CN112242764A - Lead frame for hub motor - Google Patents

Abstract

The invention relates to the field of lead frames, and discloses a lead frame for an in-wheel motor, which comprises a printed circuit board with a plurality of circuit board layers, wherein a first circuit board layer is electrically coupled to a first coil winding of a first group of coil windings and a first branch of a first inverter; the second circuit board layer is arranged to be electrically coupled to a second coil winding of the first set of coil windings and a second leg of the first inverter; a third circuit board layer is arranged to be electrically coupled to a third coil winding of the first set of coil windings and a third leg of the first inverter; the fourth circuit board layer is configured to couple with the first, second, and third coil windings of the first set of coil windings to form a neutral point between the first, second, and third coil windings. The lead frame is capable of providing a large current between the inverter and the coil winding of the motor or generator, thereby generating large torque and power values and saving space.

Description

Lead frame for hub motor

Technical Field

The invention relates to the field of lead frames of generators or motors, in particular to a lead frame for a hub motor.

Background

The motor system typically comprises an electric motor, the control unit of which is arranged to control the power of the electric motor. Known motor types include induction motors, synchronous brushless permanent magnet motors, switched reluctance motors, and linear motors. Since driving a vehicle requires high torque, the most common electric motor is a three-phase motor. A three-phase motor typically includes three coil windings, where each coil winding is arranged to generate a magnetic field associated with one of the three phases of the alternating voltage. In order to increase the number of magnetic poles formed in the machine, each coil winding typically has a number of coil sub-sets distributed around the machine, which coil sub-sets are driven to generate a rotating magnetic field. Chinese patent CN201710715959.7 provides a three-phase permanent magnet brushless dc hub motor.

As shown in fig. 1, a typical three-phase motor has three coil sets 14, 16, 18. Each coil set consists of four coil sub-sets connected in series, wherein the magnetic fields generated by the coil sub-sets will have a common phase for a given coil set. The three coil sets of a three-phase motor are typically arranged in a delta or star configuration. A control unit for a three-phase motor having a dc power supply typically includes an inverter-driven motor in which a three-phase bridge generates three-phase power. Each respective voltage phase is applied to a respective coil set of the motor. A three-phase bridge inverter includes a number of switching devices, such as power electronic switches, such as Insulated Gate Bipolar Transistor (IGBT) switches, for generating an alternating voltage from a direct current power source. In the context of electric vehicle motors, an increasingly popular drive design is one that is integrated within the wheel of the vehicle into which the motor and its associated control system are integrated. However, this may have an impact on the electric motor's power generation capability due to space constraints within the vehicle wheel into which the electric motor and its associated control system are integrated. The invention provides a motor lead frame capable of supplying large current.

Disclosure of Invention

The invention provides a lead frame for a hub motor, which is used for overcoming the defects that the space of the existing hub motor is limited and larger current cannot be supplied.

In order to solve the technical problem, the invention is solved by the following technical scheme:

a lead frame for an in-wheel motor for electrically coupling a first inverter having a plurality of inverter legs to a first set of coil windings of an engine or generator, the lead frame comprising a printed circuit board having a plurality of circuit board layers, each circuit board layer comprising a dielectric substrate; a conductive layer is formed on the insulating substrate; the printed circuit board is at least provided with a first circuit board layer, a second circuit board layer, a third circuit board layer and a fourth circuit board layer; the first circuit board layer includes a first conductive layer arranged to electrically couple to a first coil winding of the first set of coil windings and a first leg of the first inverter; the second circuit board layer includes a second conductive layer arranged to electrically couple to a second coil winding of the first set of coil windings and a second leg of the first inverter; the third circuit board layer includes a third conductive layer arranged to electrically couple to a third coil winding of the first set of coil windings and a third leg of the first inverter; the fourth circuit board layer includes a fourth conductive layer configured to couple with the first, second, and third coil windings of the first set of coil windings to form a neutral point between the first, second, and third coil windings.

Preferably, the first coil winding, the second coil winding and the third coil winding each comprise three coil sub-groups, namely a first phase winding, a second phase winding and a third phase winding; the printed circuit board further comprises a fifth circuit board layer having a plurality of conductive layers arranged to electrically couple the first, second and third phase windings of the first, second and third coil windings; the first, second and third phase windings each comprise a plurality of coils, and the plurality of conductive layers on the fifth circuit board are arranged to allow the plurality of coils for each respective phase winding to be coupled relative to each other such that each coil sub-set coil generates a magnetic field that is anti-parallel to an adjacent coil in a given current direction while having a common phase.

Preferably, the printed circuit board is circumferential.

Preferably, the first circuit board layer comprises a first conductive layer mirror layer arranged to be coupled to a first coil winding of the second set of coil windings and to a first branch of the second inverter; the second circuit board layer comprises a second conductive layer mirror layer arranged to be coupled to the second coil windings of the second set of coil windings and the second leg of the second inverter, the third circuit board layer comprises a third conductive layer mirror layer arranged to be coupled to the third coil windings of the second set of coil windings and the third leg of the second inverter; the fourth circuit board layer includes a fourth conductive layer mirror layer having a plurality of conductive layers, the eighth conductive layer being configured to couple with the first, second, and third coil windings of the second set of coil windings to form a neutral point between the first, second, and third coil windings of the second set of coil windings.

Preferably, the first conductive layer and the first conductive layer mirror image layer are electrically isolated from each other and located on different areas on the first circuit board layer, the second conductive layer and the second conductive layer mirror image layer are electrically isolated from each other and located on different areas on the second circuit board layer, and the third conductive layer mirror image layer are electrically isolated from each other and located on different areas on the third circuit board layer; the fourth conductive layer and the fourth conductive layer mirror layer are electrically isolated from each other and located on different areas of the fourth circuit board layer.

