes an arc-shaped neutral copper bar body, a plurality of transition bending portions arranged radially outside the neutral copper bar body and formed by bending the neutral copper bar body along the axial direction, and neutral hook portions connected to the transition bending portions.

[0014] In the above technical proposal, the 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, and 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 the 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 the 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 copper bars are distributed circumferentially around the axis and stacked, and of two adjacent copper bars, the flat portion of one copper bar covers the second copper bar portion of the other 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 flat 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 solution, 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 solution, the openings of all the 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 provided coaxially with the rotor structure, and the 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 above technical solutions.

[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. [Effects 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 only two types of molds are needed for production 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, and in part will be apparent from or may be learned by practice of the present application. [Brief explanation of the drawings]

[0030] [Figure 1] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present invention; [Figure 2] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present invention; [Figure 3] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present invention; [Figure 4] 1 is a structural schematic diagram of a busbar assembly according to an embodiment of the present invention; [Figure 5] 1A and 1B are structural schematic diagrams of a terminal support frame and a connection terminal according to an embodiment of the present invention; [Figure 6] 1 shows a schematic diagram of a stacked structure of multiple phase copper bars according to one embodiment of the present application; [Figure 7] 1 is a schematic diagram showing a laminated structure of a copper bar according to an embodiment of the present application. [Figure 8] 1 shows a structural schematic diagram of a plurality of neutral copper bars according to an embodiment of the present application; [Figure 9] 1 shows a structural schematic diagram of a neutral point copper bar according to an embodiment of the present application. [Figure 10] 1 is a structural schematic diagram of a motor structure according to an embodiment of the present invention; [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 structural schematic diagram of a vehicle according to an embodiment of the present invention; [Figure 13] 1 is a structural schematic diagram of a vehicle according to an embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0031] In order to more clearly understand the above-mentioned 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 examples. 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 phase copper bars 104, neutral copper bars 106, and a copper bar support frame 1022. The copper bar support frame 1022 is formed when the phase copper bars 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 bars and the neutral copper bars, providing integral fixing and insulation. Multiple copper bars are provided, specifically including the phase copper bars 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 multiple connection terminals 1082 that can be easily connected to an external power source or controller, thereby controlling the motor connected to the busbar assembly 100.

[0035] However, for all copper bars, in this application, all neutral copper bars 106 have the same shape, and all phase copper bars 104 have the same shape, so that during production, only two types of molds are needed to produce all phase copper bars 104 and neutral copper bars 106. It can be understood that one type of mold is used for all phase copper bars 104, and another type of mold is used for all neutral copper bars 106. Assembly can be achieved by simply arranging the neutral copper bars 106 individually and stacking the phase copper bars 104 in a staggered manner, which greatly reduces the development and production costs of the molds required for production.

[0036] When attaching the two types of copper bars to the copper bar support frame 1022, there must be some overlapping 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 by restricting the arrangement direction of the phase copper bar body 1041, 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. Furthermore, the width direction is further defined, and the phase copper bar 104 has a plate-like structure, 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] Furthermore, 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 risk of NVH (i.e., noise, vibration, and harshness) in an automobile structure for 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 generally in direct contact with each other.

[0040] After the phase copper bar 104 and the neutral copper bar 106 are attached to the base body 102, that is, after the phase copper bar and the neutral copper bar are integrally injection molded to form the 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 multiple connection terminals are further provided on the terminal support frame. After the multiple stator windings are joined, electrical connection with an external structure can be achieved through the connection terminals.

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

[0043] By restricting the arrangement of the neutral copper bar 106 and the phase copper bar 104, the neutral copper bar 106 has a main structure of a neutral copper bar body 1062 extending radially, and the phase copper bar 104 has a main structure of a phase copper bar body 1041 extending axially, and by adopting a mutually perpendicular arrangement form, the axial and radial dimensions of the copper bars can be minimized. In other words, the phase copper bar body is arranged vertically within the base body, and the neutral copper bar body is arranged horizontally within the base body.

