WO2021114543A1

WO2021114543A1 - Busbar structure and manufacturing method therefor

Info

Publication number: WO2021114543A1
Application number: PCT/CN2020/086080
Authority: WO
Inventors: 钟全思; 张扬
Original assignee: 深圳市凯中精密技术股份有限公司
Priority date: 2019-12-13
Filing date: 2020-04-22
Publication date: 2021-06-17
Also published as: CN112994368A

Abstract

A busbar structure and a manufacturing method therefor, relating to the technical field of motors. The method comprises: manufacturing an upper ring body (1), a middle ring body (2), and a lower ring body (3), the upper ring body (1) comprising at least two upper connecting parts (11), the middle ring body (2) comprising at least two middle connecting parts (21), and the lower ring body (3) comprising at least two lower connecting parts (31); respectively welding all the upper connecting parts (11), the middle connecting parts (21) and the lower connecting parts (31) end to end to form the upper ring body (1), the middle ring body (2), and the lower ring body (3); performing rubber coating on the middle ring body (2) to enable the middle ring body (2) to be coated by an insulating layer (22); and sequentially stacking and assembling the upper ring body (1), the middle ring body (2), and the lower ring body (3) to form a ring body assembly, performing rubber coating on the ring body assembly to form a plastic member (4), and assembling the ring body assembly and the plastic member (4) to form a busbar. By splitting the upper ring body (1), the middle ring body (2), and the lower ring body (3) into a plurality of parts for welding, direct punch forming is avoided, input costs of large stamping devices are reduced, moreover, errors in machining size of components and parts are also reduced, and the utilization of materials is improved.

Description

Busbar structure and manufacturing method thereof

Technical field

This application relates to the technical field of motors, and in particular to a busbar structure and a manufacturing method thereof.

Background technique

In the structure of the motor, the busbar unit is one of the important components in the motor, which plays the role of conveying current and connecting electrical equipment in the circuit. The bus bars in the prior art are generally arranged in a ring shape, and the bus bars are formed by integral stamping.

The Chinese utility model patent with the authorized announcement number CN208094399U discloses a permanent magnet synchronous motor busbar structure for vehicles, which includes a base, a neutral ring and three bus rings with different diameters. The base is a ring structure, and An annular groove is provided in the base, the neutral ring and the three confluence rings are all embedded in the annular groove, the neutral ring is located on the side of the annular groove close to the center of the circle, and the three confluence rings The ring rim diameter is sequentially sheathed outside the neutral ring from small to large, and each of the bus rings is provided with a nano-insulating coating. In the utility model, a nano insulating coating is used instead of filling insulating silica gel between adjacent bus rings, so that the radial size of the bus bars is reduced.

The above technical solutions have the following drawbacks: the confluence ring is formed by integral stamping, and the size of the confluence ring is relatively large, and large-scale punching equipment is required to stamp the confluence ring. However, when large parts are stamped, the machining error size of the parts is relatively large. It is easy to cause waste of materials.

Summary of the invention

The purpose of the present application is to provide a busbar structure and a manufacturing method thereof, so as to solve the problem of low material utilization rate during busbar processing and production in the prior art.

In order to achieve the above objective, the technical solution adopted in this application is to provide a confluence structure, which includes an upper ring body, a middle ring body at the bottom of the upper ring body, a lower ring body at the bottom of the middle ring body, and a plastic part The upper ring body includes at least two upper connecting parts which are connected end to end to form a closed upper ring body; the middle ring body includes at least two middle connecting parts which are connected end to end to form a closed The middle layer ring body; the lower layer ring body includes at least two lower connecting parts, which are connected end to end to form a closed lower ring body; the plastic part is in the shape of a ring, and the plastic part covers the upper layer The ring body, the middle layer ring body and the lower layer ring body.

Further, the outer side of the middle layer ring body is covered with an insulating layer.

Further, the upper connecting portion is provided with an upper connecting piece, the middle connecting portion is provided with a middle connecting piece, the lower connecting portion is provided with a lower connecting piece, and the outer motor stator is respectively connected to the upper connecting piece and the middle connecting piece. It is fixedly connected with the lower connecting piece.