Preferably, the printed board further includes a sixth circuit board layer including a ninth conductive layer, the sixth circuit board layer and the first circuit board layer function the same; the seventh circuit board layer comprises a tenth conducting layer, and the ground circuit board layer and the second circuit board layer have the same function; the first circuit board layer comprises an eleventh conducting layer, and the function of the first circuit board layer is the same as that of the third circuit board layer; the circuit board further comprises a ninth circuit board layer, the ninth circuit board layer comprises a twelfth conducting layer, and the ninth circuit board layer and the fourth circuit board layer have the same function.

Preferably, the printed circuit board further includes a tenth circuit board layer including a plurality of conductive layers, the tenth circuit board layer functioning as the same as the fifth circuit board layer.

Preferably, the printed circuit board comprises a plurality of recesses formed in the inner and outer edges of the printed circuit board, each recess being arranged to receive a respective coil winding for electrically coupling the coil windings to the printed circuit board.

Preferably, the printed circuit board comprises means for positioning said lead frame in a predetermined position on the stator of the motor or generator.

The invention also provides a motor or generator, the circumferential support comprises a plurality of teeth formed on the circumferential support, wherein the coil winding is arranged on the plurality of teeth, the lead frame is arranged on the circumferential support, and the coil winding is connected to the lead frame to form a star connection; the lead frame is mounted on the circumferential support adjacent the coil windings.

Due to the adoption of the technical scheme, the invention has the remarkable technical effects that:

the lead frame is allowed to provide high currents between the inverter and coil windings of the motor or generator, thereby producing large torque and power values, while allowing the space envelope of the motor/generator and inverter to be reduced.

Drawings

FIG. 1 illustrates a prior art three-phase motor;

FIG. 2 illustrates an exploded view of an electric machine incorporating the present invention;

FIG. 3 is a schematic diagram of a control device;

FIG. 4 illustrates electrical connections provided by a lead frame according to an embodiment of the present invention;

FIG. 5 illustrates a lead frame according to an embodiment of the present invention;

FIG. 6 illustrates a lead frame arrangement according to an embodiment of the present invention;

FIG. 7 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

FIG. 8 illustrates a lead frame according to an embodiment of the present invention;

FIG. 9 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

FIG. 10 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

fig. 11 illustrates a conductive layer on a circuit board layer of a leadframe according to an embodiment of the invention.

FIG. 12 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

FIG. 13 shows a lead frame according to an embodiment of the present invention;

fig. 14 is a schematic structural view of a stator coil winding and a stator core;

fig. 15 is an exploded view of the stator coil winding unit and the stator core.

Detailed Description

Example 1

The present embodiment provides a lead frame for coupling an inverter of a motor or a generator to a direct current power supply; the lead frame includes a printed circuit board having a plurality of circuit board layers, each circuit board layer including an insulating substrate; a conductive layer is formed on the insulating substrate; the printed circuit board is at least provided with a first circuit board layer, a second circuit board layer, a third circuit board layer and a fourth circuit board layer; the first circuit board layer includes a first conductive layer arranged to electrically couple to a first coil winding of the first set of coil windings and a first leg of the first inverter; the second circuit board layer includes a second conductive layer arranged to electrically couple to a second coil winding of the first set of coil windings and a second leg of the first inverter; the third circuit board layer includes a third conductive layer arranged to electrically couple to a third coil winding of the first set of coil windings and a third leg of the first inverter; the fourth circuit board layer includes a fourth conductive layer having a plurality of conductive layers, the fourth conductive layer configured to couple with the first, second, and third coil windings of the first set of coil windings to form a neutral point between the first, second, and third coil windings.

The first coil winding, the second coil winding and the third coil winding respectively comprise three coil sub-groups, namely a first phase winding, a second phase winding and a third phase winding; the printed circuit board further comprises a fifth circuit board layer having a plurality of conductive layers arranged to electrically couple the first, second and third phase windings of the first, second and third coil windings; the first, second and third phase windings each comprise a plurality of coils, and the plurality of conductive layers on the fifth circuit board are arranged to allow the plurality of coils for each respective phase winding to be coupled relative to each other such that each coil sub-set coil generates a magnetic field that is anti-parallel to an adjacent coil in a given current direction while having a common phase. The printed circuit board is circumferential, and the printed circuit board is coupled with two inverters to constitute two groups of sub-motors, and each group of sub-motors comprises three sub-motors.

The first circuit board layer comprises a first conductive layer mirror layer arranged to be coupled to a first coil winding of the second set of coil windings and to a first branch of the second inverter; the second circuit board layer comprises a second conductive layer mirror layer arranged to be coupled to the second coil windings of the second set of coil windings and the second leg of the second inverter, the third circuit board layer comprises a third conductive layer mirror layer arranged to be coupled to the third coil windings of the second set of coil windings and the third leg of the second inverter; the fourth circuit board layer includes a fourth conductive layer mirror layer having a plurality of conductive layers, the eighth conductive layer being configured to couple with the first, second, and third coil windings of the second set of coil windings to form a neutral point between the first, second, and third coil windings of the second set of coil windings.

The first conductive layer and the first conductive layer mirror layer are electrically isolated from each other and located on different areas on the first circuit board layer, the second conductive layer and the second conductive layer mirror layer are electrically isolated from each other and located on different areas on the second circuit board layer, and the third conductive layer mirror layer are electrically isolated from each other and located on different areas on the third circuit board layer; the fourth conductive layer and the fourth conductive layer mirror layer are electrically isolated from each other and located on different areas of the fourth circuit board layer. The fifth circuit board layer also has two parts of the same conductive layer, one part is used for being electrically connected with the first group of winding coils and the first inverter, and the other part is used for being connected with the second inverter and the second group of winding coils.

