阅读说明：本技术 母排、定子总成及发卡电机 (Busbar, stator assembly and hairpin motor ) 是由 廖肖峰 于 2020-04-29 设计创作，主要内容包括：本发明提供一种母排、定子总成及发卡电机,首先将引出线和U、V、W三相铜排预先焊接成一体,然后将星点线、引出线、星点铜排、三相铜排通过塑封成型的方式联成整体。不仅节省了多道工序,有效提升了产品的制作效率和可靠性,而且提高了产品的一致性。同时一体结构的母排,使得后组装工序中的零件数量减少。并有效减少了绕组端部的尺寸；提高了整个结构的刚性,减少了电磁力引发的振动。(The invention provides a bus bar, a stator assembly and a card-issuing motor, which are characterized in that firstly, leading-out wires and U, V, W three-phase copper bars are welded into a whole in advance, and then, a star point wire, the leading-out wires, a star point copper bar and the three-phase copper bars are connected into a whole in a plastic molding mode. Not only saves a plurality of working procedures, effectively improves the manufacturing efficiency and reliability of the product, but also improves the consistency of the product. Meanwhile, the bus bar with an integrated structure reduces the number of parts in the post-assembly process. The size of the winding end part is effectively reduced; the rigidity of the whole structure is improved, and vibration caused by electromagnetic force is reduced.)

1. Female arranging, its characterized in that: comprises four layers of copper bars arranged up and down and lead-out wires connected with the copper bars; an insulation gap is formed between every two adjacent copper bars;

the copper bar comprises a layer of star point copper bar and a layer of phase line copper bar;

wherein the content of the first and second substances,

the number of the star point copper bars is the number of the parallel branches, and the star point copper bars are not connected with each other and are uniformly distributed in the circumference; each star point copper bar is respectively in one-to-one correspondence with one of the parallel branches, and the outgoing line connected with each star point copper bar is a three-phase star point line of the corresponding parallel branch;

each phase line copper bar corresponds to a corresponding phase line one by one, and the outgoing line connected with each phase line copper bar is the corresponding phase line of all parallel branches; and each phase line copper bar is provided with a corresponding connecting terminal.

2. The busbar according to claim 1, wherein: the copper bar and the corresponding outgoing line are welded into a whole; the packaging structure is arranged outside the copper bar and packages the four layers of copper bars into a whole, wherein the connecting wires outside the wiring terminals and the welding area are exposed out of the packaging structure.

3. The busbar according to claim 2, wherein: the packaging structure is a plastic package structure.

4. The busbar according to claim 2, wherein: the star point copper bar is positioned at the lowest layer;

each copper bar is a copper plate with a certain width along the radial direction and a certain thickness along the axial direction, and is arc-shaped along the circumferential direction; defining one side close to the central axis of the circumference as the inner side and one side close to the lower layer as the lower side;

the outgoing line is positioned on the inner side of the copper bar; the lead-out wire includes long straight main part and the tip of bending, the tip welding of bending is on the surface of copper bar.

5. The busbar according to claim 4, wherein: the surface of the copper bar in the axial direction is a plane.

6. The busbar according to claim 4, wherein: the surface of the star point copper bar in the axial direction is a plane; the surface of the phase line copper bar in the axial direction is uneven; the welding position of the outgoing line corresponding to the current phase line copper bar is a concave area, and the area corresponding to the welding position of the outgoing line on the next layer of copper bar is an convex area.

7. The busbar according to claim 4, wherein: the arc length and the position of the copper bar are determined according to the positions of the outgoing lines connected with the copper bar, and two ends of the copper bar are respectively connected with one outgoing line.

8. The busbar according to claim 7, wherein: and the terminal is positioned between the welding points of the two middle outgoing lines on the phase line copper bar.

9. The busbar according to any of claims 4 to 8, wherein: the insulation gap is 1.5 mm.

10. Stator assembly, its characterized in that: a bus bar according to any of claims 2 to 9, located at an end of a stator.

11. Hairpin motor, its characterized in that: having a stator assembly according to claim 10.

Technical Field

The invention relates to a motor, in particular to a card sending motor.

Background

The electric drive system is one of the core parts of the new energy automobile, and has an important influence on the performance of the new energy automobile.

The electric driving system of the electric automobile mainly comprises four parts: the system comprises a driving motor, a speed changer, a power converter and a controller. The driving motor is the core of the electric driving system, the performance and efficiency of the driving motor directly affect the performance of the electric automobile, and the size and weight of the driving motor and the transmission also affect the overall efficiency of the automobile.

