Rotating electric machine and armature

Abstract

A rotary electric motor and an armature are disclosed. The rotary electric motor includes a neutral bus and a temperature sensor. The neutral bus has a body and a bend that holds the temperature sensor. The body has a first component and a second component, each of which has one or more connection terminals. The bend is formed between a circumferential end of the first component and a circumferential end of the second component. In the first component, a first extension extending axially or radially is formed between the circumferential end of the first component and the connection terminal formed in the first component closest to the bend. Similarly, in the second component, a second extension extending axially or radially is formed between the circumferential end of the second component and the connection terminal formed in the second component closest to the bend.

Description

Technical Field

[0001] This disclosure relates to a rotary electric machine and an armature. Background Technology

[0002] Known rotating electric machines include an armature having three-phase armature coils wound on an armature core. Furthermore, methods for defining the neutral point of the armature coils by Y-connecting (or star-connecting) the three-phase armature coils via a neutral bus are also known, for example, as disclosed in Japanese Patent Application Publication No. JP2019-110676A (hereinafter referred to as Patent Document 1) and Japanese Patent No. JP5996917B2 (hereinafter referred to as Patent Document 2).

[0003] In addition, Patent Documents 1 and 2 disclose a method for detecting the temperature of an armature coil using a temperature sensor fixed to the neutral bus.

[0004] Specifically, according to the disclosure of Patent Document 1, the neutral busbar has a bend formed in its body. The bend bends in a generally U-shape toward the radial inner periphery of the stator, which serves as the armature. The temperature sensor is clamped and thus held in this bend.

[0005] Similarly, according to Patent Document 2, the temperature sensor is also held in a generally U-shaped bend formed in the body of the neutral busbar. Furthermore, according to Patent Document 2, a fixing member is formed by resin molding, such that both the bend of the neutral busbar and the temperature sensor are fixed therein. Additionally, during the resin molding of the fixing member, a pressing member is used to press the bend of the neutral busbar and the temperature sensor together to maintain contact between the temperature sensor and the bend of the neutral busbar.

[0006] According to the aforementioned patent document, the bend is formed by bending a portion of the neutral busbar's main body. Furthermore, on each side of the bend, at least one connection terminal is formed within the main body of the neutral busbar. Typically, during the assembly of the neutral busbar to the armature, the position of the connection terminals is adjusted to allow them to engage with the winding ends of the armature coils respectively. However, during the adjustment of the connection terminal position, the bend of the neutral busbar may experience strain, causing the opening of the generally U-shaped bend to expand. Therefore, it is difficult to reliably hold the temperature sensor within the bend of the neutral busbar. As a result, it is difficult to reliably suppress displacement of the temperature sensor; and it is also difficult to reliably maintain contact between the temperature sensor and the bend of the neutral busbar.

[0007] Furthermore, according to Patent Document 2, the pressing member is removed after the resin molding of the fixing member is completed. Therefore, the position adjustment of the connecting terminal is performed without the pressing member pressing the bent portion of the neutral busbar and the temperature sensor together. Therefore, the problem described above is still difficult to avoid. Summary of the Invention

[0008] This disclosure was made in view of the problems described above. Therefore, the main object of this disclosure is to provide a rotary motor and armature that allow for easy adjustment of the position of the connection terminals of the neutral busbar while properly holding the temperature sensor in the bend of the neutral busbar.

[0009] According to one aspect of this disclosure, a rotary electric motor is provided, comprising an armature, a neutral bus, and a temperature sensor. The armature includes an annular armature core and three-phase armature coils wound on the armature core and Y-connected to define its neutral point. The neutral bus is configured to connect to the neutral-point side winding ends of the armature coils. The temperature sensor is mounted on the neutral bus to detect the temperature of the armature coils. The neutral bus has: a body extending in the circumferential direction of the armature; a plurality of connecting terminals formed in the body and respectively engaged to the neutral-point side winding ends of the armature coils; and a bend that clamps and thereby holds the temperature sensor. The body of the neutral bus has a first component and a second component spaced apart from each other in the circumferential direction and each having one or more connecting terminals formed thereon. The bend is formed between the circumferential ends of the first component and the second component to electrically connect the first component and the second component. In the first component, a first extension is formed between the circumferential end of the first component and one of the one or more connecting terminals formed in the first component that is closest to the bend in the circumferential direction; the first extension extends in the axial or radial direction of the armature. In the second component, a second extension is formed between the circumferential end of the second component and one of the one or more connecting terminals formed in the second component that is closest to the bend in the circumferential direction; the second extension also extends in the axial or radial direction of the armature.

[0010] With the above-described structure, when the portions of the first and second components where the connecting terminals are formed are slightly deformed, the strain caused by the deformation will be absorbed by the first and second extensions. Therefore, when the position of the connecting terminals is adjusted to allow them to engage with the neutral-point winding ends of the armature coil, deformation of the bending portion can be suppressed. That is, the first and second extensions act as buffer members to absorb the strain induced in the first and second components during the adjustment of the connecting terminal position. Therefore, displacement of the temperature sensor due to deformation of the bending portion can be suppressed; and insufficient contact between the temperature sensor and the bending portion due to deformation of the bending portion can be prevented. As a result, the accuracy of temperature detection of the armature coil by the temperature sensor can be prevented.

[0011] In another embodiment, the bend may have a pair of clamping surfaces between which the temperature sensor is clamped. Furthermore, both clamping surfaces of the bend may be formed to extend in an axial direction perpendicular to the armature. In this case, the temperature sensor can be brought into contact with the bend surface of the neutral busbar; therefore, the temperature sensor is easily positioned in the axial direction.

[0012] The bend can be formed to project radially from the body of the neutral busbar and bend back into a generally U-shape in the axial direction. The bend can have: a first open end connected to the circumferential end of a first component of the body; and a second open end connected to the circumferential end of a second component of the body. Both the neutral busbar and the temperature sensor can be covered by a resin member and thus integrated as a single piece. The resin member can have a pair of first and second through holes through which the first and second open ends of the bend protrude axially from the resin member; these first and second through holes correspond to a pair of first and second pressing members for pressing the bend of the neutral busbar and the temperature sensor together from opposite axial sides of the bend during resin molding of the resin member. The circumferential ends of the first component and the second extension can face each other in the circumferential direction. The first through hole can be formed in the resin member to protrude from the circumferential end of the first component toward the second extension between the circumferential end of the first component and the second extension.

[0013] In the above configuration, the bend is open radially inward and circumferentially on both sides. Therefore, the mounting angle of the temperature sensor can be adjusted in the radial and / or circumferential directions, which facilitates the mounting of the temperature sensor on the bend of the neutral busbar.

[0014] Furthermore, in the above-described manner, while pressing the bent portion of the neutral busbar and the temperature sensor together using a pair of first and second pressing members, a resin member can be used to cover both the neutral busbar and the temperature sensor. Therefore, the temperature sensor can be positioned at the desired location; and the temperature sensor can be reliably made to contact the bent portion of the neutral busbar.

[0015] Furthermore, in the above-described case, during resin molding of the resin component, the first pressing member corresponding to the first through-hole is configured to protrude from the circumferential end of the first component toward the second extension between the circumferential end of the first component and the second extension. Therefore, during resin molding, if the neutral busbar twists, thereby causing the second extension to approach the circumferential end of the first component, the first pressing member will interfere with the second extension, thus preventing the second extension from contacting the circumferential end of the first component. Therefore, a short circuit can be prevented between the first and second components; thus, current can be prevented from flowing between the first and second components without passing through the bend. In other words, the current flowing between the first and second components can be reliably made to pass through the bend. As a result, a reduction in the accuracy of temperature detection of the armature coil by the temperature sensor can be reliably prevented.

[0016] Both the neutral bus and the temperature sensor can be covered by a resin component and thus integrated into a single piece. In the resin component, at least one hook-shaped retaining member can be formed to hold the temperature sensor lead. In this case, by retaining (or temporarily fixing) at least one retaining member, the lead can be prevented from drooping from the neutral bus and thus hindering the assembly of the neutral bus to the armature during the delivery of the neutral bus before the lead is connected to the temperature sensor.

[0017] Furthermore, at least one retaining member can be formed of resin and integrated with the resin member as a single piece. At least one retaining member can have a contact surface for contacting the leads of the temperature sensor. The contact surface can be formed as a smooth, flat surface or a smooth, curved surface. In this case, there are no recesses / protrusions in the contact surface, i.e., no undercuts in the contact surface. Therefore, at least one retaining member can be easily resin-molded together with the resin member.

[0018] According to another aspect of this disclosure, an armature is provided, the armature including an annular armature core, three-phase armature coils, a neutral bus, and a temperature sensor. The armature coils are wound around the armature core and Y-connected to define its neutral point. The neutral bus is configured to connect to the neutral-point side winding ends of the armature coils. The temperature sensor is mounted on the neutral bus to detect the temperature of the armature coils. The neutral bus has: a body extending in the circumferential direction of the armature; a plurality of connection terminals formed in the body and respectively engaged to the neutral-point side winding ends of the armature coils; and a bend that clamps and thereby holds the temperature sensor. The body of the neutral bus has a first component and a second component spaced apart from each other in the circumferential direction and each having one or more connection terminals formed thereon. The bend is formed between the circumferential ends of the first component and the second component to electrically connect the first component and the second component. In the first component, a first extension is formed between the circumferential end of the first component and one of the one or more connecting terminals formed in the first component that is closest to the bend in the circumferential direction; the first extension extends in the axial or radial direction of the armature. In the second component, a second extension is formed between the circumferential end of the second component and one of the one or more connecting terminals formed in the second component that is closest to the bend in the circumferential direction; the second extension also extends in the axial or radial direction of the armature.