The electric motor in this embodiment is specifically an in-wheel motor for a wheel of an automobile. The motor includes at least one set of coils as part of a stator that is radially surrounded by a rotor that carries a set of magnets attached to the wheel. For the avoidance of doubt, the various aspects of the invention are equally applicable to generators having the same arrangement. Accordingly, the definition of electric motor is intended to include electric generators.

As shown in fig. 2, the in-wheel motor includes a stator 252, the stator 252 includes a circumferential bracket 253 as a heat sink, a plurality of coils 254, and two control devices 300, not shown, which are mounted on the circumferential bracket 253 at the rear of the stator for driving the coils. The capacitor and lead frame 255, as described below, is mounted between an axial edge of the coil 254 and an axial flange formed on the circumferential support 253 for connecting a control device to the coil 254. The coils 254 are embedded on the stator teeth 800 to form a coil assembly 60; the stator comprises a circumferential supporting piece and a stator winding arranged on the circumferential supporting piece, the circumferential supporting piece is a stator core 600, the stator winding is composed of stator winding units 550, the stator winding units 550 are teeth wound with coils, each tooth is provided with a tooth socket 801, the outer circumference of the circumferential supporting piece is provided with stator teeth 800, and the tooth sockets 801 are inserted into the stator teeth 800 in an interference mode. The number of stator winding units 550 in this embodiment is 54 because there are 2 sets of coil windings, each set of coil windings including 3 coil windings, each coil winding including 3 coil phase windings (subsets), each coil phase winding including 3 coils. A stator can is mounted to the rear of the stator 252, surrounds the control device and the annular capacitor to form the stator 252, and is then secured to the vehicle and does not rotate relative to the vehicle during use.

As shown in fig. 3, each control device 300 includes one inverter 310, wherein one control device 300 includes a controller regulator 320, and in this embodiment, the control device 300 includes one processor for controlling the operation of two inverters 310. As shown in fig. 3, each control device 300 includes inverters 310, with one of the control devices including control logic 320, and with control logic 320 including a processor in this embodiment for controlling the operation of both inverters 310. As described below, each inverter is coupled to three sets of coil windings 60, with the coil windings 60 electrically connected in parallel, forming a set of three-phase motors.

A ring capacitor is coupled between the inverter 310 and the dc power supply of the motor to reduce voltage fluctuations on the motor power lines, also referred to as the dc bus, and to reduce voltage overshoot during motor operation. In order to reduce the inductance, a capacitor is installed near the control device 300. The rotor 240 includes a front portion 220 and a cylindrical portion 221 forming a cover that substantially surrounds the stator 252. The rotor includes a plurality of permanent magnets 242, the permanent magnets 242 being arranged around the interior of the cylindrical portion 221. For the purpose of this embodiment, 32 pairs of magnets are mounted inside the cylindrical portion 221. However, any number of magnet pairs may be used.

The magnets are adjacent to the coil windings 60 on the stator 252 so that the magnetic field generated by the coils interacts with the magnets 242 disposed inside the cylindrical portion 221 of the rotor 240, thereby rotating the rotor 240. Since the permanent magnet 242 is used to generate a driving torque of the driving motor, the permanent magnet is generally referred to as a driving magnet. In this embodiment, the motor includes six coil windings, each having three coil sub-sets, also referred to as coil phase windings in this embodiment; the three coil sub-sets are coupled in a Y-shaped configuration to form a three-phase sub-motor, such that the motor has six three-phase sub-motors, wherein each coil of the six coil sets is wound on each stator tooth 800 as part of the stator, as described above. The operation of each sub-motor is controlled by one of the two control devices 300, as described below. Although the present embodiment describes a motor having six coil sets (i.e. a six-sub motor), the motor could equally have one or more coil sets with associated control means. Likewise, each coil set may have any number of coil sub-sets, allowing for two or more phases per sub-motor.

Fig. 3 illustrates the connections between the respective coil sets 60 and the control device 300, wherein three coil sets 60 are connected to respective three-phase inverters 310 on the control device 300. As is well known to those skilled in the art, a three-phase inverter includes six switches, wherein a three-phase alternating voltage may be generated by controlled operation of the six switches. However, the number of switches will depend on the number of voltage phases applied to the respective sub-motors, and any number of phases can be built on these sub-motors. Each control device 300 communicates with other control devices 300 through a communication bus.

One of the control devices 300 includes a processor 320 for controlling the operation of the inverter switches in both control devices 300. Furthermore, each control device 300 comprises an interface arrangement allowing communication between the respective control devices 300 via a communication bus 330, wherein one control device 300 is arranged to communicate with a vehicle controller mounted outside the electric motor.

The processor 320 is used to control the operation of the inverter switches installed in each control device 300 to allow each motor coil assembly 60 to be equipped with a three-phase voltage power supply, thereby allowing the respective coil sub-assemblies to generate a rotating magnetic field. As noted above, while the present embodiment describes each coil set 60 as having three coil sub-sets, the present invention is not so limited, it being understood that each coil set 60 may have one or more coil sub-sets.

Under the control of the processor, each three-phase bridge inverter 310 is configured to provide pulse width modulated voltage control in the respective subset of coils to generate current in the respective subset of coils to provide the torque required by the respective sub-motor.

The operating principle of PWM control is to drive the required current into the motor coil by averaging the applied pulse voltage with the motor inductance. The applied voltage is switched between the motor windings using pulse width modulation control. During the switching of the voltage through the motor coil, the current in the motor coil rises at a rate determined by its inductance and the applied voltage. The pulse width modulation voltage control is turned off before the current increases beyond the desired value, thereby achieving accurate control of the current.

For a given coil set 60, the three-phase bridge inverter 310 switches are arranged to apply a single voltage phase across each coil sub-set. Using PWM switching, a plurality of switches are arranged to apply an alternating voltage across respective subsets of coils. The voltage envelope and the phase angle of the electrical signal are determined by the modulated voltage pulses.