Flat wire motors have become well known in the industry as drive motors for electric vehicles. The heat exchanger has the advantages of small volume, material saving, high efficiency, strong heat conduction, low temperature rise, low noise and the like. However, compared with the traditional round wire motor, the flat wire motor has the defects of difficult design, difficult process, complex manufacture of automatic equipment, high welding reliability requirement and large high-frequency loss.

The flat line Hairpin (Hairpin) is an important component in a flat line motor, the outgoing line 3 of the flat line motor comprises three-phase lines and star point lines, as shown in figure 1, the star point lines and the corresponding star point copper bars are welded at the end part of the flat line motor, the star point copper bars are arranged in a mode of surrounding the central shaft of the flat line motor, the outgoing line of the three-phase lines is arranged at the periphery of the star point copper bars, and because multiple paths are connected in parallel, the outgoing line of the three-phase lines adopts a long lead and is manually bent to a specified position, and then is connected with an external power supply system through a welding terminal or other modes. The method has the disadvantages of complicated manual operation, poor consistency, welding work and post-treatment after welding, long consumed working hours and influence on the rapid manufacturing capability and stability of products during implementation.

Disclosure of Invention

The invention aims to provide a busbar, which is used for solving the technical problems of complex processing operation, poor consistency and long time consumption of a lead-out wire in the conventional flat wire motor.

In order to achieve the above purpose, the invention provides the following technical scheme:

the bus bar comprises four layers of copper bars arranged up and down and outgoing lines connected with the copper bars; an insulation gap is formed between every two adjacent copper bars;

the copper bar comprises a layer of star point copper bar and a layer of phase line copper bar;

wherein the content of the first and second substances,

the number of the star point copper bars is the number of the parallel branches, and the star point copper bars are not connected with each other and are uniformly distributed in the circumference; each star point copper bar is respectively in one-to-one correspondence with one of the parallel branches, and the outgoing line connected with each star point copper bar is a three-phase star point line of the corresponding parallel branch;

each phase line copper bar corresponds to a corresponding phase line one by one, and the outgoing line connected with each phase line copper bar is the corresponding phase line of all parallel branches; and each phase line copper bar is provided with a corresponding connecting terminal.

Further, in the invention, the copper bar and the corresponding outgoing line are welded into a whole; the packaging structure is arranged outside the copper bar and packages the four layers of copper bars into a whole, wherein the connecting wires outside the wiring terminals and the welding area are exposed out of the packaging structure.

Further, in the present invention, the package structure is a plastic package structure.

Further, in the invention, the star point copper bar is positioned at the lowest layer;

each copper bar is a copper plate with a certain width along the radial direction and a certain thickness along the axial direction, and is arc-shaped along the circumferential direction; defining one side close to the central axis of the circumference as the inner side and one side close to the lower layer as the lower side;

the outgoing line is positioned on the inner side of the copper bar; the lead-out wire includes long straight main part and the tip of bending, the tip welding of bending is on the surface of copper bar.

Further, in the present invention, the surface of the copper bar in the axial direction is a plane.

Further, in the present invention: the surface of the star point copper bar in the axial direction is a plane; the surface of the phase line copper bar in the axial direction is uneven; the welding position of the outgoing line corresponding to the current phase line copper bar is a concave area, and the area corresponding to the welding position of the outgoing line on the next layer of copper bar is an convex area.

Further, in the invention, the arc length and the position of the copper bar are determined according to the positions of the outgoing lines connected with the copper bar, and two ends of the copper bar are respectively connected with one outgoing line.

Furthermore, in the invention, the terminal is positioned between the welding points of the two middle outgoing lines on the phase line copper bar.

Further, in the present invention, the insulation gap is 1.5 mm.

Another object of the present invention is to provide a stator assembly having the above bus bar, wherein the bus bar is located at an end of the stator.

Another object of the present invention is to provide a hair-pin machine having the above-described stator assembly.

Has the advantages that:

according to the technical scheme, the invention provides a busbar, a stator assembly and a hairpin motor, and relates to a connection method of outgoing lines of motor windings.

Firstly, the outgoing line and the U, V, W three-phase copper bar are welded into a whole in advance, welding and post-processing work of the outgoing line and the wiring terminal are omitted, and then the star point line, the outgoing line, the star point copper bar and the three-phase copper bar are connected into a whole in a plastic molding mode through the method.

