CN218123905U - Busbar assembly, electrical equipment, electric drive assembly system and vehicle - Google Patents

Abstract

The utility model relates to a busbar subassembly, electrical equipment, electric drive assembly system and vehicle, the busbar subassembly includes: a pair of busbars (1), the pair of busbars (1) comprising a first end (11) and a second end (12), the first end (11) being connected to a direct current input of the electrical device, the second end (12) being connected to a direct current support capacitor of the electrical device; at least one magnetic ring (2, 4) sleeved on the busbar pair (1); at least one filter element electrically connected to the pair of busbars by a first connecting element; and at least one filter element holder (7 e, 8 a), the at least one filter element holder (7 e, 8 a) being mounted to the busbar pair (1), the at least one filter element being arranged in the at least one filter element holder (7 e, 8 a).

Description

Busbar assembly, electrical equipment, electric drive assembly system and vehicle

Technical Field

The utility model relates to a busbar subassembly for electrical equipment, including the electrical equipment of this kind of busbar subassembly, including the electric drive assembly system of this electrical equipment and the vehicle of including this electric drive assembly system.

Background

As is known, electric or hybrid vehicles have an electric drive assembly system that includes an electric motor and other electrical equipment, such as a power converter, that needs to be powered by a high voltage power source or, conversely, by a low voltage power source. In this case, the power converter is configured to convert an input voltage to an output voltage. For example, a motor controller (which may also be referred to as an "inverter") converts Direct Current (DC) voltage from a high-voltage power supply battery into Alternating Current (AC) power to supply to a motor to drive a vehicle. As another example, an on-board charger (OBC) converts an alternating voltage from an external power grid into a DC voltage to charge a high-voltage power supply battery.

Generally, the presence of multiple electrical components of such power converters, such as electrical conductors forming a bus bar, may cause electromagnetic interference (EMI) that may interfere with the proper operation of the power converter, especially in high power environments.

Electromagnetic compatibility (EMC), refers to the ability of a device or system to function properly in its electromagnetic environment without sustaining electromagnetic disturbance to anything in the environment. According to the EMC definition, the electronic device needs to meet EMC design specifications, on one hand, it needs to ensure that the electronic device has a certain degree of immunity to electromagnetic interference existing in the environment, and on the other hand, it is required that the electromagnetic interference generated by the electronic device in the operating process to the environment cannot exceed a specified limit value.

When the EMC scheme is designed, a general design idea is to add a filter device such as a magnetic ring and a magnetic buckle at a dc end and/or an ac end, and set a filter circuit board assembly including components such as a filter capacitor and a resistor on a transmission path. However, the filter circuit board assembly is large in size and dimension, and is not suitable for applications requiring compact design space.

Accordingly, there is a need for an integrated busbar assembly that exhibits improved mechatronics, is compact in size, and is inexpensive.

SUMMERY OF THE UTILITY MODEL

In view of the above-mentioned problems and needs, the present invention provides a novel busbar assembly for electrical devices, an electrical device including such a busbar assembly, an electric drive assembly system including the electrical device, and a vehicle including the electric drive assembly system, which solve the above-mentioned problems due to the following technical features and bring about other technical effects.

In one aspect, the utility model provides a busbar subassembly for electrical equipment, include: a pair of busbars including a first end and a second end, the first end connected to an input of the electrical device and the second end connected to a capacitor of the electrical device; at least one magnetic ring sleeved on the busbar pair; at least one filter element electrically connected to the pair of busbars by a first connecting element; and at least one filter element holder mounted to the pair of busbars, the at least one filter element being disposed in the at least one filter element holder.

According to the above features, the bus bar pair, the magnetic ring, the filter element, and the filter element holder are integrated to the bus bar assembly, the circuit board assembly is not required, the installation and support of the filter element are realized by the filter element holder, and the electrical connection among the bus bar pair, the magnetic ring, and the filter element can be realized by the connecting element in the bus bar assembly, which is compact in structure and low in cost.

In some examples, the at least one filter element holder includes a first filter element holder and a second filter element holder, the first filter element holder being connected to the pair of busbars between the first end and the second end; the second filter element holder is connected to the pair of busbars at the second end.

According to the above characteristics, when the number of the filter elements is enough, two filter element holders can be arranged and respectively arranged at different installation positions to respectively accommodate a part of the filter elements, so that the number of the filter elements is enough, and the structural compactness is kept.

In some examples, the busbar assembly further comprises a mounting clip by which the first connection element is clipped to the at least one filtering element holder.

According to the above feature, the first connecting element for electrical connection can be snap-fitted to the filter element holder without being connected by a complicated wire, saving installation cost and time. Even, the first connecting element can be preassembled in advance, which greatly saves installation and manufacturing costs.