Further, the heights of the upper connecting piece, the middle connecting piece and the lower connecting piece are all different, and the top ends of the upper connecting piece, the middle connecting piece and the lower connecting piece are all located on the same horizontal plane .

Further, the upper connecting portion, the middle connecting portion and the lower connecting portion are all provided with terminals for conducting wire connection with other parts.

Further, the plastic part is provided with a fixing hole which can be connected with the motor stator insulation cover.

Further, the plastic part is provided with a positioning hole for injection positioning the plastic part.

Further, the plastic part is provided with a connecting block that facilitates the welding of the copper wire of the stator winding.

The present application also provides a busbar manufacturing method for manufacturing the busbar structure, and the manufacturing method includes the following steps:

Manufacturing an upper ring body, the upper ring body includes at least two upper connecting parts, and welding the head and tail of all the upper connecting parts to form a closed upper ring body;

Manufacturing a middle layer ring body, the middle layer ring body includes at least two middle connecting parts, the head and tail of all the middle connecting parts are welded to form a closed middle layer ring body;

Manufacturing a lower layer ring body, the lower layer ring body includes at least two lower connecting parts, the head and tail of all the lower connecting parts are welded to form a closed lower layer ring body;

Welding terminals, respectively welding the terminals to one side of the upper ring body, the middle ring body and the lower ring body;

Providing an insulating layer, and encapsulating the middle layer ring body so that the outer side of the middle layer ring body is covered with the insulating layer;

Manufacture a plastic part, sequentially stack and assemble the upper ring body, the middle ring body and the lower ring body into a ring body assembly, encapsulate the outer edge of the ring body assembly and form the plastic part, so The ring body component and the plastic part form a bus bar.

Further, in the step of manufacturing the upper layer ring body, the middle layer ring body and the lower layer ring body, before welding the upper connecting portion, the middle connecting portion and the lower connecting portion, the The upper connecting part, the middle connecting part and the lower connecting part are cleaned.

Further, in the step of manufacturing the upper layer ring body, the middle layer ring body and the lower layer ring body, the finished upper layer ring body, the middle layer ring body and the lower layer ring body are all electroplated.

Further, in the step of welding the terminal, the terminal is electroplated before the welding installation.

Further, after the step of manufacturing the plastic part, the method further includes the following steps:

Withstand voltage test, perform a withstand voltage test on the busbar after the manufacturing is completed;

Visual inspection: Perform visual inspection on the bus bar that has passed the withstand voltage test.

The beneficial effects of the busbar structure and its manufacturing method provided by this application are as follows:

1. The busbar is arranged into a three-layer structure of upper ring body, middle ring body and lower ring body, which increases the surface area of the busbar, which is conducive to the heat dissipation of the busbar to a certain extent. The surface area of the bus bar shows the surface area of the bus bar, which is conducive to the heat dissipation of the bus bar to a certain extent. At the same time, the upper ring body, the middle ring body and the lower ring body are separated into multiple parts for welding, avoiding the direct stamping and forming of the upper ring body, the middle ring body and the lower ring body. The size of the lower ring body is relatively large. If stamping is carried out, large stamping equipment is required to meet the processing requirements, and the use of large stamping equipment sections is a waste of investment costs. By splitting the ring body assembly into multiple small parts for welding, the investment cost of large-scale stamping equipment is reduced, and at the same time, the processing size error of the parts is reduced, and the utilization rate of materials is improved.

2. The tops of the upper connecting piece, middle connecting piece and lower connecting piece are located on the same horizontal plane. The upper connecting piece, middle connecting piece and lower connecting piece are used for fixing to the motor stator. The upper connecting piece, the middle connecting piece and the lower connecting piece are used for fixing to the stator of the motor. The top part is on the same horizontal surface, which is convenient for subsequent welding and fixing.

3. First encapsulate the middle ring body, then stack and assemble the upper ring body, middle ring body, and lower ring body in turn, and finally encapsulate the assembled ring body components a second time, because the middle ring body is already The encapsulation is carried out, and the middle layer ring body is covered with an insulating layer, which avoids the contact between the upper layer ring body and the lower layer ring body. At the same time, the insulating layer is relatively rough, which prevents the upper ring body or the lower ring body from sliding after assembly, causing the upper ring body and the lower ring body to contact and short circuit, which facilitates the second encapsulation, and the finished product has better stability.

