Method for manufacturing busbar unit, busbar unit, and motor

Abstract

The present application provides a manufacturing method of bus bar unit, bus bar unit and motor. The bus bar unit can be applied to the connection of coil and external power supply in the motor. The process of manufacturing the bus bar unit has the following processes: the process of preparing the mold; the first process of positioning the bus bar and the shielding member in the mold; and the second process of forming the bus bar holder. The first process has the following processes: the first positioning pin is kept by inserting a plurality of first positioning pins into a plurality of bus bar through holes; the shielding member is arranged in the mold in a state that the lower surface of the shielding member is in contact with the front end of the first positioning pin; the second positioning pin is in contact with the upper surface of the shielding member to position the shielding member in the up-down direction; and the third positioning pin extending downward from the lower surface of the upper mold is in contact with the upper surface of the bus bar to position the bus bar in the up-down direction.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a busbar unit, a busbar unit, and a motor. Background Technology

[0002] Motors with busbar units that connect to external power terminals and coils are known. Patent Document 1 discloses a busbar unit obtained by alternately stacking busbars and positioning members made of insulating resin.

[0003] Patent Document 1: Japanese Patent No. 6353723

[0004] In the structure described in Patent Document 1, the busbar can be positioned in a planar direction using a positioning component, but positioning in the direction where the busbar and the positioning component are stacked is difficult. Furthermore, multiple dedicated positioning components are required, resulting in a large number of components and consequently, higher component costs. Summary of the Invention

[0005] According to one aspect of the present invention, a method for manufacturing a busbar unit is provided, which can be used to connect a coil in a motor to an external power source. The busbar unit comprises: a busbar composed of a plate-shaped conductor; a thin plate-shaped shielding member that shields against magnetism generated from the busbar; and a busbar holder that holds the busbar and the shielding member. The busbar has: an arc-shaped busbar body portion held in the busbar holder with its plate surface facing upwards and downwards; and a plurality of busbar through holes penetrating the busbar along its thickness direction. The shielding member has portions that overlap with the plurality of busbar through holes when viewed from the top and bottom.

[0006] The process of manufacturing the busbar unit includes the following steps: a process of preparing a mold for insert molding of the busbar and the shield; a first step of positioning the busbar and the shield within the mold; and a second step of injecting resin into the mold after the first step to form the busbar retainer.

[0007] The first process includes the following steps: inserting a plurality of first positioning pins extending upward from the upper surface of the lower mold into the plurality of busbar through holes, thereby holding the busbars in place by the first positioning pins; placing the shielding member in the mold with the lower surface of the shielding member in contact with the front end of the first positioning pins; positioning the shielding member in the vertical direction by contacting the upper surface of the shielding member with a second positioning pin extending downward from the lower surface of the upper mold; and positioning the busbars in the vertical direction by contacting the upper surface of the busbar with a third positioning pin extending downward from the lower surface of the upper mold.

[0008] According to one aspect of the present invention, a busbar unit is provided that can be used to connect a coil in a motor to an external power source. The busbar unit comprises: a busbar made of a plate-shaped conductor; a thin plate-shaped shielding member that shields against magnetism generated from the busbar; and a busbar holder that holds the busbar and the shielding member. The busbar has: an arc-shaped busbar body portion held in the busbar holder with its plate surface facing upwards and downwards; and a plurality of busbar through-holes penetrating the busbar along its thickness direction. The shielding member has portions that overlap with the plurality of busbar through-holes when viewed from the upwards and downwards direction. The busbar retainer has: a plurality of first pin insertion holes that open on the lower surface of the busbar retainer and extend upward, reaching the lower surface of the shield through the busbar through hole; a second pin insertion hole that opens on the upper surface of the busbar retainer and extends downward, reaching the upper surface of the shield; and a third pin insertion hole that opens on the upper surface of the busbar retainer and extends downward, reaching the upper surface of the busbar.

