WO2015172599A1

WO2015172599A1 - Motor and manufacturing method thereof, and vehicle drive device

Info

Publication number: WO2015172599A1
Application number: PCT/CN2015/073710
Authority: WO
Inventors: 赞姆泽⋅西维奥; 刘兴芬; 瓦根布莱特⋅马库斯
Original assignee: 舍弗勒技术股份两合公司; 赞姆泽⋅西维奥; 刘兴芬; 瓦根布莱特⋅马库斯
Priority date: 2014-05-12
Filing date: 2015-03-05
Publication date: 2015-11-19
Also published as: CN105099036A

Abstract

A motor and manufacturing method thereof, and vehicle drive device; the motor comprises a stator winding, and a wiring component electrically connected to the wire end of the stator winding; the wiring component comprises a busbar ring electrically connected to the wire end of the stator winding, and a wiring terminal for electrically connecting to an external circuit; and the busbar ring and the wiring terminal are integrally formed. The technical solution of the present invention solves the problems of unreliable mechanical connection between the busbar ring and the wiring terminal in the wiring component of an existing motor, possible air gaps occurring on the contact surface of the busbar ring and the wiring terminal, incompact structure of the existing motors, and high manufacturing costs of the existing motors.

Description

Motor, manufacturing method thereof, and vehicle drive device

The present application claims priority to Chinese Patent Application No. 201410197969.2, entitled "Motor and its manufacturing method, vehicle drive device", which is filed on May 12, 2014, the entire contents of which are incorporated herein by reference. In the application.

Technical field

The present invention relates to the field of automotive technology, and in particular to a motor, a method of manufacturing the same, and a vehicle drive device.

Background technique

A motor is an electromagnetic device that converts electrical energy into mechanical energy and mechanical energy into electrical energy. Existing electric machines generally include: stator windings and wiring components. One end of the wiring component is used to electrically connect to an external circuit to supply current to the stator windings.

As shown in FIG. 1, a wiring component of a conventional motor includes: in conjunction with FIG. 2, a busbar ring 1 is electrically connected to a wire end of a stator winding (not shown), and an axial side of the busbar ring 1 has an edge. The axially extending fixed end 10; the terminal 2, one end is fixedly connected with the fixed end 10 of the busbar ring 1 by a mechanical connection process (such as bolting, welding or riveting, in the figure, a bolted connection) to realize the terminal 2 In electrical connection with the busbar ring 1, the other end of the terminal 2 is for electrical connection with an external circuit.

In the working environment, the motor not only generates vibration but also thermal shock, causing an air gap between the bus ring 1 and the terminal 2 at the connection contact surface, resulting in poor connection between the bus ring 1 and the terminal 2. Therefore, the resistance value at the junction of the bus ring 1 and the terminal 2 is increased. When the motor is energized, a large amount of heat is generated at the junction of the bus ring 1 and the terminal 2, and the motor may be burned out.

In addition, a part of the bus bar 1 and the terminal 2 are used to fix the connection of the bus bar 1 and the terminal 2, and the space occupied by the connection between the two is large, so that the structure of the motor is not compact enough. Moreover, since the busbar ring 1 and the terminal 2 are two separate components, the two are separately manufactured, resulting in more waste and increased manufacturing cost of the motor.

The manufacturing method of the above motor comprises: packaging the terminal 2, so that one end of the terminal 2 for electrically connecting to the external circuit is covered with an insulating material; then, the stator and the bus ring 1 of the motor are packaged to remove the bus ring 1 The portion outside the fixed end 10 is covered by an insulating material (such as a resin); then, the bus ring 1 is fixedly connected to the terminal 2 by a mechanical joining process; finally, the connection between the bus ring 1 and the terminal 2 is packaged to make wiring The exposed portion of the terminal 2 and the fixed end 10 of the busbar ring 1 are covered with an insulating material.

Therefore, when manufacturing an existing motor, it is necessary to perform a plurality of packaging processes and a process of fixedly connecting the bus ring 1 and the terminal 2, resulting in a high manufacturing cost of the motor.

Summary of the invention

One of the problems to be solved by the present invention is that the mechanical connection between the bus bar and the terminal in the wiring component of the prior art motor is not reliable, and an air gap may be generated at the connection contact faces of the two.

Another problem to be solved by the present invention is that the structure of the existing motor is not sufficiently compact.