Description of the drawings

In order to more clearly illustrate the specific embodiments of this application or the technical solutions in the prior art, the following will briefly introduce the drawings that need to be used in the specific embodiments or the description of the prior art. Obviously, the appendix in the following description The drawings are some embodiments of the present application. For those of ordinary skill in the art, without creative work, other drawings can be obtained based on these drawings.

FIG. 1 is a schematic diagram of the burst structure of the overall structure of the busbar provided in Embodiment 1 of the application;

Fig. 2 is an enlarged schematic diagram of part A in Fig. 1.

Description of reference signs:

1. Upper ring body; 11, upper connecting part; 12, upper connecting piece; 2. middle ring body; 21, middle connecting part; 22, insulating layer; 23, middle connecting piece; 3. lower ring body; 31, lower 32. Lower connector; 4. Plastic part; 41. Fixing hole; 42. Connecting block; 43. Positioning hole; 5. Terminal.

Detailed ways

The technical solutions of the present application will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of this application.

In the description of this application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. The indicated orientation or positional relationship is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the application and simplifying the description, and does not indicate or imply that the pointed device or element must have a specific orientation or a specific orientation. The structure and operation cannot therefore be understood as a limitation of this application. In addition, the terms "first", "second", and "third" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance.

In the description of this application, it should be noted that the terms "installation", "connection", and "connection" should be understood in a broad sense, unless otherwise clearly specified and limited. For example, it can be a fixed connection or a detachable connection. Connected or integrally connected; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication between two components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood under specific circumstances.

In addition, the technical features involved in the different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

Example 1

1, an embodiment of the present application provides a busbar structure, which includes a ring body assembly and a plastic part 4 covering the ring body assembly. The ring body assembly includes an upper ring body 1, a middle ring body 2 and a lower layer from top to bottom. The ring body 3, the upper ring body 1 includes at least two upper connecting parts 11, which are connected end to end to form a closed ring. The middle layer ring body 2 includes at least two middle connecting parts 21, the middle connecting parts 21 are connected end to end to form a closed ring shape, and the middle layer ring body 2 is covered with an insulating layer 22. The lower ring body 3 includes at least two lower connecting parts 31 which are connected end to end to form a closed ring.

Specifically, the radii of the upper ring body 1, the middle ring body 2 and the lower ring body 3 are all the same. The radii of the upper ring body 1, the middle ring body 2 and the lower ring body 3 are all the same, which facilitates the assembly of the upper ring body 1, the middle ring body 2 and the lower ring body 3. At the same time, the upper ring body 1, the middle ring body 2 and the lower ring body The ring body 3 is the same size, which also avoids the contact between the upper ring body 1 and the lower ring body 3, and ensures the safety of the busbar. The upper connecting portion 11 is provided with an upper connecting piece 12 fixed to the stator of the motor, the middle connecting portion 21 is provided with a middle connecting piece 23 fixed to the stator of the motor, and the lower connecting portion 31 is provided with a lower connecting piece 32 fixed to the stator of the motor. The heights of the upper connecting piece 12, the middle connecting piece 23, and the lower connecting piece 32 are all different. When the upper ring body 1, the middle layer ring body 2 and the lower layer ring body 3 are stacked and assembled into a ring body assembly, the upper connecting piece 12, the middle connecting piece 23 It is located on the same horizontal plane as the top of the lower connecting member 32, which is convenient for subsequent welding and fixing.

Further, one side of the upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31 are all welded with the terminal 5. When the upper ring body 1, the middle layer ring body 2 and the lower layer ring body 3 are stacked and assembled into a ring body assembly, all The tops of the terminals 5 are all on the same horizontal plane. The upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31 are all provided with a terminal 5, and the terminal 5 is arranged to facilitate the wire connection between the bus bar and other parts.