An inverter formed on one control device is coupled to the three coil groups to form a first group of three sub-motors, and an inverter formed on the other control device is coupled to the other coil groups to form a second group of three sub-motors.

The two inverters 310 are coupled to respective coil sets by lead frames 255, with each leg of the respective inverter 310 coupled to the lead frame 255 by a respective phase winding bus. For the present embodiment, the different voltage phases produced by each inverter leg are designated W, V and U. The coil windings 60 are coupled to the lead frame 255 to allow current to flow from the dc power source to the coil windings 60 through the respective inverters 310 in the control apparatus, thereby allowing the motor to generate a driving torque.

Fig. 4 illustrates the electrical connections provided by the lead frame 255 between the phase winding bus of one of the control devices and the coil windings mounted on the stator, wherein the lead frame 255 is arranged to couple the phase windings of the respective coil sub-sets in a Y-configuration. However, the lead frame 255 may be configured to couple the phase windings of the respective coil subsets in different configurations. As described above, each coil winding includes three coil sub-groups (i.e., phase windings) to form a three-phase sub-motor. The first coil winding, the second coil winding, and the third coil winding of the first group of coil windings correspond one-to-one to the following first sub-motor, second sub-motor, and third sub-motor in this embodiment.

With the present embodiment, each coil set forming a coil sub-set is formed of three separate coils, which are coupled by the circuit board layers of the lead frame 255.

Referring to fig. 4, the coil 401 forms a first phase winding of the first sub-motor 411, the coil 402 forms a second phase winding of the first sub-motor 411, and the coil 403 forms a third phase winding of the first sub-motor 411. For the second sub-motor 412, the coil 404 forms a first phase winding of the second sub-motor 412, the coil 405 forms a second phase winding of the second sub-motor 412, and the coil 406 forms a third phase winding of the second sub-motor 412. For the third sub-motor 413, the coil 407 forms a first phase winding of the third sub-motor 413, the coil 408 forms a second phase winding of the third sub-motor 413, and the coil 409 forms a third phase winding of the third sub-motor 413. Each coil 400 shown in fig. 4 corresponds to a coil on a single stator tooth 800, wherein the ends of each coil are arranged to couple with the lead frame 255 to achieve the coupling of the coils in the configuration shown in fig. 4.

The lead frame 255 is used to connect the W-phase inverter bus to the first coil 400 of the first phase winding 401 of the first sub-motor 411, the first phase winding 404 of the second sub-motor 412, and the first phase winding 407 of the third sub-motor 413. The lead frame 255 also connects the V-phase inverter bus to the first coil 400 of the second phase winding 402 of the first sub motor 411, the second phase winding 405 of the second sub motor 412, and the second phase winding 408 of the third sub motor 413, and connects the U-phase inverter to the first coil 400 of the third phase winding 403 of the first sub motor 411, the third phase winding 406 of the second sub motor 412, and the third phase winding 409 of the third sub motor 413.

As shown in fig. 4, the lead frame 255 connects the last coil 400 of the first phase winding 401 of the first sub-motor 411 to the last coils 400 of the second phase winding 402 and the third phase winding 403 of the first sub-motor 411. Likewise, the lead frame 255 also connects the last coil 400 of the first phase winding 404 of the second sub-motor 412 to the last coils 400 of the second phase winding 405 of the second sub-motor 412 and the third phase winding 406 of the second sub-motor 412, and connects the last coil 400 of the first phase winding 407 of the third sub-motor 413 to the last coils 400 of the second phase winding 408 and the third phase winding 409 of the third sub-motor 413. These connections act as star points per sub-motor.

Further, the lead frame 255 is arranged to electrically connect the respective coils 400 of each phase winding to form a serial connection between the respective coils 400 of each phase winding. Accordingly, the lead frame provides electrical connections between the W, V, U-phase inverter busses and the respective coils 400 to form three sub-motors driven by a single inverter 310, with the coil windings 60 of the respective sub-motors coupled in a Y-configuration.

Likewise, the lead frame 255 connects the phase winding bus of the inverter 310 of the other control device 300 and the coil mounted on the stator in the same manner, forming a three-sub motor driven by the inverter 310 in the second control device 300.

The structure of the lead frame 255 will now be described, wherein in a first embodiment, as shown in fig. 5, one substantially circumferential lead frame is used to supply current from two control devices to respective coil sets.

The lead frame 255 includes a first set of three holes 660 for receiving respective bus bar lead frame pins for coupling the lead frame 255 to the inverter 310 in the first control device 300, and a second set of three holes 660 for receiving respective bus bar lead frame pins for coupling the lead frame 255 to the inverter 310 in the second set.

The lead frame 255 is opened with fixing holes at predetermined positions, and the heat stakes 630 are inserted into the fixing holes, wherein the heat stakes 630 are disposed at ends of the teeth of the stator winding unit 550, the ends being adjacent to the lead frame 255, the heat stakes 630 are designed at inner and outer sides of the stator winding unit 550, and the heat stakes 630 are disposed to extend through the holes formed in the lead frame 255. Once the lead frames 255 are mounted on the stator core 600 and the respective heat stakes 630 pass through corresponding holes formed in the lead frames 255, the heat stakes 630 melt, thereby securing the lead frames 255 to the stator core 600. However, any suitable method of attaching the lead frame to the stator core may be used.

As shown in fig. 6, the lead frame 255 includes a plurality of recesses 640 formed on the inner and outer radial edges of the lead frame 255 for receiving ends of the coil wound on the stator teeth 800 for coupling the coil 400 to the lead frame 255, as described below, wherein for each coil wound on the stator teeth 800, one portion is mounted in the recess 640 formed on the inner radial edge of the lead frame 255 and another portion is mounted in the recess 640 formed on the outer radial edge of the lead frame 255.