[0044] The terminal support frame mainly includes a bracket body 1084 and three connecting terminals 1082. The connecting terminals 1082 are fixed to the bracket body 1084, and then injection molding is performed to finally form the terminal support frame. The copper bars 104 and the connecting terminals 1082 are electrically conductive, so that the terminal support frame is electrically connected to the three copper bars 104 simultaneously, thereby realizing a modular 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. In other words, 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, and each set corresponds to one terminal support frame, i.e., each terminal support frame includes three connection terminals, thereby being 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 about the axis. The number of neutral copper bars 106 may be either 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 phase copper bars 104, neutral copper bars 106, and a copper bar support frame 1022. The copper bar support frame 1022 is formed when the phase copper bars 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 bars and the neutral copper bars, providing integral fixing and insulation. Multiple copper bars are provided, specifically including the phase copper bars 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 multiple connection terminals 1082 that can be easily connected to an external power source or controller, thereby controlling 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, the neutral copper bar body 1062 extending in the radial direction, the transition bends 1064 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.

[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 it is easy to observe whether there are any welding or winding leaks.

[0051] The above-mentioned structures allow the use of a single plate-shaped substrate, which can be formed through multiple punching and bending processes, thereby improving yield and reducing material loss.

[0052] 7, the copper bar body 1041 mainly includes three radially offset copper bar sections: a first copper bar section 1042, a second copper bar section 1044, and a third copper bar section 1046. The three copper bar sections are connected in sequence, with the offset between adjacent copper bar sections being achieved by bent sections. Specifically, the first copper bar section 1042 and the second copper bar section 1044 are connected via a first bent section 1043, and the second copper bar section 1044 and the third copper bar section 1046 are connected via a second bent section 1045. The first bent section 1043 and the second bent section 1045 ensure that the first copper bar section 1042, the second copper bar section 1044, and the third copper bar section 1046 are radially offset. This ensures that there is no mutual positional interference when multiple copper bars 104 are stacked, thereby achieving a normal current 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, or 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, and the flat portion of phase copper bar 1 covers the second copper bar portion 1044 of phase copper bar 2, and the flat portion of phase copper bar 2 covers 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 portions are the same, that is, the three first copper bar portions 1042 are on the same circumferential surface. Similarly, the radial positions of the three second copper bar portions 1044 are also the same, and the radial positions of the three third copper bar portions 1046 are also the same, that is, after stacking and arrangement, the radial positions of the first copper bar portion 1042, second copper bar portion 1044 and third copper bar portion 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. The vertical arrangement of both facilitates injection molding.

[0058] Two phase hook portions 1052 are provided for each phase copper bar 104, 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, i.e., the projections of the two hook portions onto the circumferential 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, thereby reducing unnecessary axial dimensions.

[0060] Furthermore, the heights of the hook portions of the two copper bars are the same, i.e., the axial positions of the neutral hook portion 1066 and the phase hook portion 1052 are kept the same. Therefore, when performing winding welding, the winding welding process for the entire busbar can be achieved 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 phase copper bars 104, neutral copper bars 106 and a copper bar support frame 1022. The copper bar support frame 1022 is formed when the phase copper bars 104 and the neutral copper bar 106 are injection molded. After injection molding is completed, the copper bar support frame serves as a plastic case for the phase copper bars and the neutral copper bars, providing integral fixing and insulation. Multiple copper bars are provided, specifically including the phase copper bars 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 multiple connection terminals 1082 that can be easily connected to an external power source or controller, thereby controlling 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. The neutral copper bar body 1062 extends radially, and the transition bends 1064 are formed by bending the neutral copper bar body 1062 radially outward along the axis, i.e., bending the transition bends upward from the outside. A neutral hook portion 1066 is provided at 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] 7, each copper bar 104 includes three parts: a first copper bar part 1042, a second copper bar part 1044, and a third copper bar part 1046. The three copper bar parts are connected in sequence, and the offset between adjacent two copper bar parts is achieved by a bend. Specifically, the first copper bar part 1042 and the second copper bar part 1044 are connected via a first bend 1043, and the second copper bar part 1044 and the third copper bar part 1046 are connected via a second bend 1045. The first bend 1043 and the second bend 1045 allow the first copper bar part 1042, the second copper bar part 1044, and the third copper bar part 1046 to be radially offset. This ensures that when multiple copper bars 104 are stacked, there is no mutual interference, thereby achieving a normal current flow.