[0019] By constructing the armature according to the present disclosure as described above, the same beneficial effects as those achieved by constructing the rotary motor according to the present disclosure as described above can be achieved. Attached Figure Description

[0020] Figure 1 This is a top view of the stator of a rotary electric machine according to an exemplary embodiment.

[0021] Figure 2 This is a top view of the stator core of the stator.

[0022] Figure 3 This is a connection diagram of the stator coils.

[0023] Figure 4 This is a three-dimensional view showing the stacking state of the busbars in the busbar unit of the stator.

[0024] Figure 5 This is a 3D view of the busbar unit.

[0025] Figure 6 This is a three-dimensional view of the first neutral busbar of the busbar unit.

[0026] Figure 7This is a perspective view showing how a temperature sensor is mounted on the first neutral bus.

[0027] Figure 8 This is a perspective view showing a busbar unit, a pair of first pressing members and a second pressing member, the first pressing members and the second pressing member being used to press the bent portion of the first neutral busbar and the temperature sensor together during the molding of the resin component of the busbar unit.

[0028] Figure 9 This is a top view of a part of the busbar unit.

[0029] Figure 10 This is a perspective view showing a portion of the busbar unit and the second pressing member.

[0030] Figure 11 This is a perspective view of a portion of the first neutral busbar, illustrating potential problems that may occur during the molding of the resin component.

[0031] Figure 12 This is a perspective view showing the first through-hole formed in the resin component. Detailed Implementation

[0032] Exemplary embodiments will now be described with reference to the accompanying drawings. It should be noted that, for clarity and understanding, the same reference numerals will be used as much as possible to denote the same components that have the same function throughout the specification, and to avoid redundancy, the same components will not be described repeatedly.

[0033] Figure 1 The overall structure of the stator 10 of a rotary electric motor according to an exemplary embodiment is shown.

[0034] In this embodiment, the rotating electrical mechanism is a motor used in a vehicle. Specifically, the motor is a three-phase permanent magnet synchronous motor. The motor includes... Figure 1 The stator 10 (which is cylindrical and serves as an armature) and rotor (not shown) are shown. The rotor is rotatably arranged radially inside the stator 10 and serves as an excitation system.

[0035] In this embodiment, the rotor can have any well-known construction. For example, the rotor can be configured as an IPM (Internal Permanent Magnet) rotor or an SPM (Surface Permanent Magnet) rotor. Alternatively, the rotor can be configured as an excitation coil type rotor. Furthermore, the rotor is configured relative to the stator 10 to be rotatable about a rotation axis.

[0036] In this embodiment, the axial direction (indicated by arrow Y1 in the figure) refers to the axial direction of the cylindrical stator 10, that is, the direction in which the rotation axis of the rotor extends. The radial direction (indicated by arrow Y2 in the figure) refers to the radial direction of the cylindrical stator 10, that is, the direction extending radially from the rotation axis of the rotor. The circumferential direction (indicated by arrow Y3 in the figure) refers to the circumferential direction of the cylindrical stator 10, that is, the direction extending along a circle whose center is located on the rotation axis of the rotor.

[0037] like Figure 1 and Figure 2 As shown, the stator 10 includes: an annular stator core 20 arranged radially outward of the rotor so as to face the rotor radially; three-phase stator coils 30 wound on the stator core 20; and a busbar unit 40 configured to connect the winding ends of the stator coils 30. Furthermore, in this embodiment, the stator core 20 serves as the armature core, and the stator coils 30 serve as the armature coils.

[0038] like Figure 2 As shown, the stator core 20 has an annular back yoke (or back core) 21, a plurality of pole teeth 22, and a plurality of slots 23. Each pole tooth 22 protrudes radially inward from the back yoke 21 and is arranged at a predetermined spacing in the circumferential direction Y3. Each slot 23 is formed between a pair of circumferentially adjacent pole teeth 22. More specifically, in this embodiment, the slots 23 are formed in the stator core 20 at equal spacing in the circumferential direction Y3. In addition, the stator coil 30 is wound on the pole teeth 22 so as to be received in the slots 23.

[0039] In this embodiment, the stator coil 30 is formed by inserting a plurality of generally U-shaped conductor segments 35 from a first axial side of the stator core 20 into slots 23 of the stator core 20, and joining each pair of corresponding ends of the conductor segments 35 protruding out of the slots 23 on a second axial side of the stator core 20. Each conductor segment 35 is obtained by cutting and plastically deforming an conductor having a generally rectangular cross-sectional shape and a constant thickness into a generally "U" shape. Furthermore, the above-described method for forming the stator coil 30 is well known in the art; therefore, a detailed description of the method is omitted below.

[0040] like Figure 3As shown, in this embodiment, the stator coil 30 includes a U-phase winding 30U, a V-phase winding 30V, and a W-phase winding 30W connected together in a Y-shape (or star-shaped). Each of the U-phase winding 30U, V-phase winding 30V, and W-phase winding 30W includes four partial windings connected in parallel with each other. More specifically, the U-phase winding 30U includes four partial windings 31U to 34U connected in parallel with each other; the V-phase winding 30V includes four partial windings 31V to 34V connected in parallel with each other; and the W-phase winding 30W includes four partial windings 31W to 34W connected in parallel with each other.

[0041] The stator coil 30 is connected to a power source such as a battery pack (not shown) via a power converter such as an inverter (not shown). The stator coil 30 generates magnetic flux when supplied with power from the power source (more specifically, three-phase AC power) via the power converter.

[0042] In the stator coil 30, the U-phase winding 30U, the V-phase winding 30V, and the W-phase winding 30W are connected to the power line via the bus unit 40; the power line is further connected to the power converter. Furthermore, the U-phase winding 30U, the V-phase winding 30V, and the W-phase winding 30W are Y-connected via the bus unit 40.

[0043] like Figure 4 As shown, the busbar unit 40 includes: a U-phase busbar 40U, which connects the ends of a portion of the U-phase winding 30U (windings 31U to 34U); a V-phase busbar 40V, which connects the ends of a portion of the V-phase winding 30V (windings 31V to 34V); a W-phase busbar 40W, which connects the ends of a portion of the W-phase winding 30W (windings 31W to 34W); and a neutral busbar 45, which forms the neutral line (or neutral point) of the stator coil 30. Furthermore, as... Figure 4 and Figure 5 As shown, all the U-phase busbars 40U, V-phase busbars 40V, W-phase busbars 40W and neutral busbars 45 are stacked in the axial direction Y1 and are collectively covered by resin component 60 and thus integrated into a single piece.

[0044] Return to Figure 1 In this embodiment, the busbar unit 40 is arranged on one axial side of the stator core 20 and is fixed to the back yoke 21 of the stator core 20 by a plurality of fixing members (e.g., pins) 100. Furthermore, the busbar unit 40 is located radially outward of the stator coil 30 and within the radial dimension of the back yoke 21 of the stator core 20. Additionally, the busbar unit 40 is also within the axial dimension of the coil end of the stator coil 30. Here, the coil end refers to the portion of the stator coil 30 that protrudes from the stator core 20 on its axial side where the busbar unit 40 is arranged.

[0045] like Figure 4 As shown, each of the U-phase busbar 40U, V-phase busbar 40V, and W-phase busbar 40W is formed of a flat wire with a generally rectangular cross-sectional shape. The U-phase busbars 40U, V-phase busbars 40V, and W-phase busbars 40W are stacked in the axial direction Y1, with the longer sides of the rectangular cross-sections of the busbars 40U to 40W facing each other. That is, the U-phase busbars 40U, V-phase busbars 40V, and W-phase busbars 40W are stacked in the axial direction Y1, with the main surfaces of the busbars 40U to 40W facing each other. Here, the main surfaces refer to those surfaces of the busbars 40U to 40W that have the largest area among all the surfaces of the busbars 40U to 40W. Furthermore, the U-phase busbars 40U, V-phase busbars 40V, and W-phase busbars 40W are spaced apart from each other by a predetermined distance in the axial direction Y1. The resin component 60 is inserted between the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W, thereby electrically insulating them from each other.

[0046] In this embodiment, among the U-phase busbar 40U, V-phase busbar 40V, and W-phase busbar 40W, the V-phase busbar 40V is located closest to the stator core 20 in the axial direction Y1; the U-phase busbar 40U is located furthest from the stator core 20 in the axial direction Y1; and the W-phase busbar 40W is located between the V-phase busbar 40V and the U-phase busbar 40U in the axial direction Y1. In other words, in the axial direction Y1, the V-phase busbar 40V is located at the lower layer; the W-phase busbar 40W is located at the middle layer; and the U-phase busbar 40U is located at the upper layer.