The single circumferential lead frame 255 serves as a current path from each inverter 310 within the control device 300 to each coil winding 60, wherein the lead frame 255 is a substantially circumferential printed circuit board having a plurality of circuit board layers. With the board layers having a conductive layer printed on each circuit board layer. Each circuit board layer includes a dielectric substrate; a conductive layer is formed on the insulating substrate. In other words, one half of the circumference of the lead frame printed circuit board is allocated for coupling the first control device 300 to one set of coil windings 60 to form three sub-motors formed by the first set of coil windings, and the other half of the circumference of the lead frame printed circuit board is allocated for coupling the second control device 300 to three sub-motors formed by the second set of coil windings. The plurality of circuit board layers are separated by respective insulating substrates.

To allow large currents to flow from the inverters 310 to the coil windings 60, thereby allowing the motor to generate sufficient torque to drive the vehicle, the conductive layers on each circuit board layer are arranged to extend over a substantial portion of each circuit board, with each conductive layer being arranged to correspond to a circuit path between a particular respective inverter 310 and coil winding 60 and between different subsets of coils making up respective sub-machines, and thus each circuit board layer is optimized for current flow.

To achieve the circuit configuration shown in fig. 4, the configuration of the printed circuit board layer and the conductive layers printed on the circuit board layer for coupling one inverter 310 in one control device 300 to the first set of coil windings 60 will now be described. On each circuit board layer is a mirror image of the conductive layers used to couple another inverter 310 in the second control device 300 to the second set of coil windings 60, only the conductive layers used to couple one inverter to one set of coil windings 60 being described.

Each circuit board layer includes two sets of electrical connections for coupling a first set of three coil windings to one inverter and another set of three coil windings to another inverter, but each circuit board layer may include any number of conductive layers based on the number of inverters. For example, if one inverter is used to drive all of the coil windings 60 mounted on the stator, the conductive layers printed on each circuit board layer will be arranged to form specific circuit paths between the inverter and the coil windings 60 and between the different coil subsets that make up the respective sub-motors, forming the respective sub-motors.

The printed circuit board comprises a first circuit board layer having a first conductive layer as shown in fig. 9 extending substantially to a first semi-circumferential portion of the circumferential circuit board arranged to be electrically coupled to the W-phase inverter 310 busbar and the first coil of the first phase winding 401 of the first sub-motor 411 of the first coil, the first coil of the first phase winding 404 of the second sub-motor 412 and the first coil of the first phase winding 407 of the third sub-motor 413. As mentioned above, the first circuit board layer further comprises a first conductive layer mirror layer extending to a second half circumferential portion of the substantially circumferential circuit board, which portion is arranged to be electrically coupled to the W-phase inverter busbar of the second inverter and to the corresponding coil winding of the second set of coil windings mounted on the stator.

As shown in fig. 10, the W-phase inverter 310 busbars are coupled to the first circuit board layer by busbar lead frame pins 1010, which are cylindrical conductive elements coupled to the W-phase inverter 310 busbars, which extend through associated lead frame pin holes 660 formed in the printed circuit board. The W bus bar lead frame pin 1010 is electrically coupled to the first conductive layer 900 at location 910. In order for the first coil of the first phase winding 401 of the first sub-motor 411, the first coil of the first phase winding 404 of the second sub-motor 412 and the first coil of the first phase winding 405 of the third sub-motor 413 to be coupled to the first conductive layer 900 at positions 920, 930, 940, the ends of the associated coils are mounted, as described above, within the recesses 640 formed in the inner and outer radial edges of the lead frame 255, with the ends of the coil winding 60 mounted within the recesses 640 formed in the inner radial edge of the lead frame at positions 920, 930, 940 and electrically coupled to the first conductive layer 900. The other ends of the first coil of the first phase winding of the first sub-motor, the second sub-motor and the third sub-motor and the ends of the remaining coil windings 60 are mounted in respective grooves formed in the lead frame and in the outer radial edge, electrically isolated from the first conductive layer 900.

The printed circuit board comprises a second circuit board layer having a second conductive layer 1100 as shown in fig. 11, said second conductive layer extending substantially to a first semi-circumferential portion of said circumferential circuit board, said circumferential circuit board being arranged to be electrically coupled to said U-phase inverter 310 busbar and to a first coil of a second phase winding 402 of said first sub-motor 411, to a first coil of a second phase winding 405 of a second sub-motor 412 and to a first coil of a second phase winding 408 of a third sub-motor 413. As described above, the second conductive layer mirror layer corresponding to the second conductive layer extends to the second half circumferential portion of the substantially circumferential circuit board, which is arranged to be electrically coupled to the U-phase inverter bus of the second inverter and to the corresponding coil winding of the second set of coil windings mounted on the stator.

As shown in fig. 10, the U-phase inverter 310 busbars are coupled to the second circuit board layer by busbar lead frame pins 1010, which busbar lead frame pins 1010 are cylindrical conductive elements coupled to the U-phase inverter 310 busbars that extend through associated lead frame pin holes 660 formed in the printed circuit board. The U-shaped bus bar leadframe pin 1010 is electrically coupled to the second conductive layer 1100 at location 1110. In order to couple the first coil of the second phase winding 402 of the first sub-motor 411, the first coil of the second phase winding 405 of the second sub-motor 412 and the first coil of the second phase winding 408 of the third sub-motor 413 to the locations 1120, 1130, 1140, respectively, of the second conductive layer, and as described above, the associated coils are mounted in the recesses 640 formed in the inner and outer radial edges of the lead frame 255, wherein the ends of the coil windings 60 mounted in the recesses formed in the inner radial edge of the lead frame 255 are electrically coupled with the second conductive layer at 1120, 1130, 1140. The other ends of the first coil of the second phase winding of the first, second and third sub-motors and the ends of the remaining coil windings 60 are mounted in respective grooves formed in the radial edges of the inner and outer sides of the lead frame 255, electrically isolated from the second conductive layer.