[0064] Furthermore, 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 to the injection molding tooling during installation, thereby achieving 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 the 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 connection portions 1048.

[0068] After the three phase copper bars 104 are stacked, a terminal support frame is directly attached to the three terminal connection portions 1048, thereby transmitting electrical signals from the three phase copper bars 104 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 away 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 horizontal 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 further, a phase hook portion 1052 is provided at the other end of the flat portion 1050, i.e., the end away 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 a phase hook portion 1052 at the other end of the flat portion 1050, that is, the end away from the terminal connection portion 1048, the winding can be easily welded to the phase hook portion 1052.

[0071] It will be understood 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 applying to 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 the phase copper bar 104, and a second positioning hole 1184 at a position opposite 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 achieving 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, facilitating the subsequent assembly with the base body 102 and terminals.

[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] As shown in Figure 4, the terminal support frame 108 mainly includes a bracket body 1084 and three connecting terminals 1082. The terminal support frame 108 can be formed by integrally injection molding the three connecting terminals 1082 with the bracket body 1084. The copper bars 104 and the connecting terminals 1082 are electrically conductive, allowing the terminal support frame 108 to be electrically connected to the three copper bars 104 simultaneously, thereby realizing a modular conductive relationship.

[0077] Furthermore, by providing the third positioning holes 1088 in the bracket body 1084, the terminal support frame 108 can be assembled by fitting the terminal positioning protrusions 1222 shown in FIG.

[0078] Furthermore, as shown in FIG. 4, by providing a reinforcing rib 1090 in the circumferential direction of the connection terminal, not only the strength is improved but also the stability of the terminal assembly is improved, and deformation and displacement during assembly can be avoided.

[0079] Furthermore, the extension direction of the connection terminal is restricted to the axial direction, so that the connection terminal is disposed within the bracket body and then connected to an external power supply or a circuit board in the axial direction. Furthermore, one end of the connection terminal extends axially, and the other end extends radially inward and is then bent laterally. After bending, the terminal connection portion 1048 of the copper bar 104 is welded, thereby establishing electrical continuity.

[0080] 10, the motor structure 200 according to this 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, forming a motor structure 200 with the stator on the outside and the rotor on the inside, in which a changed magnetic field is generated under the action of the inner stator structure 204, thereby rotating 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 redundant description will be omitted here.

[0082] As shown in FIG. 11, this embodiment provides an electric power steering system 400, which includes the motor structure 200 of any of the above possible embodiments, so that the electric power steering system 400 of this embodiment has all the beneficial effects of the motor structure 200 of 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 to 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, and most models of modern vehicles are basically equipped with EPS systems.

[0084] The electric power steering system 400 may have various possible forms. One of the various possible forms will be specifically described below. Specifically, in one possible form, 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 when the driver operates the steering wheel. The assist torque reduces the burden on the driver.

[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 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 the detection signal from 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 423.

[0087] As shown in FIG. 12, the vehicle 300 of this embodiment includes a vehicle body 302 and a motor structure 200 provided within the vehicle body 302. The vehicle body 302 mainly provides a certain protective effect to the motor structure 200, and since the motor structure 200 is provided within the vehicle body 302, it has the beneficial effects of any of the motor structures of the above-mentioned second aspect of the embodiment, and redundant explanations will be omitted here.