[0047] The V-phase busbar 40V is arc-shaped in its axial view. Furthermore, the two circumferential ends of the V-phase busbar 40V are spaced apart from each other at approximately 180° in the circumferential direction Y3. Four V-phase connection terminals 41V to 44V are formed in the circumferential ends of the V-phase busbar 40V to connect to the non-neutral point side ends of the four partial windings 31V to 34V of the V-phase winding 30V, respectively. More specifically, of the four V-phase connection terminals 41V to 44V, connection terminals 41V and 42V are formed in the first circumferential end of the V-phase busbar 40V; the remaining connection terminals 43V and 44V are formed in the second circumferential end of the V-phase busbar 40V. That is, connection terminals 41V and 42V are spaced apart from connection terminals 43V and 44V at approximately 180° in the circumferential direction Y3. Additionally, in the axial view of stator 10, the angle (or circumferential offset) between connecting terminals 41V and 42V is approximately equal to the angle (or circumferential pitch) between slots 23; the angle between connecting terminals 43V and 44V is also approximately equal to the angle between slots 23 (see...). Figure 1 and Figure 2 ).

[0048] Each of the V-phase connection terminals 41V to 44V is formed at the radial outer periphery of the V-phase busbar 40V. More specifically, each of the V-phase connection terminals 41V to 44V is bent to first protrude radially outward from the radial outer periphery of the V-phase busbar 40V, and then extend axially to the side opposite to the stator core 20. Furthermore, each of the V-phase connection terminals 41V to 44V is formed to be thinner at its distal end. For the distal ends of the V-phase connection terminals 41V to 44V, the non-neutral point side ends of portions of the V-phase windings 30V to 34V are respectively joined by welding or the like. Additionally, the V-phase busbar 40V is formed symmetrically in the circumferential direction Y3.

[0049] The W-phase busbar 40W is arc-shaped in its axial view. Furthermore, the two circumferential ends of the W-phase busbar 40W are spaced apart from each other at approximately 180° in the circumferential direction Y3. Four W-phase connection terminals 41W to 44W are formed at the circumferential ends of the W-phase busbar 40W to connect to the non-neutral point side ends of the four partial windings 31W to 34W of the W-phase winding 30W, respectively. More specifically, the W-phase connection terminals 41W to 44W are formed in the same manner as the V-phase connection terminals 41V to 44V as described above.

[0050] The W-phase busbar 40W is stacked on top of the V-phase busbar 40V in the axial direction Y1 (i.e., the side of the V-phase busbar 40V opposite to the stator core 20) so that it is offset counterclockwise from the V-phase busbar 40V in the circumferential direction Y3 at a predetermined angle α. Therefore, in the first and second circumferential ends of the W-phase busbar 40W, the first circumferential end does not overlap with the V-phase busbar 40V. That is, the first circumferential end of the W-phase busbar 40W protrudes counterclockwise from the first circumferential end of the V-phase busbar 40V at a predetermined angle α, while the second circumferential end of the V-phase busbar 40V protrudes clockwise from the second circumferential end of the W-phase busbar 40W at a predetermined angle α.

[0051] The U-phase busbar 40U is arc-shaped in its axial view. Furthermore, the two circumferential ends of the U-phase busbar 40U are spaced apart from each other at approximately 180° in the circumferential direction Y3. Four U-phase connection terminals 41U to 44U are formed at the circumferential ends of the U-phase busbar 40U to connect to the non-neutral point side ends of the four partial windings 31U to 34U of the U-phase winding 30U, respectively. More specifically, the U-phase connection terminals 41U to 44U are formed in the same manner as the V-phase connection terminals 41V to 44V and the W-phase connection terminals 41W to 44W as described above.

[0052] The U-phase busbar 40U is stacked on top of the W-phase busbar 40W in the axial direction Y1 (i.e., the side of the W-phase busbar 40W opposite to the stator core 20) so as to be offset clockwise from the W-phase busbar 40W in the circumferential direction Y3 by (α×2), where α is a predetermined angle. That is, the U-phase busbar 40U is offset clockwise from the V-phase busbar 40V in the circumferential direction Y3 by a predetermined angle α.

[0053] In this embodiment, the neutral busbar 45 includes a pair of first neutral busbars 451 and second neutral busbars 452. Each of the first neutral busbars 451 and the second neutral busbar 452 is arc-shaped in its axial view. Furthermore, each of the first neutral busbars 451 and the second neutral busbar 452 is shorter than the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W, and has a circumferential length corresponding to an angular range of (α×2), where α is a predetermined angle.

[0054] The first neutral busbar 451 and the second neutral busbar 452 are stacked on top of the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W in the axial direction Y1 (i.e., on the side of the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W opposite to the stator core 20). Furthermore, the first neutral busbar 451 and the second neutral busbar 452 are arranged to be spaced apart from each other in the circumferential direction Y3. Specifically, the first neutral busbar 451 is arranged to protrude counterclockwise from the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W. More particularly, in this embodiment, the first neutral busbar 451 is offset counterclockwise from the W-phase busbar 40W at a predetermined angle, and the W-phase busbar 40W protrudes counterclockwise from both the U-phase busbar 40U and the V-phase busbar 40V. Furthermore, the second neutral busbar 452 is located on the side of the central axis of the stator 10 (or the rotation axis of the rotor) opposite to the first neutral busbar 451. In other words, the second neutral busbar 452 is offset from the first neutral busbar 451 by 180° in the circumferential direction Y3.

[0055] like Figure 6 As shown, in this embodiment, the first neutral busbar 451 is configured to have a main body 50, six connection terminals 51U, 52U, 51V, 52V, 51W, 52W, and a bend 53. The main body 50 is formed to extend in the circumferential direction Y3. The connection terminals 51U, 52U, 51V, 52V, 51W, and 52W are formed in the main body 50 to connect to the neutral point side ends of portions of the U-phase winding 30U windings 31U and 32U, portions of the V-phase winding 30V windings 33V and 34V, and portions of the W-phase winding 30W windings 33W and 34W, respectively. The bend 53 is formed to clamp and thereby hold the temperature sensor 80.

[0056] In addition, such as Figure 3As shown, the neutral point ends of the windings 31U and 32U connected to the first neutral busbar 451 are located on the opposite side of the non-neutral point ends of the windings 31U and 32U connected to the U-phase busbar 40U; the neutral point ends of the windings 33V and 34V connected to the first neutral busbar 451 are located on the opposite side of the non-neutral point ends of the windings 33V and 34V connected to the V-phase busbar 40V; and the neutral point ends of the windings 33W and 34W connected to the first neutral busbar 451 are located on the opposite side of the non-neutral point ends of the windings 33W and 34W connected to the W-phase busbar 40W.

[0057] like Figure 6 As shown, the main body 50 of the first neutral busbar 451 has a first component 501 and a second component 502 spaced apart from each other in the circumferential direction Y3. Each of the first component 501 and the second component 502 of the main body 50 is formed to be generally arc-shaped along the circumferential direction Y3. In addition, the first component 501 and the second component 502 of the main body 50 are formed of radially flat flat wire.

[0058] Of the six connection terminals formed in the main body 50 of the first neutral busbar 451, connection terminals 51U, 52U, 51V, and 52V are formed in the first component 501 of the main body 50. More specifically, as... Figure 4 and Figure 6 As shown, in the first component 501 of the main body 50, the connecting terminals 51U, 52U, 51V, and 52V are arranged in the circumferential direction Y3 in the order of 52V→51V→52U→51U from the side where the first circumferential end of the bus unit 40 is located.

[0059] In addition, such as Figure 4 and Figure 6As shown, connection terminals 51U, 52U, 51V, and 52V are formed in pairs for corresponding phases; and the pairs of connection terminals 51U and 52U provided for the U-phase winding 30U and the pairs of connection terminals 51V and 52V provided for the V-phase winding 30V are offset from each other at a predetermined angle α in the circumferential direction Y3. In this embodiment, each of the connection terminals 51U, 52U, 51V, and 52V is formed at the radial inner periphery of the first component 501 of the body 50. Furthermore, each of the connection terminals 51U, 52U, 51V, and 52V is formed to extend in the axial direction Y1 from the radial inner periphery of the first component 501 of the body 50 to the side opposite to the stator core 20. More specifically, each of the connection terminals 51U, 52U, 51V, and 52V is bent to first protrude radially inward from the radial inner periphery of the first component 501 of the body 50, and then extend axially to the side opposite to the stator core 20. The distal ends of the connecting terminals 51U, 52U, 51V, and 52V are respectively joined to the neutral point side ends of the windings 31U, 32U, 33V, and 34V by welding or other means.

[0060] The first component 501 of the main body 50 has a portion that radially overlaps with the W-phase connection terminals 41W and 42W of the W-phase bus 40W. Therefore, it is necessary to reliably ensure electrical insulation between the first component 501 of the main body 50 and the W-phase connection terminals 41W and 42W. To this end, the portion of the first component 501 of the main body 50 that radially overlaps with the W-phase connection terminals 41W and 42W is formed as a radially inwardly recessed portion 54a, so as to allow the W-phase connection terminals 41W and 42W to extend axially outward from the first component 501 without contacting the first component 501.