[0009] According to one aspect of the present invention, a motor is provided, comprising: a rotor rotatable about a central axis extending in a vertical direction; an annular stator located radially outward of the rotor; and a rotational position detection unit located above the stator for detecting the rotational position of the rotor. The stator comprises: a stator body having coils and a stator core; and a busbar unit located between the stator core and the rotational position detection unit. The busbar unit comprises: a busbar composed of a plate-shaped conductor; a thin plate-shaped shielding member shielding against magnetism generated from the busbar; and a busbar retainer holding the busbar and the shielding member. The busbar has: an arc-shaped busbar body portion held in a busbar holder with its plate surface facing up and down; a plurality of busbar through holes penetrating the busbar along the plate thickness direction; and a coil wiring portion and an external power wiring portion extending from different ends of the busbar body portion. The shielding member has a plurality of through-hole shielding portions that overlap with the plurality of busbar through holes when viewed from up and down. When viewed from up and down, the external power wiring portions extend linearly from the ends of the busbar body portion outwards and are arranged along the width direction of the external power wiring portions. A portion of the through-hole shielding portions is located on the external power wiring portion, and another portion is located on the busbar body portion or the coil wiring portion.

[0010] According to one aspect of the present invention, a method for manufacturing a busbar unit is provided that enables accurate positioning of the shield and the busbar without the use of special components. Attached Figure Description

[0011] Figure 1 This is a cross-sectional view of the motor in the embodiment.

[0012] Figure 2 This is a 3D view of a busbar unit.

[0013] Figure 3 This is a top view of the busbar unit viewed from above.

[0014] Figure 4 This is a bottom view of the busbar unit.

[0015] Figure 5 This is a top view of the busbar assembly.

[0016] Figure 6 This is a bottom view of the busbar assembly and shielding.

[0017] Figure 7 This is a top view of the busbar assembly and shielding.

[0018] Figure 8 This is a cross-sectional view of a mold showing the manufacturing process of a busbar unit.

[0019] Figure 9 This is a cross-sectional view of a mold showing the manufacturing process of a busbar unit.

[0020] Figure 10 This is a cross-sectional view of a mold showing the manufacturing process of a busbar unit.

[0021] Figure 11 This is a cross-sectional view of a mold showing the manufacturing process of a busbar unit.

[0022] Figure 12 This is a cross-sectional view of a mold showing the manufacturing process of a busbar unit.

[0023] Label Explanation

[0024] 1: Motor; 1aG, 1aU, 1aV, 1aW, 2aG, 2aU, 2aV, 2aW: Busbar main body; 1bG, 1bU, 1bV, 1bW, 2bG, 2bU, 2bV, 2bW: Coil wiring section; 1cU, 1cV, 1cW, 2cU, 2cV, 2cW: External power supply wiring section; 1dG, 1dU, 1dV, 1dW, 1eG, 1eV, 1eW, 1fW, 2dG, 2dU, 2dV, 2dW, 2eG, 2eV, 2eW, 2fW: Wide section; 20: Rotor; 30: Stator; 31: Stator core; 33: Coil; 34: Busbar assembly; 35: Busbar retainer; 35a: Inner hole; 36: Busbar unit; 37: Shielding component; 37c : Shielding notch; 37d: Shielding through hole; 60: Rotation position detection unit; 200: Mold; 201: Upper mold; 202: Lower mold; 211: First positioning pin; 212: Second positioning pin; 213: Third positioning pin; 214: Fourth positioning pin; 341U: First U-phase busbar; 341V: First V-phase busbar; 341W: First W-phase busbar; 342U: Second U-phase busbar; 342V: Second V-phase busbar; 342W: Second W-phase busbar; 353: Connector section; H11~H19, H21~H29: Busbar through hole; Hp1: First pin insertion hole; Hp2: Second pin insertion hole; Hp3: Third pin insertion hole; J: Central axis; α: Range. Detailed Implementation

[0025] Hereinafter, embodiments of the present invention will be described using the accompanying drawings.

[0026] Reference Figures 1 to 5 The motor 1 of the embodiment will be described.

[0027] In this embodiment, Figure 1 The direction in which the central axis J of the motor 1 extends is simply referred to as the "axial direction". In this embodiment, the axial direction is the vertical direction. The upper side (+Z) corresponds to one side of the axial direction, and the lower side (-Z) corresponds to the other side of the axial direction. Furthermore, the radial direction centered on the central axis J is simply referred to as the "radial direction". The direction in the radial direction closest to the central axis J is called the radial inner side, and the direction in the radial direction furthest from the central axis J is called the radial outer side. In this embodiment, the radial inner side corresponds to one side of the radial direction, and the radial outer side corresponds to the other side of the radial direction. Additionally, the circumferential direction centered on the central axis J is simply referred to as the "circumferential direction".

[0028] In addition, the terms "upper and lower," "upper side," and "lower side" are merely names used to describe the relative positional relationships of each part. The actual configuration relationships may also be configuration relationships other than those represented by these names.