Another problem to be solved by the present invention is that more waste is generated when the bus bar and the terminal of the existing motor are fabricated.

In order to solve the above problems, the present invention provides an electric motor comprising: a stator winding; a wiring component electrically connected to a wire end of the stator winding;

Wherein the wiring component comprises:

a busbar ring electrically connected to the wire end of the stator winding;

a terminal for electrically connecting to an external circuit;

The busbar ring is integrally formed with the terminal.

Optionally, the stator winding is a three-phase winding, the number of the bus ring and the terminal is three, three of the bus rings are spaced apart, and the three terminals are arranged at intervals;

The stator windings are electrically connected to the three busbar rings in a star connection or a delta connection.

Optionally, three of the busbar rings are coaxially sleeved, and three of the terminals are circumferentially spaced along any of the busbar rings.

Optionally, the integrally formed bus bar ring and the connecting terminal are bent by a wire.

Optionally, the wire is a copper wire.

Compared with the prior art, the technical solution of the present invention has the following advantages:

Since the busbar ring and the terminal block are integrally formed in the wiring component, even if the motor is affected by vibration and thermal shock, the busbar ring and the terminal are always integrated, and there is no busbar ring and the terminal at the connection contact surface. There is a problem of an air gap between the two, and there is no problem that the resistance value at the junction increases due to an air gap between the connection surface of the bus bar and the terminal.

In addition, since the bus bar ring and the terminal block are integrally formed in the wiring member, it is not necessary to use the bus bar ring and a part of the terminal terminal to fix the connection bus bar ring and the terminal terminal, thereby reducing the space occupied by the wiring member and making the structure of the motor. More compact.

In addition, the busbar ring and the terminal are integrally formed, and the two are not separately manufactured, which reduces the waste generated when the busbar ring and the terminal are made, and improves the utilization rate of the manufacturing raw materials.

A further problem to be solved by the present invention is that the manufacturing cost of the existing motor is high.

In order to solve the above problems, the present invention provides a method of manufacturing a motor, comprising:

Providing a stator, the stator winding of the stator is embedded with a stator winding;

Providing wiring components, including: forming a bus ring and a terminal by an integral molding process;

Encapsulating to cover the bus bar on the insulating material;

After the packaging, electrically connecting a wire end of the stator winding to the bus bar ring;

After the electrical connection, a package is performed to cover the insulating material on the terminal.

Optionally, the integrally formed bus bar ring and the connecting terminal are formed by bending a wire.

Optionally, the wire is a copper wire.

The prior art process of fixedly connecting the busbar ring to the terminal and the one-packing process of connecting the busbar ring and the terminal in the wiring component are omitted, which reduces the manufacturing cost of the motor.

Further, the present invention provides a vehicle driving device comprising the motor of any of the above.

Optionally, the vehicle driving device is a hybrid driving device, a hub assembly or an electric drive axle.

DRAWINGS

1 is a schematic plan view showing a wiring structure of a conventional motor;

Figure 2 is a perspective view showing the structure of the bus bar in the wiring member shown in Figure 1;

3 is a schematic perspective view of a three-dimensional structure of a wiring component of a motor according to an embodiment of the present invention;

Figure 4 is a perspective view of the wiring structure of the motor in one embodiment of the present invention;

Figure 5 is a partial enlarged view of the P region of Figure 4;

6 is a schematic perspective view of the wiring component shown in FIG. 3 after being packaged;

Fig. 7 is a perspective view showing the assembled wiring member shown in Fig. 6 assembled on the stator.

detailed description

In order to make the above objects, features and advantages of the present invention more apparent, the following The specific embodiments of the present invention are described in detail with reference to the accompanying drawings.

3 and 4, the present embodiment provides an electric motor including: a stator winding (not shown); and a wiring member 1 electrically connected to a wire end of the stator winding.

Wherein the wiring component 1 comprises:

a busbar ring 10 electrically connected to a wire end of the stator winding;

a terminal 20 for electrically connecting to an external circuit (not shown);

The bus bar 10 is integrally formed with the terminal 20.

Since the bus bar 10 in the wiring component 1 is integrally formed with the terminal 20, even if the motor is subjected to vibration and thermal shock during operation, the bus ring 10 and the terminal 20 are always integrated, and the bus ring 10 and the wiring are not present. The terminal 20 has a problem of an air gap between the contact faces, and there is no problem that the resistance value at the junction increases due to an air gap occurring between the connection faces of the bus bar 10 and the terminal 20.