[0061] Furthermore, the first component 501 of the main body 50 also has a portion that radially overlaps with the V-phase connection terminals 41V and 42V of the V-phase bus 40V. Therefore, it is also necessary to reliably ensure electrical insulation between the first component 501 of the main body 50 and the V-phase connection terminals 41V and 42V. To this end, the portion of the first component 501 of the main body 50 that radially overlaps with the V-phase connection terminals 41V and 42V is formed as a radially inwardly recessed portion 54b, so as to allow the V-phase connection terminals 41V and 42V to extend axially outward from the first component 501 without contacting the first component 501.

[0062] Furthermore, in the first component 501 of the main body 50, a first extension 55 is formed between the circumferential end 501a of the first component 501 located on the side of the second component 502 and the connection terminal 52V of the second component 502 closest to the main body 50 among all the connection terminals 51U, 52U, 51V, and 52V formed in the first component 501; the first extension 55 extends in the axial direction Y1. Therefore, through the first extension 55, the circumferential end 501a of the first component 501 is offset downward from the connection portion 501b of the first component 501 in the axial direction Y1 (i.e., toward the stator core 20); in the connection portion 501b, connection terminals 51U, 52U, 51V, and 52V are formed.

[0063] Specifically, such as Figure 4 As shown, the axial length of the first extension 55 is set such that, after the first neutral busbar 451 is stacked on the U-phase busbar 40U, the V-phase busbar 40V and the W-phase busbar 40W, the circumferential end 501a of the first component 501 is located at approximately the same axial position as the W-phase busbar 40W in the middle layer of the stack of the U-phase busbar 40U, the V-phase busbar 40V and the W-phase busbar 40W.

[0064] On the other hand, of the six connecting terminals formed in the main body 50 of the first neutral busbar 451, connecting terminals 51W and 52W are formed in the second component 502 of the main body 50. More specifically, as Figure 4 and Figure 6 As shown, in the second component 502 of the main body 50, the connecting terminals 51W and 52W are arranged in the circumferential direction Y3 in the order 52W→51W from the side where the first circumferential end of the busbar unit 40 is located. Furthermore, each of the connecting terminals 51W and 52W is formed in the same manner as the connecting terminals 51U, 52U, 51V, and 52V described above. For the distal ends of the connecting terminals 51W and 52W, the neutral point side ends of the windings 33W and 34W are respectively joined by welding or the like.

[0065] Furthermore, in the second component 502 of the main body 50, a second extension 56 is formed between the circumferential end 502a of the second component 502 located on the side of the first component 501 and the connecting terminal 51W, wherein the connecting terminal 51W is closer to the first component 501 than the connecting terminal 52W; the second extension 56 also extends in the axial direction Y1, just like the first extension 55 as described above. Therefore, through the second extension 56, the circumferential end 502a of the second component 502 is offset downward from the connecting portion 502b of the second component 502 in the axial direction Y1 (i.e., toward the stator core 20); the connecting portions 502b are formed with connecting terminals 51W and 52W.

[0066] Specifically, such as Figure 4As shown, the axial length of the second extension 56 is set such that, after the first neutral busbar 451 is stacked on the U-phase busbar 40U, the V-phase busbar 40V and the W-phase busbar 40W, the circumferential end 502a of the second component 502 is located at approximately the same axial position as the V-phase busbar 40V in the lower layer of the stack of the U-phase busbar 40U, the V-phase busbar 40V and the W-phase busbar 40W.

[0067] A bend 53 is formed on the radially outer side of the body 50 to protrude radially outward from the body 50. Specifically, the bend 53 extends in the axial direction Y1 (i.e., along...). Figure 6 The bent portion 53 is formed into a general U-shape by bending back (in the direction indicated by the dashed arrow in the figure). The bent portion 53 has a pair of first open ends 53a and second open ends 53b that are respectively connected to the circumferential end 501a of the first component 501 and the circumferential end 502a of the second component 502.

[0068] In the bend 53, a pair of first opening ends 53a and second opening ends 53b are located radially innermost, while the bottom 53c of the bend 53 is located radially outermost. Furthermore, in the pair of first opening ends 53a and second opening ends 53b of the bend 53, the first opening end 53a located on the upper side (i.e., the side opposite to the stator core 20) in the axial direction Y1 is connected to the radial outer periphery of the circumferential end 501a of the first component 501, while the second opening end 53b located on the lower side (i.e., the stator core 20 side) in the axial direction Y1 is connected to the radial outer periphery of the circumferential end 502a of the second component 502.

[0069] Furthermore, as previously described, the circumferential end 501a of the first component 501 and the circumferential end 502a of the second component 502 are respectively offset downward in the axial direction Y1 from the connecting portion 501b of the first component 501 and the connecting portion 502b of the second component 502 via the first extension 55 and the second extension 56 (i.e., toward the stator core 20). Consequently, the bent portion 53 is offset downward in the axial direction Y1 from both the connecting portion 501b of the first component 501 and the connecting portion 502b of the second component 502. Therefore, as... Figure 4 As shown, the bent portion 53 is located in the axial direction Y1 between the W-phase busbar 40W arranged in the middle layer and the V-phase busbar 40V arranged in the lower layer.

[0070] As described above, in the first neutral busbar 451, a bend 53 is formed between the first component 501 and the second component 502 to electrically connect the first component 501 and the second component 502. Therefore, the current input from the U-phase winding 30U and V-phase winding 30V of the stator coil 30 to the connection terminals 51U, 52U, 51V, 52V flows through the electrical path of the first component 501 connecting portion 501b → first extension 55 → circumferential end 501a of the first component 501 → bend 53 → circumferential end 502a of the second component 502 → second extension 56 → connecting portion 502b of the second component 502 → connection terminals 51W, 52W, and then outputs from the connection terminals 51W, 52W to the W-phase winding 30W of the stator coil 30. Otherwise, the current that has been input from the W-phase winding 30W of the stator coil 30 to the connection terminals 51W and 52W flows through the connection portion 502b of the second component 502 → the second extension portion 56 → the circumferential end portion 502a of the second component 502 → the bending portion 53 → the circumferential end portion 501a of the first component 501 → the first extension portion 55 → the connection portion 501b of the first component 501 → the electrical path of the connection terminals 51U, 52U, 51V, and 52V, and then is output from the connection terminals 51U, 52U, 51V, and 52V to the U-phase winding 30U and the V-phase winding 30V of the stator coil 30.

[0071] Furthermore, the first extension 55 is formed between the portion of the first component 501 connected to the bent portion 53 (i.e., the circumferential end 501a) and the connecting terminal 52V, which is closest to the bent portion 53 in the circumferential direction Y3 among the plurality of connecting terminals formed in the first component 501. Similarly, the second extension 56 is formed between the portion of the second component 502 connected to the bent portion 53 (i.e., the circumferential end 502a) and the connecting terminal 51W, which is closest to the bent portion 53 in the circumferential direction Y3 among the plurality of connecting terminals formed in the second component 502.

[0072] like Figure 7 As shown, the bend 53 of the first neutral busbar 451 secures the temperature sensor 80 by clamping it from both axial sides. Therefore, the bend 53 is formed with a pair of clamping surfaces 53d extending perpendicularly to the axial direction Y1, and clamping the temperature sensor 80 therebetween. The temperature sensor 80 is inserted into the bend 53 from its circumferential side. More specifically, the temperature sensor 80 is inserted into the bend 53 in the circumferential direction Y3 from the first circumferential end of the busbar unit 40 to its circumferential center.

[0073] In the second neutral busbar 452, six connection terminals 53U, 54U, 53V, 54V, 53W, and 54W are formed to connect to the neutral point side ends of portions of the U-phase winding 30U (33U, 34U), the V-phase winding 30V (31V, 32V), and the W-phase winding 30W (31W, 32W), respectively. Additionally, as... Figure 3 As shown, the neutral point ends of the windings 33U and 34U connected to the second neutral busbar 452 are located on the opposite side of the non-neutral point ends of the windings 33U and 34U connected to the U-phase busbar 40U; the neutral point ends of the windings 31V and 32V connected to the second neutral busbar 452 are located on the opposite side of the non-neutral point ends of the windings 31V and 32V connected to the V-phase busbar 40V; and the neutral point ends of the windings 31W and 32W connected to the second neutral busbar 452 are located on the opposite side of the non-neutral point ends of the windings 31W and 32W connected to the W-phase busbar 40W.

[0074] like Figure 4 As shown, the connection terminals 53U, 54U, 53V, 54V, 53W, and 54W of the second neutral busbar 452 are formed in the same manner as the connection terminals 51U, 52U, 51V, 52V, 51W, and 52W of the first neutral busbar 451. Furthermore, the second neutral busbar 452 is arranged to be spaced apart from the first neutral busbar 451 in the circumferential direction Y3, such that the connection terminals 51U, 52U, 51V, 52V, 51W, and 52W of the first neutral busbar 451 and the connection terminals 53U, 54U, 53V, 54V, 53W, and 54W of the second neutral busbar 452 are symmetrically positioned relative to the central axis (or the rotation axis of the rotor) of the cylindrical stator 10.