1 and 2, further, on the top of the plastic part 4 is provided with a fixing hole 41 that can be connected to the external motor stator insulation cover and a positioning hole 43 for injection positioning of the plastic part 4. The fixing hole 41 is a square hole, and the external motor The inner side of the stator insulation cover is provided with a plug. When the external stator insulation cover is installed, the plug can be inserted into the fixing hole 41. The fixing hole 41 is provided to facilitate fixing of the external stator insulation cover. The positioning hole 43 is a circular hole, and the number of the positioning hole 43 is not limited. The positioning hole 43 supports the ring body assembly and prevents the ring body assembly from being deformed during injection molding. At the same time, a connection block 42 is installed on the plastic part 4 near the outside to facilitate the welding of the external stator winding copper wire. The specific positions of the fixing hole 41 and the connecting block 42 are not limited, and they can be adjusted accordingly according to the positions of the external motor stator insulation cover and the external stator winding copper wire.

1, an embodiment of the present application also provides a method for manufacturing a bus bar, including the following steps:

S1, the upper ring body 1 is manufactured. The upper ring body 1 includes at least two upper connecting portions 11. In this embodiment, the number of upper connecting portions 11 is four, and the three upper connecting portions 11 have the same shape and the same size. The connecting parts 11 are all arranged in an arc shape. The heads and tails of all the upper connecting parts 11 are welded to form a closed upper ring body 1, and the upper ring body 1 is formed into a flat ring shape. An upper connecting piece 12 is provided on one side of the upper connecting portion 11, the upper connecting piece 12 is located outside the upper ring body 1, and the upper connecting piece 12 is in the shape of a flat sheet;

S2, the middle layer ring body 2 is manufactured. The middle layer ring body 2 includes at least two middle connecting parts 21. In this embodiment, the number of middle connecting parts 21 is four. Among them, the three middle connecting parts 21 have the same shape and the same size. The connecting parts 21 are all arranged in an arc shape. The heads and tails of all the middle connecting parts 21 are welded to form a closed middle ring body 2, and the middle ring body 2 is in a flat ring shape. A middle connecting piece 23 is provided on one side of the middle connecting portion 21, the middle connecting piece 23 is located outside the middle ring body 2, and the middle connecting piece 23 is in the shape of a flat sheet;

S3, the lower ring body 3 is manufactured. The lower ring body 3 includes at least two lower connecting portions 31. In this embodiment, the number of lower connecting portions 31 is four, and the three lower connecting portions 31 have the same shape and the same size. The connecting parts 31 are all arranged in an arc shape. The heads and tails of all the lower connecting parts 31 are welded to form a closed lower ring body 3, and the lower ring body 3 is formed into a flat ring shape. A lower connecting piece 32 is provided on one side of the lower connecting portion 31, the lower connecting piece 32 is located outside the lower ring body 3, and the lower connecting piece 32 is in the shape of a flat sheet;

S4, welding terminals 5, welding terminals 5 on one side of the upper ring body 1, the middle ring body 2 and the lower ring body 3 respectively;

S5, the insulating layer 22 is provided, and the middle layer ring body 2 is encapsulated so that the outer side of the middle layer ring body 2 is covered with the insulating layer 22;

S6, manufacturing the plastic part 4, sequentially stack and assemble the upper ring body 1, the middle ring body 2 and the lower ring body 3 into a ring body assembly, encapsulate the outer edge of the ring body assembly and form a plastic part 4, the ring body assembly and The plastic part 4 constitutes the busbar;

S7, withstand voltage test, perform a withstand voltage test on the finished busbar;

S8, visual inspection, performing visual inspection on the bus bar that has passed the withstand voltage test.

An embodiment of the present application provides a method for manufacturing a busbar. The busbar is configured as a ring body assembly and a plastic part 4. The ring body assembly includes a three-layer structure of an upper ring body 1, a middle ring body 2 and a lower ring body 3. The body components are arranged in a three-layer structure of upper, middle and lower, which increases the surface area of the busbar, which is conducive to the heat dissipation of the busbar to a certain extent. At the same time, the upper ring body 1, the middle ring body 2 and the lower ring body 3 are split into a plurality of upper connecting parts 11, middle connecting parts 21 and lower connecting parts 31 for welding, avoiding the upper ring body 1, the middle ring Since the upper ring body 1, the middle ring body 2 and the lower ring body 2 are large in size for the direct stamping and forming of the body 2 and the lower ring body 3, if the stamping process requires large-scale stamping equipment to meet the processing requirements, the large-scale The stamping equipment section is more wasteful of input costs. By splitting the ring body assembly into multiple small parts for welding, the investment cost of large-scale stamping equipment is reduced, and at the same time, the processing size error of the parts is reduced, and the utilization rate of materials is improved.