In some examples, the at least one filter element holder includes a mounting pin, and the first connection element includes a pin hole that mates with the mounting pin to be positioned to the at least one filter element holder by the mounting pin.

Such locating features, such as pin holes, facilitate installation and location, while improving installation accuracy and avoiding mis-assembly, given that the dimensions of the filter element and the first connection element are typically small.

In some examples, at least one of the first connection elements is a forked end, and the at least one filter element includes a connection terminal electrically connected to the forked end by thermocompression bonding.

A hot crimping (hot crimping) can reliably connect the fork-shaped end of the first connecting element to the connecting terminal.

In some examples, two of the pair of busbars are L-shaped and overlap each other.

According to the above feature, the L-shaped bus bar can improve space utilization, so that the bus bar assembly accommodates more filter elements and filter element holders per unit area.

In some examples, the at least one magnetic loop includes: a first magnetic ring surrounding the pair of busbars at the first end; and a second magnetic ring disposed between the first filter element holder and the second filter element holder and surrounding the pair of bus bars.

In another aspect, the present invention further provides an electrical device including the bus bar assembly as described above.

In some examples, the electrical device is a motor controller, an on-board charger, or a DC/DC converter.

On the other hand, the utility model discloses still propose an electric drive assembly system, including as aforesaid electrical equipment.

In yet another aspect, the present invention further provides a vehicle including the electric drive assembly system as described above.

Drawings

To more clearly illustrate the technical solutions of the embodiments of the present disclosure, the drawings of the embodiments will be briefly introduced below, and it is apparent that the drawings in the following description only relate to some embodiments of the present disclosure and do not limit the present disclosure.

Fig. 1 illustrates an exploded view of an electrical device in accordance with at least one embodiment of the present disclosure;

FIG. 2 illustrates a perspective view of a buss bar assembly according to at least one embodiment of the present disclosure;

FIG. 3 illustrates an exploded view of the busbar assembly shown in FIG. 2;

FIG. 4 illustrates another exploded view of the buss bar assembly shown in FIG. 2;

fig. 5 illustrates an exploded view of a first filtering component in accordance with at least one embodiment of the present disclosure;

FIGS. 6 (a) and 6 (b) show partial schematic views of a first filter assembly showing mounting clips and mounting pins;

fig. 7 (a) shows a schematic view of a wire terminal and forked end in accordance with at least one embodiment of the present disclosure;

fig. 7 (b) shows another schematic view of a forked end in accordance with at least one embodiment of the present disclosure;

fig. 8 illustrates an exploded view of a second filtering component in accordance with at least one embodiment of the present disclosure;

fig. 9 illustrates a schematic diagram of a busbar pair according to at least one embodiment of the present disclosure.

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present disclosure more clear, the embodiments of the present disclosure will be described in detail and completely with reference to the accompanying drawings of specific embodiments of the present disclosure. Like reference symbols in the various drawings indicate like elements. It should be noted that the described embodiments are part of the embodiments of the present disclosure, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the described embodiments of the disclosure without any inventive step, are within the scope of protection of the disclosure.

Unless defined otherwise, technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this disclosure belongs. The use of "first," "second," and similar terms in the description and claims of the present disclosure are not intended to indicate any order, quantity, or importance, but rather are used to distinguish one element from another. Also, the use of the terms "a" or "an" and the like do not necessarily denote a limitation of quantity. The word "comprising" or "comprises", and the like, means that the element or item preceding the word comprises the element or item listed after the word and its equivalent, but does not exclude other elements or items. The terms "connected" or "coupled" and the like are not restricted to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "upper", "lower", "left", "right", and the like are used merely to indicate relative positional relationships, and when the absolute position of the object being described is changed, the relative positional relationships may also be changed accordingly.

Various embodiments according to the present disclosure will be described in detail with reference to the accompanying drawings. Here, it is to be noted that, in the drawings, the same reference numerals are given to constituent parts having substantially the same or similar structures and functions, and repeated description thereof will be omitted.

Possible embodiments within the scope of the disclosure may have fewer components, have other components not shown in the figures, different components, differently arranged components or differently connected components, etc. than the embodiments shown in the figures. Further, two or more of the components in the drawings may be implemented in a single component, or a single component shown in the drawings may be implemented as multiple separate components, without departing from the concepts of the present disclosure.

When an EMC scheme is designed for an electrical device, a filter circuit board assembly including filter capacitors, resistors, and the like is generally disposed on a transmission path. However, the filter circuit board assembly is large in size and dimension, and is not suitable for applications requiring compact design space.