[0029] In this embodiment, the motor 1 is, for example, mounted on an electric power steering system (illustration omitted). The electric power steering system is mounted on the steering mechanism of a vehicle's wheels. The electric power steering system is a device that reduces steering effort using a motor.

[0030] like Figure 1 As shown, the motor 1 of this embodiment includes: a rotor 20 centered on a central axis J; a stator 30 disposed radially outside the rotor 20; a housing 11; a plurality of bearings 15, 16; and a rotational position detection unit 60 for detecting the rotation of the rotor 20. In this embodiment, the rotational position detection unit 60 is a rotary transformer. The rotational position detection unit 60 has a rotary transformer rotor 61 and a rotary transformer stator 62. The rotational position detection unit 60 is not limited to a rotary transformer and may also be a Hall element or an MR element.

[0031] Motor 1 is an internal rotor type motor. The rotor 20 rotates about the central axis J relative to the stator 30. In addition, although not specifically shown, motor 1 may also have a base plate for controlling the rotation of the rotor 20.

[0032] The housing 11 houses the rotor 20 and the stator 30. The housing 11 is a cylindrical shape extending axially. The housing 11 has a peripheral wall 11a, a top wall 11b, a bottom wall 11c, and a bearing retaining wall 11d. The peripheral wall 11a is a cylindrical shape extending axially. The top wall 11b closes the opening on the upper side of the peripheral wall 11a. The bottom wall 11c closes the opening on the lower side of the peripheral wall 11a. The bottom wall 11c retains the bearing 16. The bearing retaining wall 11d is fixed to the peripheral wall 11a. The bearing retaining wall 11d retains the bearing 15.

[0033] The rotor 20 has a shaft 21, a rotor core 22, and a magnet 23. The shaft 21 is cylindrical and extends axially. Alternatively, the shaft 21 may be cylindrical and extend axially. The shaft 21 is supported by a plurality of bearings 15 and 16 to enable it to rotate about a central axis J. The plurality of bearings 15 and 16 are spaced apart from each other axially and supported on the housing 11. That is, the shaft 21 is supported on the housing 11 via the plurality of bearings 15 and 16.

[0034] Shaft 21 protrudes upwards from bearing 15. A rotary transformer rotor 61 is connected to the upper end of shaft 21. The rotary transformer rotor 61 is capable of rotating together with shaft 21 about its central axis J. A rotary transformer stator 62 is positioned above the bearing retaining wall 11d of bearing 15. The rotary transformer stator 62 is annular, surrounding the rotary transformer rotor 61 radially outwards. The rotary transformer stator 62 is located above the busbar unit 36, described later.

[0035] The rotor core 22 is a cylindrical shape extending axially. The outer diameter of the rotor core 22 is larger than the outer diameter of the shaft 21. The axial length of the rotor core 22 is smaller than the axial length of the shaft 21. The inner circumferential surface of the rotor core 22 is fixed to the outer circumferential surface of the shaft 21. The rotor core 22 is fixed to the shaft 21 by pressing and bonding. The rotor core 22 is axially positioned between a pair of bearings 15 and 16. A magnet 23 is fixed to the outer circumference of the rotor core 22.

[0036] The stator 30 and the rotor 20 are positioned radially opposite each other with a gap. The stator 30 surrounds the rotor 20 from the radially outer side over the entire circumference. The stator 30 has a stator core 31, an insulator 32, coils 33, and busbar units 36.

[0037] The stator core 31 is annular with the central axis J as its center. The stator core 31 is cylindrical, extending axially. The stator core 31 surrounds the rotor 20 radially outward. The stator core 31 is composed of multiple electromagnetic steel plates stacked axially. The stator core 31 is fixed to the inner circumferential surface of the housing 11. The stator core 31 and the housing 11 are fixed, for example, by thermoforming, pressing, or other means.

[0038] The stator core 31 has a core back 31a and a plurality of teeth 31b. The core back 31a is cylindrical about the central axis J. The radially outer surface of the core back 31a is fixed to the inner circumferential surface of the peripheral wall 11a. The teeth 31b protrude radially inward from the radially inner surface of the core back 31a. The plurality of teeth 31b are arranged circumferentially spaced apart from each other. The radially inner surface of each tooth 31b is opposite to the radially outer surface of the rotor 20 with a gap between them.