The invention has the advantages that:

the step that outgoing lines of the multi-path parallel winding need to be manually bent to the outgoing line position is omitted, and the efficiency in batch manufacturing is effectively improved;

the star point line and the star point copper bar are welded into a whole in advance, so that welding and post-treatment work after wire plugging is omitted, and the efficiency and reliability in batch manufacturing are effectively improved;

by the method, the star point line, the outgoing line, the star point copper bar and the three-phase copper bar are connected into a whole in advance in a plastic package forming mode, so that a plurality of subsequent procedures of star point welding, outgoing line bending, outgoing line and outgoing line terminal welding, outgoing line fixing, welding position insulation processing and the like are omitted, the manufacturing efficiency and reliability of products are effectively improved, and the consistency of the products is improved; the number of parts in the post-assembly process is reduced, and the size of the winding end part is effectively reduced; the rigidity of the whole structure is improved, and vibration caused by electromagnetic force is reduced.

It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of this disclosure unless such concepts are mutually inconsistent.

The foregoing and other aspects, embodiments and features of the present teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of specific embodiments in accordance with the teachings of the present invention.

Drawings

The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic structural view of an end of a conventional flat wire motor;

FIG. 2 is a schematic structural diagram of a structure in which star points of 4 parallel branches are welded with corresponding star point copper bars;

FIG. 3 is a schematic structural view of 4U-phase lead-out wires and a U-phase copper bar welded together;

FIG. 4 is a schematic structural diagram of 4V-phase lead-out wires and a V-phase copper bar welded together;

FIG. 5 is a schematic structural diagram of 4W-phase lead-out wires and a W-phase copper bar welded together;

FIG. 6 is a structural schematic diagram of relative positions of U, V, W three-phase copper bars;

FIG. 7 is a schematic structural diagram of relative positions of U, V, W three-phase copper bars and 4 star point copper bars;

fig. 8 is an appearance schematic diagram of a bus bar formed by plastic-molding U, V, W three-phase copper bars and 4 star point copper bars.

FIG. 9 is an external view of the stator assembly of the motor;

fig. 10 is an appearance diagram of the bus bar after final molding in the motor stator assembly.

In the figures, the meaning of the reference numerals is as follows:

the device comprises an outgoing line terminal 1, a star point copper bar 2, an outgoing line 3 and a positioning hole 4.

Detailed Description

In order to better understand the technical content of the present invention, specific embodiments are described below with reference to the accompanying drawings.

In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in greater detail below, may be implemented in any of numerous ways, as the disclosed concepts and embodiments are not limited to any one implementation. In addition, some aspects of the present disclosure may be used alone, or in any suitable combination with other aspects of the present disclosure.

Because the number of the outgoing lines 3 at the end part of the hairpin motor in the prior art is large, a plurality of procedures such as star point welding, outgoing line bending, outgoing line and outgoing line terminal welding, outgoing line fixing, welding position insulation processing and the like are required in the production process, and as shown in fig. 1, the process is complex and the consistency is poor.

For the above reasons, the embodiment of the present invention provides a busbar, which reduces unnecessary bending processes by changing the structure, and prepares the busbar as an independent part in advance, as shown in fig. 9, the busbar structure according to the embodiment of the present invention can be directly fixed to a stator core when needed, and does not need to rely on the stator core for busbar preparation.

Next, a specific structure of the busbar will be described.

The busbar shown in fig. 7 comprises four layers of copper bars arranged up and down and outgoing lines connected with the copper bars; and an insulation gap is formed between adjacent copper bars, and the insulation gap is preferably 1.5 mm.

The copper bar comprises a layer of star point copper bar and a layer of phase line copper bar.

Wherein the content of the first and second substances,

as shown in fig. 2-3, the schematic diagram of the star point copper bar is shown. The number of the star point copper bars is the number of the parallel branches, and as shown in fig. 2, 4 star point copper bars are arranged when 4 paths are connected in parallel. The star point copper bars are not connected with each other and are uniformly distributed in the circumference; each star point copper bar is in one-to-one correspondence with one of the parallel branches, and the outgoing line connected with each star point copper bar is a three-phase star point line of the corresponding parallel branch, as shown in fig. 2, 3 outgoing lines are connected with each star point copper bar, and are three-phase star point lines respectively.

Fig. 4-6 are schematic diagrams of the phase line copper bar. Each phase line copper bar corresponds to a corresponding phase line one by one, and the outgoing line connected with each phase line copper bar is the corresponding phase line of all parallel branches; and each phase line copper bar is provided with a corresponding connecting terminal. Taking fig. 4 as an example, the U-phase copper bar is correspondingly connected to the 4U-phase lead-out lines, and the U-phase copper bar is provided with a U-phase wiring terminal.

Preferably, the outgoing line 3 and the copper bar are integrated in a welding mode.