To prior art's defect and the technical problem who exists, the utility model provides a new busbar subassembly for electrical equipment, this busbar subassembly integrated level is high, need not the circuit board, compact size, low cost.

Preferred embodiments of the bus bar assembly according to the present disclosure will be described in detail below with reference to the accompanying drawings. It should be noted that, for convenience of description, the present disclosure will illustrate exemplary embodiments by taking as an example a DC input bus bar assembly, i.e., a bus bar assembly disposed on a DC input side of a motor controller, but not limited thereto, the bus bar assembly adopting the concept of the present disclosure may also be applied to other electrical devices requiring EMC, such as an on-board charger or a DC/DC converter. In addition, the busbar assembly can also be arranged at other positions, for example at the ac output of the motor controller.

Electric drive assembly systems typically include an electric motor, a transmission, and a motor controller for effecting a conversion between converted dc power and ac power to drive the motor or recover energy from the motor. The gearbox is used for outputting the torque of the motor to drive the new energy automobile, and belongs to a core power component of the new energy automobile. The motor controller is configured to convert a DC voltage from the high-voltage power supply battery into an alternating-current voltage so as to drive the motor. The alternating voltage may be a multi-phase alternating voltage, in particular a three-phase voltage.

Referring initially to fig. 1, an exploded view of a motor controller in accordance with at least one embodiment of the present disclosure is shown. The motor controller includes a housing 01, a dc high-voltage connector, a dc input bus bar assembly 100 (hereinafter, may be simply referred to as a bus bar assembly 100), a capacitor 02, a power device module 03, a current sensor bus bar, an ac output bus bar, a circuit board, a top cover, an EMC shield bracket, and the like. The housing 01 may include a cooling portion on which the power device module 03 is disposed, the cooling portion having an opening so that a coolant in the cooling portion can contact the power device module 03, forming a good heat exchange, thereby taking away heat generated by the power device module 03 at the time of operation through the coolant, and further reducing the temperature thereof at the time of operation.

The dc high voltage connector, the dc input bus assembly 100, the capacitor 02, the power device module 03, and the ac output bus are electrically connected in sequence to form a complete dc-ac conversion loop. The dc high voltage connector is electrically connected to an external dc input (e.g., dc supply of a battery pack), and the dc power is filtered by the dc input bus assembly 100 and the capacitor 02 to the power device module 03, converted to three-phase ac power by the power device module 03, and finally output UVW three-phase ac power via the ac output bus.

A circuit board (not shown in the figure) is configured to drive the power device module 03 and control elements in the motor controller. Illustratively, the circuit board may be integrated with a control unit and a driving unit, the control unit may include a main control MCU and circuits for phase current sampling, resolver (resolver) sampling, and the like, and the driving unit may include an IGBT driving chip and circuits for high voltage sampling, active discharging, passive discharging, and the like. The disclosure is not limited thereto, and the control unit and the driving unit may further add or reduce corresponding circuits according to actual needs as long as the driving and controlling functions are realized. The circuit board may further include a connector integrated on the circuit board, and an external signal of the motor controller may be transmitted through the connector.

In this embodiment, the motor controller may also include components that perform other ancillary functions, such as current sensor busses and resolver cables. Signals between the motor controller and the motor are transmitted through the resolver cable. The current sensor bus bar collects bus bar voltage and bus bar current of the motor controller, and obtains corresponding voltage and current information so as to monitor in real time.

In addition, a top cover (not shown) may be fixed to the housing 01 by screws to physically close the housing 01, and a sealing adhesive may be provided at a contact portion between the top cover and the housing 01 to ensure sealing performance of the motor controller. An EMC shield bracket may be further provided between the circuit board and the dc input bus bar assembly 100 to secure EMC performance of the product.

The above describes exemplarily preferred embodiments of the motor controller. The utility model discloses a machine controller can adopt single integrated circuit board, has removed the connection between the different circuit boards from, improves the reliability of product when reducing the cost, has avoided the potential risk of connection failure between the circuit board. It is worth mentioning, the utility model discloses a machine controller's direct current input interface and exchange output interface can set up in the same one side of casing, can match the setting of low reaches product interface better.

Fig. 2-9 illustrate more specifically the structure of a buss bar assembly according to at least one embodiment of the present disclosure.

As shown in fig. 2, the busbar assembly 100 includes a busbar pair 1, a first magnetic ring 2, a second magnetic ring 4, a first filter element holder 7e, and a second filter element holder 8a. Each filter element holder 7e, 8a is provided with a plurality of filter elements, such as capacitors, resistors and/or inductors. Each filter element is electrically connected to the busbar pair 1 via a respective first connection element.