Wherein, in other embodiments of the present application, the number of the upper connecting portion 11, the middle connecting portion 21, and the lower connecting portion 31 may also be three or five respectively, as long as the upper connecting portion 11, the middle connecting portion 21 and the The lower connecting portion 31 can be welded to form a closed ring respectively. And the numbers of the upper connecting parts 11, the middle connecting parts 21 and the lower connecting parts 31 are generally the same. Of course, the numbers of the upper connecting parts 11, the middle connecting parts 21 and the lower connecting parts 31 may also be inconsistent according to actual conditions and specific requirements. There is no limitation here.

Wherein, in other embodiments of the present application, the method for manufacturing the upper ring body 1, the middle ring body 2 and the lower ring body 3 may be as follows: first bending the profile to form a ring with an open side, and then aligning the ring The ring is stamped to form a semi-finished product, and finally the openings of the semi-finished product are welded to form the upper ring body 1, the middle layer ring body 2 and the lower layer ring body 3 respectively. The method for manufacturing the upper ring body 1, the middle ring body 2 and the lower ring body 3 can be as follows: first bending the profile to form a ring with an opening on one side, and then welding the opening of the ring to form a closed ring. Finally, the closed ring is punched to form the upper ring body 1, the middle ring body 2 and the lower ring body 3.

1, specifically, in the steps S1, S2, and S3, the manufacturing methods of the upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31 are all stamping and forming, and the stamping and forming method is simple and convenient at the same time. Mass production. The upper connecting piece 12, the middle connecting piece 23, and the lower connecting piece 32 are respectively the convex sheets formed by the upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31, which are respectively located at the upper connecting portion 11 and the middle connecting portion 21. And the outer edge of the lower connecting part 31 is conveniently used for fixing with the stator of the external motor. The upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31 are all welded by laser welding. The laser welding speed is fast and the deformation is small, the welding equipment is simple, and the welding point can be accurately positioned, which can be applied to mass automation in production.

After the upper ring body 1, the middle ring body 2 and the lower ring body 3 are stacked and assembled into a ring body assembly, the tops of the upper connecting piece 12, the middle connecting piece 23 and the lower connecting piece 32 are all located on the same horizontal plane, which is convenient for subsequent connection with the external motor stator The welding is fixed. The radii of the upper ring body 1, the middle ring body 2 and the lower ring body 3 are all the same. On the one hand, it is convenient to stack and assemble the upper ring body 1, the middle ring body 2 and the lower ring body 3, and on the other hand, it is convenient for the subsequent assembly of the ring body components. The outer edge is encapsulated to make plastic parts4. The plastic part 4 is an insulating part formed after the ring body assembly is encapsulated with an insulating material such as plastic.

1, specifically, in the steps S1, S2, and S3, before welding the upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31, the upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion are first welded. 31 Clean, keep the parts clean, and facilitate subsequent welding. The cleaning method can be ultrasonic cleaning or cleaning with a high-pressure water gun, which is convenient for cleaning the remaining metal dust on the upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31. After the above cleaning is completed, the upper connecting portion 11, the middle connecting portion 21 and the lower connecting portion 31 are respectively welded to form the upper ring body 1, the middle ring body 2 and the lower ring body 3, and then the upper ring body 1, the middle ring body Both the 2 and the lower ring body 3 are electroplated. Electroplating can enhance the corrosion resistance of metals, increase hardness, prevent abrasion, improve conductivity, lubricity and heat resistance. In step S4, the terminal 5 is also electroplated before being soldered and installed. Among them, electroplating can be replaced with sprayed metal powder layer, and the air pressure of powder must be controlled during spraying to ensure that the sprayed parts are not damaged. The processing sequence of S1, S2, and S3 can be replaced with each other according to actual conditions and specific needs.