[0039] Insulator 32 is mounted on stator core 31. Insulator 32 is made of insulating material, such as resin. Insulator 32 is mounted on multiple teeth 31b. Coils 33 are mounted on stator core 31 via insulator 32. Multiple coils 33 are arranged circumferentially.

[0040] The motor 1 in this embodiment is a three-phase motor. Three phases refer to the U phase, V phase, and W phase. In the case of a three-phase motor, the coils 33 of the U phase, V phase, and W phase are electrically connected to the busbar unit 36.

[0041] like Figure 1 As shown, the busbar unit 36 ​​is located on the upper side (+Z side) of the stator core 31. In this embodiment, the busbar unit 36 ​​is located between the stator core 31 and the bearing retaining wall 11d. The busbar unit 36 ​​may also be located above the bearing retaining wall 11d. When viewed axially, the busbar unit 36 ​​overlaps with the rotary transformer stator 62.

[0042] like Figure 2As shown, the busbar unit 36 ​​includes: a busbar assembly 34 composed of multiple busbars; and a busbar retainer 35 that holds the busbar assembly 34. The busbar assembly 34 has eight busbars 341U, 341V, 341W, 341G, 342U, 342V, 342W, and 342G. In this embodiment, the busbar assembly 34 is embedded in the busbar retainer 35.

[0043] like Figure 3 As shown, the busbar retainer 35 has a retainer body 351 that is annular when viewed axially, three support legs 352 that project radially outward from the outer periphery of the retainer body 351, and a connector portion 353 that projects radially outward from the outer periphery of the retainer body 351. The busbar retainer 35 has an inner hole 35a extending along the central axis J. The busbar retainer 35 is made of resin. The ends of a plurality of busbars project radially outward from the outer periphery of the busbar retainer 35. Figure 5 A busbar assembly 34 is shown, which is held in a busbar holder 35. Each busbar constituting the busbar assembly 34 extends circumferentially inside the busbar holder 35, and at least a portion of the connection terminal portion, as well as the coil wiring portion and the external power supply wiring portion, which will be described later, are exposed to the outside of the busbar holder 35.

[0044] like Figures 2-4 As shown, support legs 352 are disposed at three locations on the cage body 351. Viewed axially, the three support legs 352 are arranged at 120° intervals circumferentially. Each support leg 352 is L-shaped, extending radially outward from the outer periphery of the cage body 351 and bending downward at its radially outward end. The lower end of each support leg 352 contacts the stator core 31 or the insulator 32. The support legs 352 axially position the busbar unit 36 ​​relative to the stator core 31 or the insulator 32. The number of support legs 352 can be two or less, or four or more. The busbar cage 35 can also be a structure without support legs 352.

[0045] Busbar unit 36 ​​is configured to be connected to the three-phase coil of the dual system. Figure 3 The coil structure of the motor 1 according to this embodiment is shown schematically. The six coils 33 are composed of a dual-system three-phase coil. That is, the motor 1 has: a first system coil group 331, which consists of a set of U-phase coils 33U, V-phase coils 33V, and W-phase coils 33W; and a second system coil group 332, which consists of another set of U-phase coils 33U, V-phase coils 33V, and W-phase coils 33W. The position and number of coils 33 are not limited to... Figure 3 The configuration shown is as follows. For example, the U-phase coil 33U, V-phase coil 33V, and W-phase coil 33W can each be composed of multiple coils.

[0046] like Figure 5 As shown, the busbar group 34 has a first system busbar group 341 and a second system busbar group 342. The first system busbar group 341 has a first U-phase busbar 341U, a first V-phase busbar 341V, a first W-phase busbar 341W, and a first neutral point busbar 341G. The second system busbar group 342 has a second U-phase busbar 342U, a second V-phase busbar 342V, a second W-phase busbar 342W, and a second neutral point busbar 342G.

[0047] That is, the bus bar unit 36 ​​has multiple U-phase bus bars, V-phase bus bars, and W-phase bus bars. More specifically, the bus bar group 34 includes: a first U-phase bus bar 341U and a second U-phase bus bar 342U, which together constitute a U-phase bus bar group; a first V-phase bus bar 341V and a second V-phase bus bar 342V, which together constitute a V-phase bus bar group; and a first W-phase bus bar 341W and a second W-phase bus bar 342W, which together constitute a W-phase bus bar group.