[0075] The second neutral busbar 452 has a portion that radially overlaps with the W-phase connection terminals 43W and 44W of the W-phase busbar 40W. Therefore, it is necessary to reliably ensure electrical insulation between the second neutral busbar 452 and the W-phase connection terminals 43W and 44W. For this purpose, the portion of the second neutral busbar 452 that radially overlaps with the W-phase connection terminals 43W and 44W is formed as a radially inwardly recessed portion 54c, so as to allow the W-phase connection terminals 43W and 44W to extend axially outward from the second neutral busbar 452 without contacting it.

[0076] Furthermore, the second neutral busbar 452 also has a portion that radially overlaps with the V-phase connection terminals 43V and 44V of the V-phase busbar 40V. Therefore, it is necessary to reliably ensure electrical insulation between the second neutral busbar 452 and the V-phase connection terminals 43V and 44V. To this end, the portion of the second neutral busbar 452 that radially overlaps with the V-phase connection terminals 43V and 44V is formed as a radially inwardly recessed portion 54d, so as to allow the V-phase connection terminals 43V and 44V to extend axially outward from the second neutral busbar 452 without contacting the second neutral busbar 452.

[0077] In this embodiment, the bus unit 40 is formed by stacking all the U-phase busbars 40U, V-phase busbars 40V, W-phase busbars 40W and neutral busbars 45 (i.e., the first neutral busbar 451 and the second neutral busbar 452) in the axial direction Y1, and covering them with resin components 60 in the stacked state, thereby integrating them into a single piece. Figure 5 As shown, the resin component 60 covers the U-phase busbar 40U, V-phase busbar 40V, W-phase busbar 40W, and neutral busbar 45, such that the connection terminals 41U-44U, 41V-44V, 41W-44W, 51U-54U, 51V-54V, and 51W-54W are exposed from the resin component 60. More specifically, each of the connection terminals 41U-44U, 41V-44V, 41W-44W, 51U-54U, 51V-54V, and 51W-54W protrudes radially inward or radially outward from the resin component 60, and then extends axially to the side opposite to the stator core 20 in the exposed state.

[0078] The resin component 60 is formed in an arc shape along the circumferential direction Y3 to cover the busbars 40U-40W and 45. More specifically, the resin component 60 covers the busbars 40U-40W and 45 so that there is a gap filled with the resin forming the resin component 60 between the busbars 40U-40W and the busbar 45 in the axial direction Y1. Therefore, the axial distance between the busbars 40U-40W and the busbar 45 can be kept constant, thereby electrically insulating them from each other.

[0079] In addition, such as Figure 8 As shown, the resin component 60 is formed to cover at least a portion of the temperature sensor 80 and the first neutral busbar 451, thereby integrating the temperature sensor 80 and the first neutral busbar 451 into a single piece. As previously described, the temperature sensor 80 is held in the bend 83 of the first neutral busbar 451.

[0080] Furthermore, a pair of hooks 61 are formed at the circumferential ends of the resin component 60 to serve as retaining members for holding the lead 81 of the temperature sensor 80. Each hook 61 is integrally formed as part of the resin component 60 by resin molding. That is, the hook 61 is formed of resin. Furthermore, as... Figure 8 and Figure 9 As shown, each hook 61 is bent upward and elastically deformed in the axial direction Y1 to hold the lead wire 81 therein. Furthermore, each hook 61 has a generally J-shaped contact surface (i.e., an inner surface) for contacting the lead wire 81. The contact surface is formed as a smooth flat surface or a smooth curved surface; in other words, it is formed as a flat or curved surface without any recesses / protrusions that can engage with the lead wire 81. Alternatively, each hook 61 may also be formed as a generally L-shape or as a protrusion.

[0081] like Figures 8 to 10 As shown, in the portions of the resin member 60 that cover the curved portion 53 of the first neutral busbar 451, a pair of first through holes 62 and second through holes 63 are formed that penetrate the resin member 60 in the axial direction Y1, respectively.

[0082] in addition, Figure 8 This is a perspective view of the busbar unit 40 viewed from above (i.e., the side opposite to the stator core 20) in the axial direction Y1. Figure 9 This is a top view of a portion of the busbar unit 40 viewed from above (i.e., the side opposite to the stator core 20) in the axial direction Y1, showing the first through hole 62 formed in the resin member 60. Figure 10 This is a perspective view of a portion of the busbar unit 40 viewed from the lower side (i.e., the stator core 20 side) in the axial direction Y1, showing the second through hole 63 formed in the resin member 60.

[0083] like Figure 9 As shown, in the pair of first through holes 62 and second through holes 63 formed in the resin member 60, the first through hole 62 is formed in the portion of the resin member 60 that covers the curved portion 53 of the first neutral busbar 451 from above in the axial direction Y1. Therefore, the upper surface (more specifically, the upper outer surface) of the curved portion 53 of the first neutral busbar 451 in the axial direction Y1 is exposed through the first through hole 62. Furthermore, as... Figure 10 As shown, in the pair of first through holes 62 and second through holes 63 formed in the resin member 60, the second through hole 63 is formed in the portion of the resin member 60 that covers the bent portion 53 of the first neutral busbar 451 from below in the axial direction Y1. Therefore, the lower surface (more specifically, the lower outer surface) of the bent portion 53 of the first neutral busbar 451 in the axial direction Y1 is exposed through the second through hole 63.

[0084] In this embodiment, the first through-hole 62 and the second through-hole 63 are formed as follows. During the process of covering the first neutral busbar 451 with resin, the first neutral busbar 451, which holds the temperature sensor 80 in its bend 53, is placed in a cavity formed in a metal mold. Then, resin molding is performed by injecting resin into the cavity of the metal mold under high pressure. However, during resin molding, the first neutral busbar 451 may bend or wobble due to the high resin injection pressure, causing its bend 53 to twist. Therefore, the force holding the temperature sensor 80 in the bend 53 may weaken, resulting in displacement of the temperature sensor 80 clamped in the bend 53 and / or insufficient contact between the temperature sensor 80 and the bend 53.

[0085] In view of the above, in this embodiment, resin molding is performed in the cavity of the metal mold by a pair of first pressing members 91 and second pressing members 92 (see...). Figure 8 and Figure 10 This is performed when the upper and lower surfaces of the bent portion 53 are pressed from opposite axial sides; both the first pressing member 91 and the second pressing member 92 are approximately cylindrical in shape. Therefore, the temperature sensor 80 can be reliably held in the bent portion 53 during resin molding, thereby suppressing displacement of the temperature sensor 80 and preventing insufficient contact between the temperature sensor 80 and the bent portion 53. Furthermore, after resin molding is completed, both the first pressing member 91 and the second pressing member 92 are removed from the resulting resin component 60. Therefore, in the resin component 60, a first through hole 62 and a second through hole 63 are formed at the positions where the first pressing member 91 and the second pressing member 92 are placed to press the bent portion 53 during resin molding.

[0086] That is, the first through hole 62 and the second through hole 63 correspond to the first pressing member 91 and the second pressing member 92 respectively for pressing the upper surface and the lower surface of the bent portion 53 during resin molding, and the upper surface and the lower surface of the bent portion 53 are exposed from the resin member 60 in the axial direction Y1 through the first through hole 62 and the second through hole 63 respectively.

[0087] In addition, such as Figure 11As shown, in the first neutral busbar 451, the circumferential end 501a of the first component 501 is separated from the second extension 56 in the circumferential direction Y3 and faces the second extension 56. However, the separation distance between the circumferential end 501a of the first component 501 and the second extension 56 is very short. Therefore, if the first neutral busbar 451 is twisted during resin molding due to high resin injection pressure, the circumferential end 501a of the first component 501 and the second extension 56 can come into contact with each other, and resin molding can proceed in this contacting state. Consequently, due to the contact between the circumferential end 501a of the first component 501 and the second extension 56, a short circuit will be formed, causing current to flow from the circumferential end 501a of the first component 501 through the second extension 56 to the second component 502 without passing through the bend 53. As a result, the temperature sensor 80 cannot be arranged in the current path; therefore, the accuracy of detecting the temperature of the stator coil 30 by the temperature sensor 80 will be reduced.

[0088] In view of the above, in this embodiment, the shape and pressing position of the first pressing member 91, which presses the upper surface of the first opening end 53a of the curved portion 53 during resin molding, are configured such that the first pressing member 91 protrudes from the circumferential end 501a of the first component 501 toward the second extension 56 between the circumferential end 501a of the first component 501 and the second extension 56. Therefore, during resin molding, if the first neutral busbar 451 twists, thereby causing the second extension 56 to approach the circumferential end 501a of the first component 501, the first pressing member 91 will interfere with the second extension 56, thereby preventing the second extension 56 from contacting the circumferential end 501a of the first component 501.

[0089] Therefore, in this embodiment, as Figure 12 As shown by the dashed line, the first through hole 62 formed in the resin member 60 by removing the first pressing member 91 from the resin member 60 has the following shape: it protrudes from the circumferential end 501a of the first member 501 toward the second extension 56 between the circumferential end 501a of the first member 501 and the second extension 56.