1, specifically, in the step S4, the terminal 5 is in the shape of a sheet, and the arrangement of the terminal 5 facilitates the wire connection between the bus bar and other parts. The manufacturing method is also stamping and forming, which is convenient for mass production. Electroplating is performed on the stamped and formed terminal 5 to enhance the corrosion resistance and heat resistance of the terminal 5, and then the electroplated terminal 5 is welded and installed.

1, specifically, in the step S5, the middle layer ring body 2 is encapsulated, and the encapsulation is made of insulating materials such as rubber or plastic, so that the outer side of the middle layer ring body 2 is covered with an insulating layer 22, and then The middle layer ring body 2 is kept insulated from the upper layer ring body 1 and the lower layer ring body 3. Among them, it is also possible to provide insulating sheets on both the upper and lower surfaces of the intermediate ring body 2. The insulating sheets are made of insulating materials such as ceramics, rubber or plastic, so that the upper and lower surfaces of the intermediate ring body 2 form an insulating layer 22. In this case, there is no need to align the intermediate ring body. 2 Carry out encapsulation.

1 and 2, specifically, in the step S6, after the plastic part 4 is manufactured, a fixing hole 41 that can be connected to the outer motor stator insulation cover is formed on the top of the plastic part 4, and the plastic part 4 is positioned by injection molding The positioning holes 43 and the fixing holes 41 are square holes. The inner side of the external motor stator insulation cover is provided with a plug pin. When the external stator insulation cover is installed, the plug can be inserted into the fixing hole 41. The fixing hole 41 is provided to facilitate the external stator insulation cover Fix it. The positioning hole 43 is a circular hole that supports the ring body assembly and prevents the ring body assembly from deforming during injection molding. At the same time, a connection block 42 is installed on the plastic part 4 near the outside to facilitate the welding of the external stator winding copper wire. The specific positions of the fixing hole 41 and the connecting block 42 are not limited, and they can be adjusted accordingly according to the positions of the external motor stator insulation cover and the external stator winding copper wire.

Specifically, in step S7, the manufactured busbar is subjected to a withstand voltage test by a withstand voltage tester to check whether the performance of the busbar meets the requirements for use. Avoid accidental damage to the busbar during subsequent use.

Specifically, in step S8, visual inspection is performed on the bus bar that has passed the withstand voltage test by means of human eye inspection or machine scanning. The appearance inspection can detect whether the structure of the busbar is defective, and screen out the unqualified busbar in time to ensure the pass rate of the busbar. At the same time, the withstand voltage test may cause damage to the appearance of some bus bars, so the appearance inspection must be performed after the withstand voltage test. Finally, install or store the bus without any defects.

Example 2

1, the present application provides a method for manufacturing a bus bar, which includes the following steps:

S1, the upper ring body 1 is manufactured. The upper ring body 1 includes at least two upper connecting portions 11. In this embodiment, the number of upper connecting portions 11 is four. All upper connecting portions 11 have the same shape and the same size, and they are all set in an arc shape. . The heads and tails of all the upper connecting parts 11 are welded to form a closed upper ring body 1, and the upper ring body 1 is formed into a flat ring shape. An upper connecting piece 12 is provided on one side of the upper connecting portion 11, the upper connecting piece 12 is located outside the upper ring body 1, and the upper connecting piece 12 is in the shape of a flat sheet;

S2. Manufacturing the middle layer ring body 2. The middle layer ring body 2 includes at least two middle connecting parts 21. In this embodiment, the number of middle connecting parts 21 is four. All middle connecting parts 21 have the same shape and the same size, and they are all set in an arc shape. . The heads and tails of all the middle connecting parts 21 are welded to form a closed middle ring body 2, which is formed into a flat ring shape. A middle connecting piece 23 is provided on one side of the middle connecting portion 21, the middle connecting piece 23 is located on the outside of the middle ring body 2, and the middle connecting piece 23 is in the shape of a flat sheet;