In addition, since the bus bar 10 is integrally formed with the terminal 20, it is not necessary to use the bus ring 10 and a part of the terminal 20 to fix the bus bar 10 and the terminal 20, thereby reducing the space occupied by the wiring member 1 and making the motor The structure is more compact.

In addition, the bus bar 10 is integrally formed with the terminal 20, which reduces the waste generated when the bus ring 10 and the terminal 20 are formed, and improves the utilization rate of the manufacturing raw materials.

In this embodiment, the stator winding is a three-phase winding, the number of the bus ring 10 and the terminal 20 is three, three bus rings 10 are arranged at intervals, and three terminals 20 are arranged at intervals; the stator windings are arranged according to The star connection or the delta connection is electrically connected to the three bus bar rings 10.

Further, as shown in FIG. 5, three bus bar rings 10 are coaxially sleeved, and three terminal blocks 20 are circumferentially spaced along any of the bus bar rings 10 to reduce the space occupied by the wiring member 1. Of course, in other embodiments, three bus rings 10 and three terminals 20 are also available. Arranged in other ways.

In the present embodiment, the integrally formed bus bar 10 and the terminal 20 are bent by wires.

In this embodiment, the wire is a copper wire because the copper wire has good electrical conductivity and is moderately priced. In other embodiments, the wires may also be wires of other materials, such as silver wires, gold wires, aluminum wires, and the like.

In the present embodiment, the busbar ring 10 is open-loop, that is, the busbar ring 10 is not fully enclosed, and the terminal 20 extends from one of the ends of the busbar ring 10 to the outside of the busbar ring 10. In other embodiments, the busbar ring 10 can also be a closed loop.

In the present embodiment, the ends of the stator windings are soldered to the busbar ring 10 to effect electrical connection between the ends of the stator windings and the busbar ring 10. A fork joint 11 can be provided on the busbar ring 10 for electrically connecting the wire ends of the stator windings, and the wire ends of the stator windings are welded to the fork joint 11.

In the present embodiment, one end of the terminal 20 for electrical connection with the external circuit is fixedly coupled to an insert nut 30. In this way, the terminal 20 and the external circuit can be electrically connected by bolting.

It should be noted that, in the technical solution of the present invention, the motor may only have the function of an electric motor, that is, only electric energy can be converted into mechanical energy; the electric motor may also only have the function of a generator, that is, only other energy can be Converted into electrical energy; the motor can also have the function of both the motor and the generator, that is, it can convert electrical energy into mechanical energy and convert other energy into electrical energy.

The motor manufacturing method of the above embodiment will be described below with reference to Figs. 3 to 7 . Specifically, the manufacturing method includes:

As shown in FIG. 7, the stator 50 is provided, and stator windings (not shown) are embedded in the slots of the stator core of the stator 50;

As shown in FIG. 3 and FIG. 4, the wiring component 1 is provided, including: using an integral molding worker Forming the bus ring 10 and the terminal 20;

As shown in FIG. 3 and FIG. 6, the encapsulation is performed to cover the insulating material 40 on the bus bar 10, but the position on the bus bar 10 partially for electrically connecting to the wire ends of the stator winding is not covered by the insulating material 40. That is, the fork joint 11 on the busbar ring 10 is not covered by the insulating material;

After the encapsulation, the wire ends of the stator windings are electrically connected to a position on the bus bar ring 10 that is not partially covered by the insulating material 40, that is, the wire ends of the stator windings are electrically connected to the fork joints 11 on the bus bar ring 10. ;

After the electrical connection, packaging is performed to cover the insulating material on the terminal 20.

In the present invention, the step of encapsulating the bus bar 10 and electrically connecting the wire ends of the stator windings to the bus bar 10 is collectively referred to as encapsulating the stator and the bus bar 10.

Compared with the manufacturing method of the existing motor, the motor manufacturing method of the technical solution of the present invention has the following advantages:

As shown in FIG. 3 and FIG. 6, after the bus bar 10 and the terminal 20 are integrally formed, and then the stator and the bus bar 10 are packaged, the terminal 20 can be directly packaged so that the terminal 20 is insulated with a material (such as a resin). ) 40 coverage. The prior art process of fixedly connecting the busbar ring to the terminal and the one-packing process of connecting the busbar ring and the terminal in the wiring component are omitted, which reduces the manufacturing cost of the motor.