[0090] According to this embodiment, the following beneficial effects can be achieved.

[0091] In the rotating electric machines disclosed in the aforementioned Patent Documents 1 and 2, a temperature sensor is mounted on the neutral bus to detect the temperature of the stator coil (or armature coil). The detected stator coil temperature is used to control the current supplied to the stator coil and to prevent malfunctions due to overheating of the stator coil. Therefore, accurate detection of the stator coil temperature is required. Consequently, it is desirable to arrange the temperature sensor in the current path of the neutral bus. That is, it is desirable to arrange the temperature sensor between the connection terminals of different phases. Furthermore, in order to reliably bring the temperature sensor into contact with the neutral bus and fix them together in a contacting state, the temperature sensor is held in the generally U-shaped bend of the neutral bus. In addition, during the assembly of the neutral bus to the stator (or armature), the radial and / or circumferential positions of the connection terminals of the neutral bus are usually adjusted to allow the connection terminals to engage with the winding ends of the stator coil respectively. However, during the adjustment of the position of the connection terminals, the bend of the neutral bus may experience strain, resulting in the expansion of the opening of the generally U-shaped bend. Therefore, it is difficult to reliably hold the temperature sensor within the bend of the neutral busbar. As a result, it is difficult to reliably suppress temperature sensor displacement; it is also difficult to reliably maintain contact between the temperature sensor and the bend of the neutral busbar.

[0092] In view of the above, in this embodiment, the first neutral busbar 451 is configured to have: a main body 50 extending in the circumferential direction Y3; connecting terminals 51U, 52U, 51V, 52V, 51W, and 52W formed in the main body 50 and respectively connected to the neutral point side ends of portions of the stator coil 30 windings 31U, 32U, 33V, 34V, 33W, and 34W; and a bending portion 53 that clamps and thereby holds the temperature sensor 80. The main body 50 has a first component 501 and a second component 502 spaced apart from each other in the circumferential direction Y3. The first component 501 has connecting terminals 51U, 52U, 51V, and 52V formed in its connecting portion 501b, while the second component 502 has connecting terminals 51W and 52W formed in its connecting portion 502b. A bend 53 is formed between the circumferential end 501a of the first component 501 and the circumferential end 502a of the second component 502 to electrically connect the first component 501 and the second component 502. In the first component 501, a first extension 55 is formed between the circumferential end 501a of the first component 501 and the connection terminal 52V, which is closest to the bend 53 among all the connection terminals 51U, 52U, 51V, and 52V formed in the first component 501; the first extension 55 extends in the axial direction Y1. On the other hand, in the second component 502, a second extension 56 is formed between the circumferential end 502a of the second component 502 and the connection terminal 51W, wherein the connection terminal 51W is closer to the bend 53 than the connection terminal 52W; the second extension 56 also extends in the axial direction Y1.

[0093] With the above configuration, when the connecting portion 501b of the first component 501, on which the connecting terminals 51U, 52U, 51V, and 52V are formed, is slightly deformed, the strain caused by the deformation will be absorbed by the first extension portion 55. Similarly, when the connecting portion 502b of the second component 502, on which the connecting terminals 51W and 52W are formed, is slightly deformed, the strain caused by the deformation will be absorbed by the second extension portion 56.

[0094] Therefore, when the positions of the connection terminals 51U, 52U, 51V, 52V, 51W, and 52W are adjusted to allow these connection terminals to engage with the neutral point side ends of the portions of the stator coil 30 windings 31U, 32U, 33V, 34V, 33W, and 34W respectively, deformation of the bending portion 53 can be suppressed. That is, the first extension 55 and the second extension 56 act as buffer members to absorb the strain caused in the first component 501 and the second component 502 during the position adjustment of the connection terminals 51U, 52U, 51V, 52V, 51W, and 52W. As a result, displacement of the temperature sensor 80 due to deformation of the bending portion 53 can be suppressed; and insufficient contact between the temperature sensor 80 and the bending portion 53 can be prevented due to deformation of the bending portion 53. Consequently, the accuracy of the temperature sensor 80 in detecting the temperature of the stator coil 30 can be prevented from decreasing.

[0095] Furthermore, in this embodiment, the bent portion 53 of the first neutral busbar 451 has a pair of clamping surfaces 53d, between which the temperature sensor 80 is clamped. Both clamping surfaces 53d of the bent portion 53 are formed to extend perpendicular to the axial direction Y1.

[0096] Therefore, the temperature sensor 80 can be made to contact the curved portion 53 surface of the first neutral busbar 451; therefore, the temperature sensor 80 can be easily positioned in the axial direction Y1.

[0097] In this embodiment, the bent portion 53 of the first neutral busbar 451 is formed to protrude radially outward from the main body 50 of the first neutral busbar 451 and bend back into a generally U-shape in the axial direction Y1.

[0098] Therefore, the bend 53 is open on both the radially inner side and the circumferential sides. As a result, the mounting angle of the temperature sensor 80 can be adjusted in the radial and / or circumferential directions, thereby facilitating the mounting of the temperature sensor 80 on the bend 53 of the first neutral busbar 45.

[0099] Furthermore, in this embodiment, the bent portion 53 of the first neutral busbar 451 has: a first open end portion 53a connected to the circumferential end portion 501a of the first component 501 of the main body 50; and a second open end portion 53b connected to the circumferential end portion 502a of the second component 502 of the main body 50. Both the first neutral busbar 451 and the temperature sensor 80 are covered by the resin component 60 and thus integrated as a single piece. The resin component 60 has a pair of first through holes 62 and second through holes 63, through which the first open end portion 53a and the second open end portion 53b of the bent portion 53 are exposed in the axial direction Y1. The pair of first through holes 62 and second through holes 63 correspond to a pair of first pressing members 91 and second pressing members 92 for pressing the bent portion 53 of the first neutral busbar 451 and the temperature sensor 80 together from opposite axial sides of the bent portion 53 during resin molding of the resin component 60.

[0100] With the above configuration, the bent portion 53 of the first neutral busbar 451 and the temperature sensor 80 can be pressed together using a pair of first pressing members 91 and second pressing members 92, while both the first neutral busbar 451 and the temperature sensor 80 are covered by the resin member 60. Therefore, the temperature sensor 80 can be positioned at the desired location; and the temperature sensor 80 can be reliably contacted with the bent portion 53 of the first neutral busbar 451.

[0101] Furthermore, in this embodiment, the circumferential end portion 501a of the first component 501 and the second extension portion 56 face each other in the circumferential direction Y3. A first through hole 62 is formed in the resin member 60 so as to protrude from the circumferential end portion 501a of the first component 501 toward the second extension portion 56 between the circumferential end portion 501a of the first component 501 and the second extension portion 56. That is, during the resin molding of the resin member 60, a first pressing member 91 corresponding to the first through hole 62 is provided to protrude from the circumferential end portion 501a of the first component 501 toward the second extension portion 56 between the circumferential end portion 501a of the first component 501 and the second extension portion 56.

[0102] With the above configuration, during resin molding, if the first neutral busbar 451 twists, causing the second extension 56 to approach the circumferential end 501a of the first component 501, the first pressing member 91 will interfere with the second extension 56, thereby preventing the second extension 56 from contacting the circumferential end 501a of the first component 501. Therefore, a short circuit between the first component 501 and the second component 502 can be prevented; thus, current can be prevented from flowing between the first component 501 and the second component 502 without passing through the bend 53. In other words, the current flowing between the first component 501 and the second component 502 can be reliably made to pass through the bend 53. As a result, the accuracy of the temperature sensor 80 in detecting the temperature of the stator coil 30 can be reliably prevented.

[0103] In this embodiment, the first neutral busbar 451 and the temperature sensor 80 are both covered by the resin component 60 and thus integrated into a single piece. A pair of hooks 61 are formed at the circumferential ends of the resin component 60 to serve as retaining members for holding the leads 81 of the temperature sensor 80.

[0104] By holding (or temporarily securing) the hook 61 of the lead 81, the lead 81 can be prevented from drooping from the bus unit 40 and thus hindering the assembly of the bus unit 40 to the stator 10 during the delivery of the bus unit 40 before the lead 81 is connected to the temperature sensor 80.

[0105] In this embodiment, each hook 61 is formed as an integral part of the resin component 60 by resin molding. Furthermore, each hook 61 has a generally J-shaped contact surface for contacting the lead wire 81. The contact surface is formed as a smooth, flat surface or a smooth, curved surface.

[0106] With the above-described structure, there is no undercut in the contact surface of the hook portion 61. Therefore, the hook portion 61 can be easily molded together with the resin component 60.

[0107] In this embodiment, the axial lengths of the first extension 55 and the second extension 56 are configured such that, after the first neutral busbar 451 is stacked on the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W, both the circumferential end 501a of the first component 501 and the circumferential end 502a of the second component 502 are axially located within the axial dimension of the stack of the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W. More specifically, the axial length of the first extension 55 is configured such that the circumferential end 501a of the first component 501 is located at approximately the same axial position as the W-phase busbar 40W disposed in the intermediate layer of the stack of the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W. On the other hand, the axial length of the second extension 56 is set such that the circumferential end 502a of the second component 502 is located at approximately the same axial position as the V-phase bus 40V in the lower layer of the stack of U-phase bus 40U, V-phase bus 40V and W-phase bus 40W. Furthermore, in this embodiment, each of the first extension 55 and the second extension 56 is formed to extend straight in the axial direction Y1.