Above-mentioned structure compares in traditional hairpin motor's end structure, has increased 3 looks line copper bars to be vertical range with the star point line copper bar, practiced thrift radial space, and because the lead-out wire 3 of phase line is located the inside of copper bar, can be so that the lead-out wire 3 of phase line need not bend again and directly be connected with the phase line copper bar, avoided loaded down with trivial details manual operation and inconsistent problem.

Further, in order to form an independent structure for the busbar, a packaging structure is arranged outside the copper bar, and preferably, the plastic packaging structure or the whole is formed in a paint dipping mode. The packaging structure packages the four layers of copper bars into a whole, wherein the connecting wires outside the connecting terminals and the welding area are exposed out of the packaging structure.

Therefore, the independent busbar is obtained and used as an independent accessory, the rigidity of the whole motor structure is improved, and the integral end structure can reduce vibration caused by electromagnetic force.

With the above basic structure, the embodiments of the present invention also provide the following more detailed designs.

Regarding the sequence of the 4 copper bars, the specific embodiment of the present invention is not limited.

The star point copper bar is positioned at the lowest layer as an example for specific explanation.

As shown in the figure, each copper bar is a copper plate with a certain width along the radial direction and a certain thickness along the axial direction, and is arc-shaped along the circumferential direction. Defining one side close to the central axis of the circumference as the inner side and one side close to the lower layer as the lower side; the outgoing line is positioned on the inner side of the copper bar; the lead-out wire includes long straight main part and the tip of bending, the tip welding of bending is on the surface of copper bar.

The outgoing line is welded on the upper surface or the lower surface of the copper bar. The lead-out wire shown in the figure is welded on the upper surface of the copper bar for example.

Whether or not the surface of the copper bar in the axial direction is flat is not particularly limited.

In the embodiment shown in fig. 2, the surface of the copper row of the star point line in the axial direction is a plane. But the surface of the phase line copper bar in the axial direction is uneven; the welding position of the outgoing line corresponding to the current phase line copper bar is a concave area, and the area corresponding to the welding position of the outgoing line on the next layer of copper bar is an convex area.

Above-mentioned unevenness's design is mainly considered from practicing thrift axial space angle, under the prerequisite of guaranteeing the insulating clearance, compresses the height value that accumulates in the axial between lead-out wire and the copper bar as far as possible.

In the circumferential direction, the arc length and the position of the copper bar are determined according to the positions of the outgoing lines connected with the copper bar, and two ends of the copper bar are respectively connected with one outgoing line. Therefore, the specific structure and position of the copper bar need to be carried out according to the position of the outgoing line, as shown in fig. 2 and 7, the overall structure schematic diagram of the star point line copper bar and the overall structure schematic diagram of the phase line copper bar are respectively shown, 4 star point line copper bars are located on the same circumference, and 3 phase line copper bars are vertically arranged and are circumferentially staggered due to the specific position distribution of each phase line.

And finally, the terminal is positioned between the welding points of the two middle outgoing lines on the phase line copper bar, and the current enters the copper bar from the terminal and then enters each phase line.

Secondly, the material and the thickness of the copper bar are determined by considering the magnitude of the load current, and the copper bar can be obtained by combining target parameters according to the prior art.

As shown in fig. 9 and 10, the molded busbar is mounted on the end of the stator to form a stator assembly. The bus bar is provided with a necessary positioning area, such as a positioning hole 4 shown in fig. 10, for accurately positioning the bus bar and the stator core.

At the other end of the stator core, the lead wires 3 are bent as necessary and connected to other hairpins so that the entire stator core circuit is designed in a three-phase four-path manner.

The card-issuing motor with the stator assembly not only saves a plurality of working procedures, effectively improves the manufacturing efficiency and reliability of products, but also improves the consistency of the products. Meanwhile, the bus bar with an integrated structure reduces the number of parts in the post-assembly process. And the bus bar is arranged at the outer circle position of the end part, and the axial size is reduced by reasonably utilizing the radial surplus space.

All the wires form a whole in a plastic package or paint dipping mode and the like, when the wires are subjected to external force or electromagnetic force, the whole is stressed, and all the wires in the manual bending structure are mutually independent. Therefore, in the hair pin motor of the present invention, rigidity is improved.

On the other hand, in the motor use, the vibration that the electromagnetic force arouses generally exists in adjacent copper bar or copper line inter attraction, friction and brings, and the female arranging of this patent does not have the gap each other after whole plastic envelope or dip coating, forms a whole, consequently the vibration that the reduction electromagnetic force that can be obvious arouses.

Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention should be determined by the appended claims.