After encapsulation, the three busbar rings 10 are separated by an insulating material 40, and the three terminals 20 are separated by an insulating material 40.

While the terminal 20 is being packaged, the insulating material 40 may also be covered on the surface of the embedded nut 30 such that the insert nut 30 is fixedly coupled to one end of the terminal 20.

As shown in FIG. 3 to FIG. 5, in the present embodiment, the integrally formed bus bar 10 and the terminal 20 are formed by bending a wire. Specifically, prepare a length of appropriate a wire, one end of which is bent into a step shape and used as a terminal 20; then, the remaining portion of the wire is bent so as to be perpendicular to the terminal 20 and the axis of the bus bar 10, and then the wire is The remaining portion is bent into a ring shape and used as the bus ring 10.

It can be seen from the above that when the integrally formed busbar ring 10 and the terminal 20 are formed by using the wire as a raw material, the busbar ring 10 and the terminal block 20 can be simultaneously formed by directly bending a pair of off-the-shelf wires without the need of raw materials. After the partial cutting, the remaining portion is used to form the bus ring 10 and the terminal 20, which improves the manufacturing raw material utilization rate of the bus ring 10 and the terminal 20, and reduces the manufacturing cost of the motor.

As shown in FIG. 7, in the present embodiment, the stator 50 of the motor is sleeved in a rotor (not shown). As shown in FIG. 3, after the wiring member 1 is packaged, the bus bar 10 is placed on the end surface of the stator 50. Upper, and the terminal 20 is located radially outward of the stator 50.

In other embodiments, the stator of the electric machine can also be sleeved outside the rotor. In this case, after the wiring component is packaged, the busbar ring can be sleeved outside the stator.

In addition, the present invention also provides a driving device for a vehicle comprising the above-described electric machine capable of providing a power source for driving of the automobile. In this embodiment, the vehicle driving device is a hybrid driving device, a hub assembly or an electric drive axle.

The hybrid drive device may be a parallel hybrid drive device, a series hybrid drive device, or a hybrid hybrid drive device. The hybrid drive device includes, in addition to the above-described electric machine, an engine, a battery, a motor controller, a transmission, and the like.

The hub assembly includes, in addition to the above-described motor, a hub, a motor controller, and the like.

The electric drive axle includes, in addition to the above-mentioned motor, a final drive, a differential, a wheel transmission, and a transaxle case.

It should be noted that, in the technical solution of the present invention, the vehicle driving device may also be other devices capable of providing a power source for the automobile driving, and should not be limited to Give the example.

Although the present invention has been disclosed above, the present invention is not limited thereto. Any changes and modifications may be made by those skilled in the art without departing from the spirit and scope of the invention, and the scope of the invention should be determined by the scope defined by the appended claims.

Claims

An electric motor comprising: a stator winding; a wiring component electrically connected to a wire end of the stator winding;

Wherein the wiring component comprises:

a busbar ring electrically connected to the wire end of the stator winding;

a terminal for electrically connecting to an external circuit;

The utility model is characterized in that the busbar ring is integrally formed with the connection terminal.
The motor according to claim 1, wherein said stator winding is a three-phase winding, said bus ring and terminal are each three in number, three said bus rings are spaced apart, and said three said wiring Terminals are arranged at intervals;

The stator windings are electrically connected to the three busbar rings in a star connection or a delta connection.
The motor of claim 2 wherein three of said busbar rings are coaxially nested and three of said terminals are circumferentially spaced along said one of said busbar rings.
The motor according to claim 1, wherein said integrally formed bus bar ring and terminal are bent from a wire.
The motor of claim 4 wherein said wire is a copper wire.
A method of manufacturing a motor, comprising:

Providing a stator, the stator winding of the stator is embedded with a stator winding;

Providing wiring components, including: forming a bus ring and a terminal by an integral molding process;

Encapsulating to cover the bus bar on the insulating material;

After the packaging, electrically connecting a wire end of the stator winding to the bus bar ring;

After the electrical connection, a package is performed to cover the insulating material on the terminal.
A method of manufacturing a motor according to claim 6, wherein said integrally formed bus bar ring and terminal are formed by bending a wire.
A method of manufacturing a motor according to claim 7, wherein said wire is a copper wire.
A vehicle drive device comprising the motor of any one of claims 1 to 5.
The vehicular drive device according to claim 9, wherein the vehicular drive device is a hybrid drive device, a hub assembly or an electric drive axle.