S3, the lower ring body 3 is manufactured. The lower ring body 3 includes at least two lower connecting parts 31. In this embodiment, the number of lower connecting parts 31 is four, and all the lower connecting parts 31 have the same shape and the same size, and they are all set in an arc shape. . The heads and tails of all the lower connecting parts 31 are welded to form a closed lower ring body 3, and the lower ring body 3 is formed into a flat ring shape. A lower connecting piece 32 is provided on one side of the lower connecting portion 31, the lower connecting piece 32 is located outside the lower ring body 3, and the lower connecting piece 32 is in the shape of a flat sheet;

S4, the insulating layer 22 is provided, and the middle layer ring body 2 is encapsulated so that the outer side of the middle layer ring body 2 is covered with the insulating layer 22;

S5, welding terminals 5, welding terminals 5 on one side of the upper ring body 1, the middle ring body 2 and the lower ring body 3 respectively;

Among them, the order of S1, S2, S3, and S4 can be replaced with each other according to actual conditions and specific needs, but it is sufficient to ensure that the step of S2 is before the step of S4. The difference between this embodiment and Embodiment 1 is only in the order of the processing steps, and other specific implementations are the same as in Embodiment 1, so they will not be repeated.

Example 3

S1, the upper ring body 1 is manufactured. The upper ring body 1 includes at least two upper connecting portions 11. In this embodiment, the number of upper connecting portions 11 is four. All upper connecting portions 11 have the same shape and the same size, and they are all set in an arc shape. . The heads and tails of all the upper connecting parts 11 are welded to form a closed upper ring body 1, and the upper ring body 1 is formed into a flat ring shape. An upper connecting piece 12 is provided on one side of the upper connecting portion 11, the upper connecting piece 12 is located outside the upper ring body 1, and the upper connecting piece 12 is in the shape of a flat sheet. Solder terminal 5 to side 1 of the upper ring body;

S2. Manufacturing the middle layer ring body 2. The middle layer ring body 2 includes at least two middle connecting parts 21. In this embodiment, the number of middle connecting parts 21 is four. All middle connecting parts 21 have the same shape and the same size, and they are all set in an arc shape. . The heads and tails of all the middle connecting parts 21 are welded to form a closed middle ring body 2, and the middle ring body 2 is formed into a flat ring shape. One side of the middle connecting portion 21 is provided with a middle connecting piece 23, which is located outside the middle ring body 2, and the middle connecting piece 23 is in the shape of a flat sheet. Weld the terminal 5 on one side of the middle ring body 2;

S3, the lower ring body 3 is manufactured. The lower ring body 3 includes at least two lower connecting parts 31. In this embodiment, the number of lower connecting parts 31 is four, and all the lower connecting parts 31 have the same shape and the same size, and they are all set in an arc shape. . The heads and tails of all the lower connecting parts 31 are welded to form a closed lower ring body 3, and the lower ring body 3 is formed into a flat ring shape. A lower connecting piece 32 is provided on one side of the lower connecting portion 31, the lower connecting piece 32 is located outside the lower ring body 3, and the lower connecting piece 32 is in the shape of a flat sheet. Solder terminals 5 on one side of the lower ring body 3;

S5, manufacturing the plastic part 4, sequentially stack and assemble the upper ring body 1, the middle ring body 2 and the lower ring body 3 into a ring body assembly, encapsulate the outer edge of the ring body assembly and form a plastic part 4, the ring body assembly and The plastic part 4 constitutes the busbar;

S6, withstand voltage test, perform a withstand voltage test on the busbar after manufacturing;

S7, visual inspection, performing visual inspection on the bus bar that has passed the withstand voltage test.

The examples of this specific implementation manner are all preferred examples of the application, and the scope of protection of the application is not limited accordingly. Therefore: all equivalent changes made in accordance with the structure, shape, and principle of the application shall be covered in Within the scope of protection of this application.