[0048] Figure 3 The three coils of the first system coil group 331 shown are connected to the first system busbar group 341. The U-phase coil 33U of the first system coil group 331 is connected to the first U-phase busbar 341U and the first neutral point busbar 341G. The V-phase coil 33V of the first system coil group 331 is connected to the first V-phase busbar 341V and the first neutral point busbar 341G. The W-phase coil 33W of the first system coil group 331 is connected to the first W-phase busbar 341W and the first neutral point busbar 341G.

[0049] The three coils of the second system coil group 332 are connected to the second system busbar group 342. The U-phase coil 33U of the second system coil group 332 is connected to the second U-phase busbar 342U and the second neutral point busbar 342G. The V-phase coil 33V of the second system coil group 332 is connected to the second V-phase busbar 342V and the second neutral point busbar 342G. The W-phase coil 33W of the second system coil group 332 is connected to the second W-phase busbar 342W and the second neutral point busbar 342G.

[0050] like Figure 5As shown, the first U-phase busbar 341U includes: a main line portion 41U extending in a plane perpendicular to the central axis J with its plate surface facing axially; a coil connection terminal portion Tc located at one end of the main line portion 41U; and an external power supply connection terminal portion Te located at the other end of the main line portion 41U. The main line portion 41U has a plate surface facing axially and a side surface facing a direction perpendicular to the axial direction. Furthermore, the main line portion 41U includes: a busbar body portion 1aU extending in an arc shape along the circumference of the central axis J; a coil wiring portion 1bU extending linearly from one end of the busbar body portion 1aU towards the outer periphery of the busbar unit 36; and an external power supply wiring portion 1cU extending linearly from the other end of the busbar body portion 1aU towards the outer periphery of the busbar unit 36.

[0051] The second U-phase busbar 342U, like the first U-phase busbar 341U, has a main line portion 42U, a coil connection terminal portion Tc, and an external power supply connection terminal portion Te. The main line portion 42U has a plate surface facing the axial direction and a side surface facing a direction perpendicular to the axial direction. The main line portion 42U has: a busbar body portion 2aU, which extends in an arc shape along the circumference around the central axis J; a coil wiring portion 2bU, which extends in a straight line from one end of the busbar body portion 2aU to the outer periphery of the busbar unit 36; and an external power supply wiring portion 2cU, which extends in a straight line from the other end of the busbar body portion 2aU to the outer periphery of the busbar unit 36.

[0052] The first V-phase busbar 341V includes: a main line portion 41V extending in a plane perpendicular to the central axis J with its plate surface facing axially; a coil connection terminal portion Tc located at one end of the main line portion 41V; and an external power supply connection terminal portion Te located at the other end of the main line portion 41V. The main line portion 41V has a plate surface facing axially and a side surface facing a direction perpendicular to the axial direction. The main line portion 41V includes: a busbar body portion 1aV extending in an arc shape along the circumference of the central axis J; a coil wiring portion 1bV extending in a straight line from one end of the busbar body portion 1aV toward the outer periphery of the busbar unit 36; and an external power supply wiring portion 1cV extending in a straight line from the other end of the busbar body portion 1aV toward the outer periphery of the busbar unit 36.

[0053] The second V-phase busbar 342V, like the first V-phase busbar 341V, has a main line portion 42V, a coil connection terminal portion Tc, and an external power supply connection terminal portion Te. The main line portion 42V has a plate surface facing the axial direction and a side surface facing a direction perpendicular to the axial direction. The main line portion 42V has: a busbar body portion 2aV, which extends in an arc shape along the circumference around the central axis J; a coil wiring portion 2bV, which extends in a straight line from one end of the busbar body portion 2aV to the outer periphery of the busbar unit 36; and an external power supply wiring portion 2cV, which extends in a straight line from the other end of the busbar body portion 2aV to the outer periphery of the busbar unit 36.

[0054] The first W-phase busbar 341W includes: a main line portion 41W extending in a plane perpendicular to the central axis J with its plate surface facing axially; a coil connection terminal portion Tc located at one end of the main line portion 41W; and an external power supply connection terminal portion Te located at the other end of the main line portion 41W. The main line portion 41W has a plate surface facing axially and a side surface facing a direction perpendicular to the axial direction. The main line portion 41W includes: a busbar body portion 1aW extending in an arc shape along the circumference of the central axis J; a coil wiring portion 1bW extending in a straight line from one end of the busbar body portion 1aW towards the outer periphery of the busbar unit 36; and an external power supply wiring portion 1cW extending in a straight line from the other end of the busbar body portion 1aW towards the outer periphery of the busbar unit 36.