The printed circuit board comprises a third circuit board layer 1200 having a third conductive layer as shown in fig. 12 extending substantially to a first semi-circumferential portion of the circumferential circuit board arranged to be electrically coupled to the V-phase inverter 310 busbar and the phase winding 403 of the first coil first sub-motor 411, the first coil of the third phase winding 406 of the second sub-motor 412 and the first coil of the third phase winding 409 of the third sub-motor 413. As mentioned above, the third conductive layer mirror layer extends to a second half circumferential portion of the substantially circumferential circuit board, the conductive layer being arranged to be electrically coupled to a V-phase inverter busbar of a second inverter and a corresponding coil winding of a second set of coil windings mounted on the stator. As shown in fig. 10, the V-phase inverter 310 busbars are coupled to the third circuit board layer by busbar lead frame pins 1010, which are cylindrical conductive elements coupled to the V-phase inverter 310 busbars that extend through associated lead frame pin holes 660 formed in the printed circuit board. The V-bus lead frame pin 1010 is arranged to electrically couple to the third conductive layer 1200 of the printed circuit board at location 1210. In order to couple the first coil of the third phase winding 403 of the first sub-motor 411, the first coil of the third phase winding 406 of the second sub-motor 412 and the first coil of the third phase winding 409 of the third sub-motor 413 to the third conductive layer, the ends of the relevant coils are arranged such that, as described above, the ends of the coil windings 60 mounted in the grooves formed at the lead frames 1220, 1230, 1240 are electrically coupled to the third conductive layer in the grooves 640 formed in the inner and outer radial edges of the lead frame 255. The other ends of the first coil of the third phase windings of the first, second and third sub-motors, as well as the ends of the remaining coil windings 60, are mounted in respective recesses formed in the lead frame and in the outer radial edge, and are electrically isolated from the third conductive layer.

The printed circuit board includes a fourth circuit board layer having a fourth conductive layer 1310, a fifth conductive layer 1320, and a sixth conductive layer 1330, as shown in fig. 13, wherein the fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 together extend onto the first half-circumferential portion of the annular circuit board. The fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 are electrically isolated from each other.

The fourth conductive layer 1310 is arranged to electrically couple the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 of the first sub-motor 411 and the last coil of the third phase winding 403. A neutral point (i.e., a star point) is formed between the first coil winding 401, the second coil winding 402, and the third coil winding 403 of the first sub-motor 411. To couple the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 of the first sub-motor 411, and the last coil of the third phase winding 403 of the first sub-motor 411, the ends of the associated coils are mounted on the inner and outer radial edges of the lead frame 255 formed as described above, with the ends of the coil windings 60 mounted in the recesses formed in the outer radial edges of the lead frame being electrically coupled with the fourth conductive layer 1310 at 1311, 1312, 1313. The other end portion of the last coil of the first phase winding 401 of the first sub-motor 411, the second phase winding 402 of the last coil of the first sub-motor 411 and the last coil of the third phase winding 403 of the first sub-motor 411 and the end portions of the remaining coil windings are fitted in the respective grooves formed therein. The inner and outer radial edges of the lead frame 255 are electrically isolated from the fourth conductive layer 1310.

The fifth conductive layer 1320 is arranged to electrically couple the last coil of the first phase winding 404 of the second sub-motor 412, the last coil of the second phase winding 405 and the last coil of the third phase winding 406 of the second sub-motor 412. A neutral point (i.e., a star point) is formed between the first coil winding 404, the second coil winding 405 of the second sub-motor 412 and the third coil winding 405 of the second sub-motor 412. In order to couple the last coil of the first phase winding 404 of the second sub-motor 412, the last coil of the second phase winding 405 of the second sub-motor 412 and the last coil of the third phase winding 406 of the second sub-motor 412, the ends of the relevant coils are arranged to be mounted at the inner and outer radial edges of the lead frame 255 as described above, wherein the ends of the coil windings 60 mounted in the recesses formed in the outer radial edges of the lead frame are electrically coupled with the fifth conductive layer 1320 at 1321, 1322, 1323. The other end of the last coil of the first phase winding 404 of the second sub-motor 412, the second phase winding 405 of the last coil second sub-motor 412, and the last coil of the third phase winding 406 of the second sub-motor 412, and the ends of the remaining coil windings, which are mounted in the respective grooves 640 formed to thin the inner and outer radial edges of the lead frame 255, are electrically isolated from the fifth conductive layer 1320. Sixth conductive layer 1330 is arranged to electrically couple the last coil of first phase winding 407 of third sub-motor 413, the last coil of second phase winding 408 and the last coil of third phase winding 409 of third sub-motor 413. A neutral point (i.e., a star point) is formed between the first coil winding 407, the second coil winding 408 of the third sub-motor 413 and the third coil winding 409 of the third sub-motor 413.

To couple the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 of the first sub-motor 411, and the last coil of the third phase winding 403 of the first sub-motor 411, the ends of the associated coils are mounted on the inner and outer radial edges of the lead frame 255 formed as described above, wherein the ends of the coil windings mounted in the recesses formed in the outer radial edges of the lead frame are electrically coupled with the fourth conductive layer 1310 at 1311, 1312, 1313. The other end portion of the last coil of the first phase winding 407 of the third sub-motor 413, the last coil of the second phase winding 408 of the last coil third sub-motor 413 and the third phase winding 409 of the third sub-motor 413, and the end portions of the remaining coil windings are mounted in the corresponding respective grooves 640, and the inner and outer radial edges of the lead frame 255 are electrically isolated from the sixth conductive layer 1330.