Claims

A busbar structure, which is characterized in that it comprises:

The upper ring body (1), the upper ring body (1) includes at least two upper connecting parts (11), the upper connecting parts (11) are connected end to end to form a closed upper ring body (1);

A middle ring body (2) located at the bottom of the upper ring body (1), the middle ring body (2) includes at least two middle connecting parts (21), the middle connecting parts (21) are connected end to end to form a closed Middle ring body (2);

The lower ring body (3) located at the bottom of the middle ring body (2), the lower ring body (3) includes at least two lower connecting parts (31), the lower connecting parts (31) are connected end to end to form a closed Lower ring body (3); and

A plastic part (4), the plastic part (4) is in the shape of a ring, and the plastic part (4) covers the upper ring body (1), the middle ring body (2) and the lower ring body (3).
The busbar structure according to claim 1, characterized in that the outer side of the middle layer ring body (2) is covered with an insulating layer (22).
The busbar structure according to claim 1, wherein the upper connecting portion (11) is provided with an upper connecting piece (12), and the middle connecting portion (21) is provided with a middle connecting piece (23) The lower connecting part (31) is provided with a lower connecting piece (32), and the outer motor stator is respectively fixedly connected with the upper connecting piece (12), the middle connecting piece (23) and the lower connecting piece (32).
The busbar structure according to claim 3, characterized in that the heights of the upper connecting piece (12), the middle connecting piece (23) and the lower connecting piece (32) are all different, so The top ends of the upper connecting piece (12), the middle connecting piece (23) and the lower connecting piece (32) are all located on the same horizontal plane.
The busbar structure according to claim 1, characterized in that the upper connecting portion (11), the middle connecting portion (21) and the lower connecting portion (31) are all provided for connecting with other parts. Terminal for wire connection (5).
The busbar structure according to claim 1, wherein the plastic part (4) is provided with a fixing hole (41) that can be connected with the motor stator insulation cover.
The busbar structure according to claim 1, wherein the plastic part (4) is provided with a positioning hole (43) for injection positioning the plastic part (4).
The busbar structure according to claim 1, characterized in that the plastic part (4) is provided with a connecting block (42) that facilitates the welding of the copper wire of the stator winding.
A method for manufacturing a busbar for manufacturing the busbar structure according to any one of claims 1 to 8, characterized in that it comprises the following steps:

Manufacture the upper ring body (1), the upper ring body (1) includes at least two upper connecting parts (11), and welding the head and tail of all the upper connecting parts (11) to form a closed upper ring body (1) );

Manufacturing the middle layer ring body (2), the middle layer ring body (2) includes at least two middle connecting parts (21), the head and tail of all the middle connecting parts (21) are welded to form a closed middle layer ring body (2) );

Manufacture the lower layer ring body (3), the lower layer ring body (3) includes at least two lower connecting parts (31), the head and tail of all the lower connecting parts (31) are welded to form a closed lower ring body (3) );

Welding terminals (5), welding the terminals (5) to one side of the upper ring body (1), the middle ring body (2) and the lower ring body (3) respectively;

An insulating layer (22) is provided, and the middle layer ring body (2) is encapsulated so that the outer side of the middle layer ring body (2) is covered with the insulating layer (22);

Manufacture a plastic part (4), sequentially stack and assemble the upper ring body (1), the middle ring body (2) and the lower ring body (3) into a ring body assembly, and the outer ring body assembly The edge is encapsulated to form the plastic part (4), and the ring body assembly and the plastic part (4) form a bus bar.
A method for manufacturing a busbar according to claim 9, characterized in that, in the steps of manufacturing the upper ring body (1), the middle ring body (2) and the lower ring body (3), Before the upper connecting portion (11), the middle connecting portion (21) and the lower connecting portion (31) are welded, the upper connecting portion (11), the middle connecting portion (21) and the The following connection part (31) is cleaned.
A method for manufacturing a busbar according to claim 9, characterized in that, in the steps of manufacturing the upper ring body (1), the middle ring body (2) and the lower ring body (3), The finished upper ring body (1), the middle layer ring body (2) and the lower layer ring body (3) are all electroplated.
The method of manufacturing a busbar according to claim 9, characterized in that, in the step of welding the terminal (5), the terminal (5) is electroplated before the welding installation.
A method for manufacturing a busbar structure according to claim 9, characterized in that, after the step of manufacturing the plastic part (4), the method further comprises the following steps:

Withstand voltage test, perform a withstand voltage test on the busbar after the manufacturing is completed;

Visual inspection: Perform visual inspection on the bus bar that has passed the withstand voltage test.