[0055] The second W-phase busbar 342W, like the first W-phase busbar 341W, has a main line portion 42W, a coil connection terminal portion Tc, and an external power supply connection terminal portion Te. The main line portion 42W has a plate surface facing the axial direction and a side surface facing a direction perpendicular to the axial direction. The main line portion 42W has: a busbar body portion 2aW, which extends in an arc shape along the circumference around the central axis J; a coil wiring portion 2bW, which extends in a straight line from one end of the busbar body portion 2aW to the outer periphery of the busbar unit 36; and an external power supply wiring portion 2cW, which extends in a straight line from the other end of the busbar body portion 2aW to the outer periphery of the busbar unit 36.

[0056] The first neutral point busbar 341G has: a main line portion 41G extending in a plane perpendicular to the central axis J with its plate surface facing axially; and three coil connection terminal portions Tc located at one and the other ends of the main line portion 41G and at the circumferential center of the main line portion 41G. The main line portion 41G has a plate surface facing axially and a side surface facing a direction perpendicular to the axial direction. The main line portion 41G has: a busbar body portion 1aG extending in an arc shape along the circumference of the central axis J; and three coil wiring portions 1bG extending in a straight line from one and the other ends of the busbar body portion 1aG and at the circumferential center towards the outer periphery of the busbar unit 36.

[0057] The second neutral point busbar 342G, like the first neutral point busbar 341G, has a main wire portion 42G and three coil connection terminal portions Tc. The main wire portion 42G has a plate surface facing the axial direction and a side surface facing a direction perpendicular to the axial direction. The main wire portion 42G has: a busbar body portion 2aG, which extends in an arc shape along the circumference around the central axis J; and three coil wiring portions 2bG, which extend in a straight line from one end and the other end of the busbar body portion 2aG and the circumferential center portion toward the outer periphery of the busbar unit 36.

[0058] Busbar unit 36 ​​can also be structured without the first neutral point busbar 341G and the second neutral point busbar 342G. By using the first neutral point busbar 341G and the second neutral point busbar 342G, the wiring structure of the interconnecting wires of the connecting coils 33 can be easily simplified, thereby improving productivity.

[0059] like Figure 5 As shown, the multiple busbars constituting the busbar group 34 are arranged circumferentially around the central axis J. The first W-phase busbar 341W and the second W-phase busbar 342W are located at the innermost radial position among the multiple busbars.

[0060] A first V-phase busbar 341V and a first neutral point busbar 341G are arranged radially outside the first W-phase busbar 341W. A first U-phase busbar 341U is arranged radially outside the first V-phase busbar 341V.

[0061] A second V-phase busbar 342V and a second neutral point busbar 342G are arranged radially outside the second W-phase busbar 342W. A second U-phase busbar 342U is arranged radially outside the second V-phase busbar 342V.

[0062] like Figure 5As shown, when viewed along the axial direction, the first system busbar group 341 and the second system busbar group 342 are respectively disposed in two adjacent regions with a first imaginary line VL1 passing through the central axis J as the boundary. Furthermore, in this embodiment, the first U-phase busbar 341U and the second U-phase busbar 342U have a shape that is linearly symmetrical about the first imaginary line VL1 as the axis of symmetry, and are disposed in a position that is linearly symmetrical about the first imaginary line VL1 as the axis of symmetry. Similarly, the first V-phase busbar 341V and the second V-phase busbar 342V have shapes that are linearly symmetrical about each other with the first imaginary line VL1 as the axis of symmetry, and are disposed in a position that is linearly symmetrical. The first W-phase busbar 341W and the second W-phase busbar 342W have shapes that are linearly symmetrical about each other with the first imaginary line VL1 as the axis of symmetry, and are disposed in a position that is linearly symmetrical. The first neutral point busbar 341G and the second neutral point busbar 342G have shapes that are linearly symmetrical to each other with the first imaginary line VL1 as the axis of symmetry, and are arranged in linearly symmetrical positions.

[0063] Busbars are manufactured by bending a blank, which is formed by punching a metal sheet using a die. In this embodiment, two busbars positioned symmetrically across a first imaginary line VL1 have shapes that are linearly symmetrical to each other, thus allowing them to be manufactured using a shared blank. That is, the first U-phase busbar 341U and the second U-phase busbar 342U can be manufactured from a shared blank. Similarly, the first V-phase busbar 341V and the second V-phase busbar 342V, the first W-phase busbar 341W and the second W-phase busbar 342W, and the first neutral point busbar 341G and the second neutral point busbar 342G can also be manufactured using shared blanks.