[0108] The axial and radial dimensions of the busbar unit 40 can be minimized by the above-described construction of the first extension 55 and the second extension 56.

[0109] Although the specific embodiments described above have been shown and described, those skilled in the art will understand that various modifications, alterations and improvements can be made without departing from the spirit of this disclosure.

[0110] For example, in the embodiment described above, the neutral bus 45 is integrated into the bus unit 40 together with the U-phase bus 40U, V-phase bus 40V, and W-phase bus 40W. Alternatively, the neutral bus 45 may not be integrated into the bus unit 40.

[0111] In the embodiment described above, the U-phase busbar 40U, V-phase busbar 40V, W-phase busbar 40W, and neutral busbar 45 are stacked in the axial direction Y1 from the stator core 20 side in the order of V-phase busbar 40V, W-phase busbar 40W, U-phase busbar 40U, and neutral busbar 45. However, the stacking order of the U-phase busbar 40U, V-phase busbar 40V, W-phase busbar 40W, and neutral busbar 45 can be arbitrarily changed.

[0112] In the embodiment described above, the U-phase bus 40U, V-phase bus 40V, W-phase bus 40W, and neutral bus 45 are offset from each other in the circumferential direction Y3. Alternatively, the U-phase bus 40U, V-phase bus 40V, W-phase bus 40W, and neutral bus 45 are not offset from each other in the circumferential direction Y3.

[0113] In the embodiment described above, the neutral busbar 45 is formed of a radially flattened flat wire. Alternatively, the neutral busbar 45 may be formed of an axially flattened flat wire. Another alternative is that the neutral busbar 45 may be formed of a wire having a circular or elliptical cross-sectional shape.

[0114] In the embodiment described above, each of the first extension 55 and the second extension 56 of the first neutral busbar 451 is formed to extend in the axial direction Y1. Alternatively, each of the first extension 55 and the second extension 56 of the first neutral busbar 451 may be formed to extend in the radial direction Y2.

[0115] In the embodiment described above, in the first neutral busbar 451, the bend 53 is formed to protrude radially outward from the main body 50. Alternatively, the bend 53 may be formed to protrude radially inward from the main body 50.

[0116] In the embodiment described above, the axial lengths of the first extension 55 and the second extension 56 are configured such that, after the first neutral busbar 451 is stacked on the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W, both the circumferential end 501a of the first component 501 and the circumferential end 502a of the second component 502 are axially located within the axial dimension of the stack of the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W. However, the axial lengths of the first extension 55 and the second extension 56 can be arbitrarily changed. For example, the axial lengths of the first extension 55 and the second extension 56 can alternatively be configured such that the bent portion 53 of the first neutral busbar 451 is located below the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W in the axial direction Y1 (i.e., on the stator core 20 side). Alternatively, the first extension 55 and the second extension 56 may be configured to extend upward in the axial direction Y1 from the connection portion 501b of the first component 501 and the connection portion 502b of the second component 502, respectively. Furthermore, the bend 53 of the first neutral busbar 451 may alternatively be located above the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W in the axial direction Y1 (i.e., on the side of the U-phase busbar 40U, the V-phase busbar 40V, and the W-phase busbar 40W opposite to the stator core 20).

[0117] In the embodiment described above, the first component 501 of the first neutral busbar 451 has recesses 54a and 54b. Alternatively, the first component 501 of the first neutral busbar 45 may not have recesses 54a and 54b.

[0118] In the embodiment described above, the bent portion 53 of the first neutral busbar 451 is bent back into a generally U-shape in the axial direction Y1. Alternatively, the bent portion 53 of the first neutral busbar 451 may be bent back into a generally U-shape in the radial direction Y2.

[0119] In the embodiment described above, the resin molding of the resin member 60 is performed while the first pressing member 91 and the second pressing member 92 press the upper and lower surfaces of the bent portion 53, respectively. Alternatively, the resin molding may not be performed while the first pressing member 91 and the second pressing member 92 press the upper and lower surfaces of the bent portion 53, respectively. In this case, through holes 62 and 63 are not formed in the upper and lower surfaces of the bent portion 53, respectively.

[0120] In the embodiment described above, the first pressing member 91 is formed to protrude from the circumferential end 501a of the first member 501 toward the second extension 56 between the circumferential end 501a of the first member 501 and the second extension 56. Alternatively, the first pressing member 91 may be formed not to protrude from the circumferential end 501a of the first member 501 toward the second extension 56. In this case, the first through hole 62 corresponding to the first pressing member 91 will also be formed not to protrude from the circumferential end 501a of the first member 501 toward the second extension 56.

[0121] In the embodiment described above, a pair of hooks 61 are formed at the circumferential ends of the resin member 60 to serve as retaining members for holding the lead wire 81 of the temperature sensor 80. However, the number and position of the hooks 61 can be arbitrarily changed. Furthermore, the busbar unit 40 may not have the hooks 61 formed therein.

[0122] In the embodiment described above, the rotary motor becomes an electric motor used in a vehicle. However, the rotary motor can alternatively be configured as an electric motor for other applications, such as an electric motor for an aircraft.

Claims

1. A rotary electric motor, comprising: An armature (10) comprising an annular armature core (20) and a three-phase armature coil (30) wound around the armature core and connected in a Y-shape to define the neutral point of the armature coil; Neutral bus (451), the neutral bus is configured to connect to the neutral point side winding end of the armature coil; as well as A temperature sensor (80) is mounted on the neutral bus to detect the temperature of the armature coil. in, The neutral busbar has: a body (50) extending in the circumferential direction (Y3) of the armature; a plurality of connection terminals (51U, 52U, 51V, 52V, 51W, 52W) formed in the body and respectively connected to the neutral point side winding end of the armature coil; and a bend (53) clamping and thereby holding the temperature sensor. The main body of the neutral busbar has a first component (501) and a second component (502), the first component and the second component being spaced apart from each other in the circumferential direction, and each having one or more connection terminals. The bent portion is formed between the circumferential end (501a) of the first component and the circumferential end (502a) of the second component to electrically connect the first component and the second component. In the first component, a first extension (55) is formed between the circumferential end of the first component and one of the one or more connecting terminals (51U, 52U, 51V, 52V) formed in the first component, which is closest to the bend in the circumferential direction. The first extension extends in the axial direction (Y1) or radial direction (Y2) of the armature. In the second component, a second extension (56) is formed between the circumferential end of the second component and one of the connecting terminals (51W) formed in the second component that is closest to the bend in the circumferential direction. The second extension also extends in the axial or radial direction of the armature. The curved portion has a pair of clamping surfaces (53d), and the temperature sensor is clamped between the pair of clamping surfaces. Both clamping surfaces of the curved portion are formed to extend in a direction perpendicular to the axial direction of the armature.

2. The rotary motor as described in claim 1, characterized in that, The curved portion is formed to protrude radially from the main body of the neutral generatrix and bend back into a generally U-shape in the axial direction. The curved portion has: a first open end (53a) connected to the circumferential end of the first component of the body; and a second open end (53b) connected to the circumferential end of the second component of the body. Both the neutral busbar and the temperature sensor are covered by a resin component (60) and thus integrated into a single piece. The resin component has a pair of first through holes (62) and second through holes (63). The first opening end and the second opening end of the bend are exposed from the resin component in the axial direction through the pair of first through holes and the second through holes, respectively. The pair of first through holes and the second through holes correspond to a pair of first pressing members (91) and second pressing members (92) for pressing the bend of the neutral busbar and the temperature sensor together from opposite axial sides of the bend during the resin molding of the resin component. The circumferential ends of the first component and the second extension face each other in the circumferential direction. The first through hole (62) is formed in the resin member so as to protrude from the circumferential end of the first member toward the second extension between the circumferential end of the first member and the second extension.