The printed circuit board includes a fifth circuit board layer having a plurality of conductive layers shown in fig. 14 for electrically coupling the coil 400 forming the first phase winding 401 of the first sub-motor 411, the coil 400 forming the second phase winding 402 of the first sub-motor 411 and the coil 400 forming the third phase winding 402 of the first sub-motor 411. With respect to the second sub-motor, a plurality of conductive layers are arranged for electrically coupling the coil 400 forming the first phase winding 404 of the second sub-motor 412, the coil 400 forming the second phase winding 405 of the second sub-motor 412, and the coil 400 forming the third phase winding 406 of the second sub-motor 412 with respect to the third sub-motor, a plurality of conductive layers are arranged for electrically coupling the coil 400 forming the first phase winding 407 of the third sub-motor 413, the coil 400 forming the second phase winding 408 of the third sub-motor 413, and the coil 400 forming the third phase winding 409 of the third sub-motor 413.

The plurality of conductive layers on the fifth circuit board layer are arranged to allow the plurality of coils of each respective coil sub-set to be coupled such that each coil within the coil winding generates a magnetic field that is anti-parallel to its neighboring coils in a given current direction while having a common phase.

Among the plurality of conductive layers formed on the fifth circuit board layer, two conductive layers 1501,1502 are used to form the coupling coil 400 of the first phase winding 401 of the first sub-motor 411, two conductive layers 1503,1504 are used to form the coupling coil 400 of the second phase winding 402 of the first sub-motor 411, and two conductive layers 1505,1506 are used to couple the coils 400 forming the third phase winding 403 of the first sub-motor 411. In the second sub-motor, two conductive layers 1507,1508 are used to form the coupling coil 400 of the first phase winding 404 of the second sub-motor 412, two conductive layers 1509,1510 are used to couple the phase winding 405 of the second sub-motor 412 forming the coil 400 of the second sub-motor 412 and two conductive layers 1511,1512 are used to couple the coil 400, which forms the third phase winding 406 of the second sub-motor 412 for the third sub-motor, two conductive layers 1513,1514 are used to form the coupling coil 400 of the first phase winding 407 of the third sub-motor 413, and two conductive layers 1515,1516 are used to couple. The coil 400 forming the second phase winding 408 of the third sub-motor 413 and the two conductive layers 1517,1518 are used to couple the coil 400, which forms the third phase winding 409 of the third sub-motor 413. As described above, one end portion of the first coil forming the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in the groove 640 formed at the position 920 on the inner radial edge of the lead frame 255. Is electrically coupled to a first conductive layer 900 formed on a first circuit board layer while being electrically isolated from any other conductive layers on other circuit board layers. The other end of the first coil is mounted in an opposing groove formed on the outer radial edge of the lead frame at location 950 and is electrically coupled to the conductive layer 1502 on the fifth circuit board layer.

One end of the second coil of the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in a groove formed at a position 951 at the outer radial edge of the lead frame and electrically coupled to the layer 1502 on the conductive fifth circuit board layer, thereby electrically connecting the second coil to the W-phase bus bar pin through the first coil. The other end of the second coil is mounted in an opposing recess formed at position 952 on the inner radial edge of the leadframe and electrically coupled to a conductive layer 1501 on the fifth circuit board layer, the conductive layer 1501 being electrically isolated from the conductive layer 1502. One end portion of the third coil of the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in a recess formed at a position 953 at the inner radial edge of the lead frame and electrically coupled to the layer 1501 on the conductive fifth circuit board layer, thereby electrically connecting the third coil to the W-phase bus bar pin through the first and second coils. The other end of the third coil is mounted in an opposing recess formed on the outer radial edge of the lead frame at location 954 and is electrically connected to a fourth conductive layer 1310 on a fourth circuit board layer for coupling the third coil to the respective coils for forming the second phase winding 402 and the third phase winding 403 of the first sub-motor 411.

The next two conductive layers 1503,1504 on the fifth circuit board layer are used to couple the coils 400 forming the second phase windings 402 of the first sub-motor 411 to the V-phase busbar pins and the next two conductive layers 1505,1506 on the fifth circuit board layer are used to couple the coils 400 forming the third phase windings 403 of the first sub-motor 411 to the U-phase busbar pins. The next two conductive layers 1507,1508 on the fifth circuit board layer are used to couple the coils 400 forming the first phase winding 404 of the second sub-motor 412 to the W-phase bus pins of the next two conductive layers 1509,1510 on the fifth circuit board layer are used to couple the coils 400 forming the second phase winding 405 of the second sub-motor 412 to the V-phase bus pins, and 1511,1512 on the fifth circuit board layer are used to couple the coils 400 forming the third phase winding 406 of the second sub-motor 412 to the U-phase bus pins. The next two conductive layers 1513,1514 on the fifth circuit board layer are used to couple the coils 400 forming the first phase winding 407 of the third sub-motor 413 to the W-phase bus pins of the next two conductive layers 1515,1516 on the fifth circuit board layer is used to couple the coils 400 forming the second phase winding 408 of the third sub-motor 413 to the V-phase bus pins, and the next two conductive layers 1517,1518 on the fifth circuit board layer are used to couple the coils 400 forming the third phase winding 409 of the third sub-motor 413 to the U-phase bus pins.

It is apparent that another half-circumference portion of the printed circuit board is provided with a circuit board layer of the same structure as the fifth circuit board layer for connection with the second group of coil windings and the second inverter to form a second group of three sub-motors (4/5/6).

Example 2

To allow for increased current, and therefore increased torque, one or more circuit board layers may be replicated. In this embodiment, the printed board further includes a sixth circuit board layer, the sixth circuit board layer includes a ninth conductive layer, and the sixth circuit board layer and the first circuit board layer have the same structure; the structure of the first circuit board layer is the same as that of the second circuit board layer; the structure of the first circuit board layer is the same as that of the second circuit board layer; the structure of the fourth circuit board layer is the same as that of the fourth circuit board layer; the printed circuit board further includes a tenth circuit board layer including a plurality of conductive layers, the tenth circuit board layer functioning in the same structure as the fifth circuit board layer. Thus, the first circuit board layer is replaced with two circuit board layers having the same configuration as the first circuit board layer, thereby doubling the conductive area provided by the first circuit board. Similarly, the second circuit board layer is replaced with two circuit board layers having the same construction as the second circuit board layer, the third circuit board layer is replaced with two circuit board layers having the same construction as the third circuit board layer, the fourth circuit board layer is replaced with two circuit board layers having the same construction as the fourth circuit board layer, and the fifth circuit board layer is replaced with two circuit board layers having the same construction as the fifth circuit board layer.