[0064] According to this embodiment, eight busbars constituting the busbar unit 36 ​​can be manufactured from four types of blanks. Therefore, the number of molds used to manufacture the busbars can be reduced, enabling efficient and low-cost manufacturing of the busbars. This improves the productivity of the busbar unit 36.

[0065] Furthermore, in this embodiment, the busbars having shapes that are linearly symmetrical to each other are arranged in positions that are linearly symmetrical about the first imaginary line VL1 as the axis of symmetry. According to this structure, the first system busbar group 341 and the second system busbar group 342 are arranged in positions that are linearly symmetrical about the first imaginary line VL1 as the axis of symmetry. The busbar holder 35 holding the busbar group 34 can easily be made into a near-circular annular shape, thereby enabling it to be easily positioned on the upper side of the annular stator core 31.

[0066] Furthermore, in this embodiment, the shape and arrangement of the paired busbars adopt a linearly symmetrical structure with the first imaginary line VL1 as the axis of symmetry, but it is not limited to this structure. The first U-phase busbar 341U and the second U-phase busbar 342U only need to have their respective main line portions 41U and 42U having a shape that is linearly symmetrical with respect to the first imaginary line VL1. The same applies to the first V-phase busbar 341V and the second V-phase busbar 342V, the first W-phase busbar 341W and the second W-phase busbar 342W, and the first neutral point busbar 341G and the second neutral point busbar 342G. As long as the main line portions have a linearly symmetrical shape, the blanks used to manufacture the busbars can be shared, thereby improving the manufacturing efficiency of the busbars.

[0067] The shapes of the connection terminals Tc and Te, which are parts other than the main wire section, vary depending on the position and orientation of the lead wires extending from the coil 33. For example, sometimes the orientation of the opening of the connection terminal Tc used for coil connection that holds the lead wires from the coil 33 is different between the first U-phase busbar 341U and the second U-phase busbar 342U.

[0068] In this case, by sharing the stamping shape obtained from the metal sheet and performing only slight cutting after stamping, it is possible to manufacture two blanks with different shapes only for the portions forming the connecting terminals Tc and Te. This reduces the number of dies required for blank manufacturing.

[0069] In this embodiment, such as Figure 5 As shown, the first U-phase busbar 341U, the second U-phase busbar 342U, the first V-phase busbar 341V, the second V-phase busbar 342V, the first W-phase busbar 341W, the second W-phase busbar 342W, the first neutral point busbar 341G, and the second neutral point busbar 342G are respectively arranged in positions that do not overlap when viewed axially. These eight busbars are arranged in positions that overlap with at least one other busbar when viewed radially. In this embodiment, the main line portions of the eight busbars are arranged on a common plane with the plate surface facing axially.

[0070] According to this structure, multiple busbars can be arranged in positions that coincide when viewed radially, and the multiple busbars are arranged with the plate surface facing axially, thus significantly reducing the axial thickness of the busbar unit 36. By using the busbar unit 36 ​​of this embodiment, a stator 30 and motor 1 that are compact in the axial direction can be achieved.

[0071] like Figure 5 As shown, each busbar constituting the busbar group 34 has a wide portion that protrudes from the side of the busbar in a direction perpendicular to the axial direction when viewed along the axial direction.

[0072] The first U-phase busbar 341U has a cross section at the intersection of the busbar body 1aU and the external power wiring section 1cU, extending from the side of the external power wiring section 1cU towards the external power wiring section 1cV side. Figure 5 The right side) protrudes a wide section 1dU. The second U-phase busbar 342U has a cross-section at the intersection of the busbar body 2aU and the external power wiring section 2cU, extending from the side of the external power wiring section 2cU towards the external power wiring section 2cV side. Figure 5 (Left side) Protruding wide section 2dU.

[0073] The first U-phase busbar 341U has two busbar through holes H11 and H12 at a position of 1dU in the width portion, penetrating the main line portion 41U along the thickness direction (axial direction). The second U-phase busbar 342U has two busbar through holes H21 and H22 at a position of 2dU in the width portion, penetrating the main line portion 42U along the thickness direction. The two busbar through holes H11 and H12 of the first U-phase busbar 341U are arranged along the direction extending from the external power wiring portion 1cU. The two busbar through holes H21 and H22 of the second U-phase busbar 342U are arranged along the direction extending from the external power wiring portion 2cU. The busbar through holes H11 and H12 are holes into which support pins for fixing each busbar in the mold are inserted when the busbar assembly 34 insert is formed into the busbar holder 35. The other manifold through holes H13 to H19 and H23 to H29 described later are the same.