In the present embodiment, the busbar pair 1 includes a first end 11 and a second end 12, the first end 11 being connected to the dc input of the electrical device, and the second end 12 being connected to a capacitor (e.g., a dc support capacitor) of the electrical device. The first magnet ring 2 surrounds the busbar pair 1 at a first end 11, and the second magnet ring 4 is arranged between the first filter element holder 7e and the second filter element holder 8a and surrounds the busbar pair 1. In other words, the busbar pair 1 passes through the first magnetic ring 2 and/or the second magnetic ring 4. The first magnetic loop 2 and/or the second magnetic loop 4 are particularly configured to act as inductors to filter common mode or differential mode currents or a combination of both.

The busbar pair 1 comprises a pair of busbars, also known as busbars, busbars or electrical flat conductors, which are commonly used for electrical connections in electrical equipment, each of the busbars being in the form of a strip. Furthermore, the busbars are typically made of a metallic material, most commonly copper.

In the case where the electrical apparatus is a motor controller, the busbar pair 1 includes a positive DC busbar and a negative DC busbar. In particular, the positive and negative DC busbars are arranged one above the other in a substantially vertical direction, that is to say, one above the other, to pass the voltage/current of the direct positive and negative poles. To improve space utilization, both busbars in the busbar pair 1 may be L-shaped, as shown in fig. 9.

For ease of installation, the first filter element holder 7e may be formed after the first filter element is installed to form the first filter assembly 3, and then installed to the busbar pair 1. Likewise, the second filter element holder 8a can also be assembled in a similar manner to the second filter assembly 5, as shown in fig. 3 and 4. The first filter assembly 3 and the second filter assembly 5 may then be connected to the busbar pair 1 by screws.

As shown in fig. 2, the first filter element holding frame 7e is connected to the busbar pair 1 between the first end 11 and the second end 12, and the second filter element holding frame 8a is connected to the busbar pair 1 at the second end 12. The first filter element holder 7e and the second filter element holder 8a can be made, for example, of plastic to facilitate manufacture and insulation.

Fig. 5 and 8 exemplarily show exploded views of the first filter assembly 3 and the second filter assembly 5, respectively.

As shown in fig. 5, the first filter assembly 3 includes a first filter element holding frame 7e and a plurality of first connection elements 7a, 7b, 7c, 7d. The filter element arranged in the first filter element holder 7e comprises first filter capacitors 7f, 7g, 7h and a first filter resistor 7j, the first filter capacitors 7f, 7g, 7h and the first filter resistor 7j being electrically connected to one another via at least one first connection element 7a, 7b, 7c, 7d of the plurality of first connection elements 7a, 7b, 7c, 7d. Specifically, at least one end of the first connection elements 7a, 7b, 7c, 7d is a fork-shaped end 10, and accordingly, the first filter capacitors 7f, 7g, 7h and the first filter resistor 7j include connection terminals 9, and the connection terminals 9 are electrically connected to the fork-shaped end 10 by thermocompression bonding, as shown in fig. 7 (a) and 7 (b). On the one hand, the first filter capacitors 7f, 7g, 7h and the first filter resistor 7j can be electrically and partially mechanically connected by thermocompression bonding to the first connecting element, and on the other hand, these filter elements can also be fixedly connected to the first filter element holder 7e by snapping, welding or the like.

The first connecting elements 7a, 7b, 7c, 7d can be, for example, leads (leads) whose forked ends 10 can differ in number, as required. For example, the first connection element 7d comprises two fork-shaped ends 10, while the first connection element 7b comprises three fork-shaped ends 10, the first connection element 7a comprising only one fork-shaped end 10, depending on the different connection modes of the filter circuit, fig. 5 being merely an example and not intended to limit the choice of its arrangement.

In order to reliably and accurately mount the first connection elements 7a, 7b, 7c, 7d to the first filter element holder 7e, the first filter element holder 7e may comprise mounting pins 7e-1 and mounting catches 7e-2, while the first connection elements 7a, 7b, 7c, 7d may comprise pin holes cooperating with the mounting pins 7e-1 for positioning to at least one filter element holder 7e, 8a by means of the mounting pins 7e-1, while being snapped to the first filter element holder 7e by means of the mounting catches 7 e-2.

For example, as shown in fig. 6 (a) and 6 (b), the first filter element holder 7e is provided with four mounting hooks 7e-2, which are respectively opposed two by two in the width direction of the first connection element, for one first connection element. The mounting catch 7e-2 is, for example, hook-shaped and has a certain elasticity. When mounting, the pin hole of the first connecting element can be aligned with the mounting pin 7e-1, inserted into the mounting catch 7e-2 in the up-down direction in fig. 6 (b), and snapped therein.