[0088] The motor structure of the vehicle may be the main drive structure of an electric vehicle or the like, or 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] In the busbar assembly, motor structure, electric power steering system, and vehicle according to the present application, all neutral copper bars have the same shape, and all phase copper bars also have the same shape. Therefore, during production, only two types of molds need to be designed 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 expressly limited otherwise. Terms such as "attach," "coupled," "connected," and "fixed" should be understood broadly; for example, "connected" may mean fixed connection, detachable connection, or integral connection. "Coupled" may mean direct connection or indirect connection via an intermediate medium. Those skilled in the art can understand the specific meanings of the above terms in this application according to the specific circumstances.

[0092] In the description of this application, the orientations or positional relationships indicated by terms such as "upper," "lower," "left," "right," "front," and "rear" 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 referred-to devices or units have a particular direction or must be constructed or operate in a particular orientation. Therefore, they should not be understood as limiting this application.

[0093] In the description herein, the use of terms 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. Exemplary references to such terms herein do not necessarily refer to the same embodiment or example. Furthermore, the described particular features, structures, materials, or characteristics 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 variations to the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application shall fall within the protection scope of the present application. [Explanation of symbols]

[0095] The correspondence between the reference numerals and the names of the members in FIGS. 1 to 13 is as follows:

[0096] 100 Busbar Assembly 102 Base body 1022 Copper Bar Support Frame 104 Phase Copper Bar 1041 Copper bar body 1042 First Copper Bar Section 1043 First bending part 1044 Second Copper Bar Section 1045 Second bending part 1046 Third Copper Bar Section 1048 Terminal connection part 1050 Plane section 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 Third 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 plurality of phase copper bars and the plurality of neutral copper bars being arranged in the circumferential direction of the copper bar support frame; a terminal support frame provided on the base body and including a plurality of connection terminals connected to the phase copper bars; A plurality of the phase copper bars have the same shape, a plurality of the neutral copper bars have the same shape, the neutral copper bar includes 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 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, The copper bar body includes a first copper bar portion, a second copper bar portion, and a third copper bar portion that 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, 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. 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 symmetrical 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 has an arc shape; A plurality of transition bent portions are provided radially outward of the neutral point copper bar body and are formed by bending the neutral point 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 bars are distributed in the circumferential direction around the axis and stacked in groups of three, and of two adjacent copper bars, the planar portion of one copper bar covers the second copper bar portion of the other copper bar. The busbar assembly according to claim 3 .

5. In the three stacked copper bars, the radial positions of the first copper bar portions of the three copper bars are the same, the radial positions of the second copper bar portions of the three copper bars are the same, and the radial positions of the third copper bar portions of the three copper bars are the same. The busbar assembly according to claim 4 .

6. 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 according to claim 5 .

7. 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 flat portion and the third copper bar portion, respectively. The busbar assembly according to claim 3 .

8. 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 radially inward 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 openings of the phase hook portion and the neutral hook portion have the same orientation, 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 according to claim 7.

9. a terminal connection portion extending in an axial direction is provided on the first copper bar portion, 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 on the first copper bar portion; The busbar assembly of claim 1 .

10. A first positioning hole provided in the copper bar support frame corresponding to the phase copper bar; and a second positioning hole provided in the copper bar support frame corresponding to the neutral point copper bar. The busbar assembly of claim 1 .

11. A weight reduction groove is provided in the copper bar support frame along the circumferential direction of the base body; The busbar assembly of claim 1 .

12. 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. The busbar assembly of claim 1 .

13. 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; The busbar assembly of claim 1 .

14. a rotor structure; a stator structure disposed coaxially with the rotor structure; the busbar assembly of claim 1 provided at one end of the stator structure. Motor structure.

15. 15. A motor structure comprising: Electric power steering system.

16. The car body and A motor structure according to claim 14, which is provided in the vehicle body; and the electric power steering system according to claim 15 provided in the vehicle body. vehicle.

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