Example 3

The present embodiment provides an electric motor, the lead frame of embodiment 1 or embodiment 2 is mounted on the circumferential support, the coil windings are connected to the lead frame to form a star connection; the lead frame is mounted on the circumferential support adjacent the coil windings.

In summary, the above-mentioned embodiments are only preferred embodiments of the present invention, and all equivalent changes and modifications made in the claims of the present invention should be covered by the claims of the present invention.

Claims (10)

1. A lead frame for an in-wheel electric machine for electrically coupling a first inverter having a plurality of inverter legs to a first set of coil windings of an engine or generator, characterized by: the lead frame includes a printed circuit board having a plurality of circuit board layers, each circuit board layer including an insulating substrate; a conductive layer is formed on the insulating substrate; the printed circuit board is at least provided with a first circuit board layer, a second circuit board layer, a third circuit board layer and a fourth circuit board layer; the first circuit board layer includes a first conductive layer arranged to electrically couple to a first coil winding of the first set of coil windings and a first leg of the first inverter; the second circuit board layer includes a second conductive layer arranged to electrically couple to a second coil winding of the first set of coil windings and a second leg of the first inverter; the third circuit board layer includes a third conductive layer arranged to electrically couple to a third coil winding of the first set of coil windings and a third leg of the first inverter; the fourth circuit board layer includes a fourth conductive layer having a plurality of conductive layers, the fourth conductive layer configured to couple with the first, second, and third coil windings of the first set of coil windings to form a neutral point between the first, second, and third coil windings.

2. The lead frame for an in-wheel motor according to claim 1, wherein: the first coil winding, the second coil winding and the third coil winding respectively comprise three coil sub-groups, namely a first phase winding, a second phase winding and a third phase winding; the printed circuit board further comprises a fifth circuit board layer having a plurality of conductive layers arranged to electrically couple the first, second and third phase windings of the first, second and third coil windings; the first, second and third phase windings each comprise a plurality of coils, and the plurality of conductive layers on the fifth circuit board are arranged to allow the plurality of coils for each respective phase winding to be coupled relative to each other such that each coil sub-set coil generates a magnetic field that is anti-parallel to an adjacent coil in a given current direction while having a common phase.

3. The lead frame for an in-wheel motor according to claim 1, wherein: the printed circuit board is circumferential.

4. The lead frame for an in-wheel motor according to claim 1, wherein: the first circuit board layer comprises a first conductive layer mirror layer arranged to be coupled to a first coil winding of the second set of coil windings and to a first branch of a second inverter; the second circuit board layer comprises a second conductive layer mirror layer arranged to be coupled to the second coil windings of the second set of coil windings and the second leg of the second inverter, the third circuit board layer comprises a third conductive layer mirror layer arranged to be coupled to the third coil windings of the second set of coil windings and the third leg of the second inverter; the fourth circuit board layer includes a fourth conductive layer mirror layer having a plurality of conductive layers, the eighth conductive layer being configured to couple with the first, second, and third coil windings of the second set of coil windings to form a neutral point between the first, second, and third coil windings of the second set of coil windings.

5. A lead frame for an in-wheel motor according to claim 4, characterized in that: the first conductive layer and the first conductive layer mirror layer are electrically isolated from each other and located on different areas on the first circuit board layer, the second conductive layer and the second conductive layer mirror layer are electrically isolated from each other and located on different areas on the second circuit board layer, and the third conductive layer mirror layer are electrically isolated from each other and located on different areas on the third circuit board layer; the fourth conductive layer and the fourth conductive layer mirror layer are electrically isolated from each other and located on different areas of the fourth circuit board layer.

6. The lead frame for an in-wheel motor according to claim 1, wherein: the printed board further comprises a sixth circuit board layer, the sixth circuit board layer comprises a ninth conductive layer, and the sixth circuit board layer and the first circuit board layer are identical in structure; the structure of the first circuit board layer is the same as that of the second circuit board layer; the structure of the first circuit board layer is the same as that of the second circuit board layer; the structure of the circuit board further comprises a ninth circuit board layer, the ninth circuit board layer comprises a twelfth conducting layer, and the ninth circuit board layer and the fourth circuit board layer are identical in structure.

7. A lead frame for an in-wheel motor according to claim 6, characterized in that: the printed circuit board further comprises a tenth circuit board layer comprising a plurality of conductive layers, the tenth circuit board layer functioning in the same configuration as the fifth circuit board layer, including all the features of claim 2.

8. The lead frame for an in-wheel motor according to claim 1, wherein: the printed circuit board includes a plurality of recesses formed in inner and outer edges of the printed circuit board, each recess arranged to receive a respective coil winding for electrically coupling the coil windings to the printed circuit board.

9. The lead frame for an in-wheel motor according to claim 1, wherein: the printed circuit board comprises means for positioning said lead frame in a predetermined position on the stator of the motor or generator.

10. An electric motor or generator comprising a stator having a circumferential support, characterized in that: a circumferential support comprising a plurality of teeth formed on the circumferential support, wherein coil windings are mounted on the plurality of teeth, and a lead frame according to any one of claims 1 to 9 is mounted on the circumferential support, the coil windings being connected to the lead frame to form a star connection; the lead frame is mounted on the circumferential support adjacent the coil windings.

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