As shown in fig. 8, the second filter assembly 5 includes a second filter element holding frame 8a and a plurality of second leads 8b, 8c, 8d. The filter element disposed on the second filter element holding frame 8a includes a second filter capacitor 8e and an inductor 8f, and the second filter capacitor 8e and the inductor 8f are electrically connected to each other by at least one of the plurality of first connection elements 8b, 8c, 8d.

Similar to the first filter element holder 7e, the second filter element holder 8a may also be provided with mounting pins 7e-1 and mounting catches 7e-2, which are not described in detail here.

Therefore, the bus bar assembly according to the embodiment of the disclosure can arrange as many filter elements as possible in a limited size space, and simultaneously saves a circuit board, the filter elements are arranged on the filter element holder, so that physical fixation and electrical connection are realized, an improved mechatronic structure is presented, the size is compact, and the cost is low.

In yet another aspect, embodiments of the present disclosure also provide an electrical device including the bus bar assembly as described above.

Alternatively, the electrical device may be a motor controller. Alternatively, the electrical device may also be an on-board charger or a DC/DC converter of an electric vehicle or a hybrid electric vehicle.

In another aspect, embodiments of the present disclosure also provide an electric drive assembly system including the electric device as described above.

In yet another aspect, embodiments of the present disclosure further provide a vehicle including the electric drive assembly system as described above.

The present invention provides electrical devices, electric drive assembly systems and vehicles having similar or identical technical advantages due to the above-described features including the busbar assembly.

Exemplary embodiments of the bus bar assembly, the electrical device, the electric drive assembly system and the vehicle proposed by the present disclosure have been described above in detail with reference to preferred embodiments, however, it will be understood by those skilled in the art that many variations and modifications may be made to the specific embodiments described above without departing from the concept of the present disclosure. In addition, various combinations of the various features and structures presented in the various aspects of the disclosure may be made without departing from the scope of the disclosure, which is defined in the appended claims.

Claims (11)

1. A busbar assembly (100) for an electrical device, comprising:

a pair of busbars (1), the pair of busbars (1) comprising a first end (11) and a second end (12), the first end (11) being connected to an input of the electrical device, the second end (12) being connected to a capacitor of the electrical device;

at least one magnetic ring (2, 4) sleeved on the busbar pair (1);

at least one filter element electrically connected to the pair of busbars by a first connecting element; and

at least one filter element holder (7 e, 8 a), the at least one filter element holder (7 e, 8 a) being mounted to the busbar pair (1), the at least one filter element being arranged in the at least one filter element holder (7 e, 8 a).

2. The busbar assembly (100) of claim 1, wherein the at least one filter element holder (7 e, 8 a) comprises:

a first filter element holder (7 e) connected to the busbar pair (1) between the first end (11) and the second end (12); and

a second filter element holder (8 a) connected to the busbar pair (1) at the second end (12).

3. The busbar assembly (100) according to claim 1, wherein the busbar assembly (100) further comprises a mounting catch (7 e-2), the first connecting element being clipped to the at least one filter element holder (7 e, 8 a) by means of the mounting catch (7 e-2).

4. The bus bar assembly (100) of claim 3, wherein the at least one filter element holder (7 e, 8 a) comprises a mounting pin (7 e-1), and the first connection element comprises a pin hole cooperating with the mounting pin (7 e-1) for positioning to the at least one filter element holder (7 e, 8 a) by means of the mounting pin (7 e-1).

5. The busbar assembly (100) according to claim 3, wherein at least one of the first connection elements ends in a forked end (10), the at least one filter element comprising a connection terminal (9), the connection terminal (9) being electrically connected to the forked end (10) by thermocompression bonding.

6. The busbar assembly (100) according to claim 1, wherein two busbars of the busbar pair (1) are L-shaped and are stacked on each other.

7. The busbar assembly (100) according to claim 2, wherein the at least one magnetic ring (2, 4) comprises:

a first magnetic ring (2), the first magnetic ring (2) surrounding the busbar pair (1) at the first end (11); and

a second magnet ring (4), wherein the second magnet ring (4) is arranged between the first filter element holder (7 e) and the second filter element holder (8 a) and surrounds the busbar pair (1).

8. An electrical apparatus, characterized in that it comprises a busbar assembly (100) according to any one of claims 1 to 7.

9. The electrical apparatus of claim 8, wherein the electrical apparatus is a motor controller, an on-board charger, or a DC/DC converter.

10. An electric drive assembly system comprising an electric device as claimed in claim 8 or 9.

11. A vehicle comprising the electric drive assembly system of claim 10.

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