3. A rotary electric motor, comprising: An armature (10) comprising an annular armature core (20) and a three-phase armature coil (30) wound around the armature core and connected in a Y-shape to define the neutral point of the armature coil; Neutral bus (451), the neutral bus is configured to connect to the neutral point side winding end of the armature coil; as well as A temperature sensor (80) is mounted on the neutral bus to detect the temperature of the armature coil. in, The neutral busbar has: a body (50) extending in the circumferential direction (Y3) of the armature; a plurality of connection terminals (51U, 52U, 51V, 52V, 51W, 52W) formed in the body and respectively connected to the neutral point side winding end of the armature coil; and a bend (53) clamping and thereby holding the temperature sensor. The main body of the neutral busbar has a first component (501) and a second component (502), the first component and the second component being spaced apart from each other in the circumferential direction, and each having one or more connection terminals. The bent portion is formed between the circumferential end (501a) of the first component and the circumferential end (502a) of the second component to electrically connect the first component and the second component. In the first component, a first extension (55) is formed between the circumferential end of the first component and one of the one or more connecting terminals (51U, 52U, 51V, 52V) formed in the first component, which is closest to the bend in the circumferential direction. The first extension extends in the axial direction (Y1) or radial direction (Y2) of the armature. In the second component, a second extension (56) is formed between the circumferential end of the second component and one of the connecting terminals (51W) formed in the second component that is closest to the bend in the circumferential direction. The second extension also extends in the axial or radial direction of the armature. The curved portion is formed to protrude radially from the main body of the neutral generatrix and bend back into a generally U-shape in the axial direction. The curved portion has: a first open end (53a) connected to the circumferential end of the first component of the body; and a second open end (53b) connected to the circumferential end of the second component of the body. Both the neutral busbar and the temperature sensor are covered by a resin component (60) and thus integrated into a single piece. The resin component has a pair of first through holes (62) and second through holes (63). The first opening end and the second opening end of the bend are exposed from the resin component in the axial direction through the pair of first through holes and the second through holes, respectively. The pair of first through holes and the second through holes correspond to a pair of first pressing members (91) and second pressing members (92) for pressing the bend of the neutral busbar and the temperature sensor together from opposite axial sides of the bend during the resin molding of the resin component. The circumferential ends of the first component and the second extension face each other in the circumferential direction. The first through hole (62) is formed in the resin member so as to protrude from the circumferential end of the first member toward the second extension between the circumferential end of the first member and the second extension.

4. The rotary electric motor as described in any one of claims 1 to 3, characterized in that, Both the neutral busbar and the temperature sensor are covered by a resin component and thus integrated into a single unit. In the resin component, at least one hook-shaped retaining member (61) is formed to retain the lead (81) of the temperature sensor.

5. A rotary electric motor, comprising: An armature (10) comprising an annular armature core (20) and a three-phase armature coil (30) wound around the armature core and connected in a Y-shape to define the neutral point of the armature coil; Neutral bus (451), the neutral bus is configured to connect to the neutral point side winding end of the armature coil; as well as A temperature sensor (80) is mounted on the neutral bus to detect the temperature of the armature coil. in, The neutral busbar has: a body (50) extending in the circumferential direction (Y3) of the armature; a plurality of connection terminals (51U, 52U, 51V, 52V, 51W, 52W) formed in the body and respectively connected to the neutral point side winding end of the armature coil; and a bend (53) clamping and thereby holding the temperature sensor. The main body of the neutral busbar has a first component (501) and a second component (502), the first component and the second component being spaced apart from each other in the circumferential direction, and each having one or more connection terminals. The bent portion is formed between the circumferential end (501a) of the first component and the circumferential end (502a) of the second component to electrically connect the first component and the second component. In the first component, a first extension (55) is formed between the circumferential end of the first component and one of the one or more connecting terminals (51U, 52U, 51V, 52V) formed in the first component, which is closest to the bend in the circumferential direction. The first extension extends in the axial direction (Y1) or radial direction (Y2) of the armature. In the second component, a second extension (56) is formed between the circumferential end of the second component and one of the connecting terminals (51W) formed in the second component that is closest to the bend in the circumferential direction. The second extension also extends in the axial or radial direction of the armature. Both the neutral busbar and the temperature sensor are covered by a resin component and thus integrated into a single unit. In the resin component, at least one hook-shaped retaining member (61) is formed to retain the lead (81) of the temperature sensor.

6. The rotary motor as described in claim 5, characterized in that, At least one of the retaining members is formed of resin and is integrated with the resin member as a single piece. At least one of the retaining members has a contact surface for contacting the lead of the temperature sensor. The contact surface is formed as a smooth, flat surface or a smooth, curved surface.

7. An armature (10), comprising: Annular armature core (20); A three-phase armature coil (30), the armature coil being wound on the armature core and Y-connected to define the neutral point of the armature coil; Neutral bus (451), the neutral bus is configured to connect to the neutral point side winding end of the armature coil; as well as A temperature sensor (80) is mounted on the neutral bus to detect the temperature of the armature coil. in, The neutral busbar has: a body (50) extending in the circumferential direction (Y3) of the armature; a plurality of connection terminals (51U, 52U, 51V, 52V, 51W, 52W) formed in the body and respectively connected to the neutral point side winding end of the armature coil; and a bend (53) clamping and thereby holding the temperature sensor. The main body of the neutral busbar has a first component (501) and a second component (502), the first component and the second component being spaced apart from each other in the circumferential direction, and each having one or more connection terminals. The bent portion is formed between the circumferential end (501a) of the first component and the circumferential end (502a) of the second component to electrically connect the first component and the second component. In the first component, a first extension (55) is formed between the circumferential end of the first component and one of the one or more connecting terminals (51U, 52U, 51V, 52V) formed in the first component, which is closest to the bend in the circumferential direction. The first extension extends in the axial direction (Y1) or radial direction (Y2) of the armature. In the second component, a second extension (56) is formed between the circumferential end of the second component and one of the connecting terminals (51W) formed in the second component that is closest to the bend in the circumferential direction. The second extension also extends in the axial or radial direction of the armature. The curved portion has a pair of clamping surfaces (53d), and the temperature sensor is clamped between the pair of clamping surfaces. Both clamping surfaces of the curved portion are formed to extend in a direction perpendicular to the axial direction of the armature.

8. An armature (10), comprising: Annular armature core (20); A three-phase armature coil (30), the armature coil being wound on the armature core and Y-connected to define the neutral point of the armature coil; Neutral bus (451), the neutral bus is configured to connect to the neutral point side winding end of the armature coil; as well as A temperature sensor (80) is mounted on the neutral bus to detect the temperature of the armature coil. in, The neutral busbar has: a body (50) extending in the circumferential direction (Y3) of the armature; a plurality of connection terminals (51U, 52U, 51V, 52V, 51W, 52W) formed in the body and respectively connected to the neutral point side winding end of the armature coil; and a bend (53) clamping and thereby holding the temperature sensor. The main body of the neutral busbar has a first component (501) and a second component (502), the first component and the second component being spaced apart from each other in the circumferential direction, and each having one or more connection terminals. The bent portion is formed between the circumferential end (501a) of the first component and the circumferential end (502a) of the second component to electrically connect the first component and the second component. In the first component, a first extension (55) is formed between the circumferential end of the first component and one of the one or more connecting terminals (51U, 52U, 51V, 52V) formed in the first component, which is closest to the bend in the circumferential direction. The first extension extends in the axial direction (Y1) or radial direction (Y2) of the armature. In the second component, a second extension (56) is formed between the circumferential end of the second component and one of the connecting terminals (51W) formed in the second component that is closest to the bend in the circumferential direction. The second extension also extends in the axial or radial direction of the armature. The curved portion is formed to protrude radially from the main body of the neutral generatrix and bend back into a generally U-shape in the axial direction. The curved portion has: a first open end (53a) connected to the circumferential end of the first component of the body; and a second open end (53b) connected to the circumferential end of the second component of the body. Both the neutral busbar and the temperature sensor are covered by a resin component (60) and thus integrated into a single piece. The resin component has a pair of first through holes (62) and second through holes (63). The first opening end and the second opening end of the bend are exposed from the resin component in the axial direction through the pair of first through holes and the second through holes, respectively. The pair of first through holes and the second through holes correspond to a pair of first pressing members (91) and second pressing members (92) for pressing the bend of the neutral busbar and the temperature sensor together from opposite axial sides of the bend during the resin molding of the resin component. The circumferential ends of the first component and the second extension face each other in the circumferential direction. The first through hole (62) is formed in the resin member so as to protrude from the circumferential end of the first member toward the second extension between the circumferential end of the first member and the second extension.

9. An armature (10), comprising: Annular armature core (20); A three-phase armature coil (30), the armature coil being wound on the armature core and Y-connected to define the neutral point of the armature coil; Neutral bus (451), the neutral bus is configured to connect to the neutral point side winding end of the armature coil; as well as A temperature sensor (80) is mounted on the neutral bus to detect the temperature of the armature coil. in, The neutral busbar has: a body (50) extending in the circumferential direction (Y3) of the armature; a plurality of connection terminals (51U, 52U, 51V, 52V, 51W, 52W) formed in the body and respectively connected to the neutral point side winding end of the armature coil; and a bend (53) clamping and thereby holding the temperature sensor. The main body of the neutral busbar has a first component (501) and a second component (502), the first component and the second component being spaced apart from each other in the circumferential direction, and each having one or more connection terminals. The bent portion is formed between the circumferential end (501a) of the first component and the circumferential end (502a) of the second component to electrically connect the first component and the second component. In the first component, a first extension (55) is formed between the circumferential end of the first component and one of the one or more connecting terminals (51U, 52U, 51V, 52V) formed in the first component, which is closest to the bend in the circumferential direction. The first extension extends in the axial direction (Y1) or radial direction (Y2) of the armature. In the second component, a second extension (56) is formed between the circumferential end of the second component and one of the connecting terminals (51W) formed in the second component that is closest to the bend in the circumferential direction. The second extension also extends in the axial or radial direction of the armature. Both the neutral busbar and the temperature sensor are covered by a resin component and thus integrated into a single unit. In the resin component, at least one hook-shaped retaining member (61) is formed to retain the lead (81) of the temperature sensor.

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