[0074] The first V-phase busbar 341V has a wide portion 1dV at the inner corner of the intersection of the busbar body 1aV and the coil wiring portion 1bV. The first V-phase busbar 341V has a wide portion 1dV at the intersection of the busbar body 1aV and the external power wiring portion 1cV, extending from the side of the external power wiring portion 1cV towards the side of the external power wiring portion 1cW. Figure 5 The right side) protrudes a wide section of 1eV. The first V phase busbar 341V has two busbar through holes H13 and H14 that penetrate the wide section of 1dV and 1eV respectively along the thickness direction.

[0075] The second V-phase busbar 342V has a wide portion 2dV at the inner corner of the intersection of the busbar body 2aV and the coil wiring portion 2bV. The second V-phase busbar 342V has a wide portion 2dV at the intersection of the busbar body 2aV and the external power wiring portion 2cV, extending from the side of the external power wiring portion 2cV towards the side of the external power wiring portion 2cW. Figure 5 The left side shows a prominent wide section of 2eV. The second V-phase busbar 342V has two busbar through holes H23 and H24 that penetrate the wide section of 2dV and 2eV respectively along the thickness direction.

[0076] The first W-phase busbar 341W has a wide portion 1dW at the inner corner of the intersection of the busbar body 1aW and the coil wiring portion 1bW. The first W-phase busbar 341W has a wide portion 1dW at the intersection of the busbar body 1aW and the external power wiring portion 1cW, extending from the side of the external power wiring portion 1cW towards the external power wiring portion 1cV side. Figure 5 (Left side) A wide portion 1eW protrudes. The first W-phase busbar 341W has a wide portion 1fW protruding radially outward from the side of the busbar body 1aW at the center of the busbar body 1aW. The first W-phase busbar 341W has three busbar through holes H15, H16, and H17 that penetrate the wide portions 1dW, 1eW, and 1fW respectively along the plate thickness direction.

[0077] The second W-phase busbar 342W has a wide portion 2dW at the inner corner of the intersection of the busbar body 2aW and the coil wiring portion 2bW. The second W-phase busbar 342W has a wide portion 2dW at the intersection of the busbar body 2aW and the external power wiring portion 2cW, extending from the side of the external power wiring portion 2cW towards the external power wiring portion 2cV side. Figure 5 The right side) has a protruding wide portion 2eW. The second W-phase busbar 342W has a wide portion 2fW protruding radially outward from the side of the busbar body 2aW at the center of the busbar body 2aW. The second W-phase busbar 342W has three busbar through holes H25, H26, and H27 that penetrate the wide portions 2dW, 2eW, and 2fW respectively along the plate thickness direction.

[0078] The first neutral point busbar 341G has a wide portion 1dG that protrudes outward from the corner of a section formed by connecting the busbar main body 1aG and the coil wiring portion 1bG on one circumferential side. The first neutral point busbar 341G also has a wide portion 1eG that protrudes outward from the corner of a section formed by connecting the busbar main body 1aG and the coil wiring portion 1bG on the other circumferential side. The first neutral point busbar 341G has two busbar through holes H18 and H19 that penetrate the wide portions 1dG and 1eG respectively along the plate thickness direction.

[0079] The second neutral point busbar 342G has a wide portion 2dG that protrudes outward from the corner of a section formed by connecting the busbar main body 2aG and the coil wiring portion 2bG on one circumferential side. The second neutral point busbar 342G also has a wide portion 2eG that protrudes outward from the corner of a section formed by connecting the busbar main body 2aG and the coil wiring portion 2bG on the other circumferential side. The second neutral point busbar 342G has two busbar through holes H28 and H29 that penetrate the wide portions 2dG and 2eG respectively along the plate thickness direction.

[0080] According to this embodiment, each busbar belonging to the busbar group 34 has a wide portion that protrudes from the side of each busbar in a direction perpendicular to the axial direction when viewed axially. This allows for suppression of increased resistance in the busbar even when it has a through-hole. In this embodiment, the through-hole of the busbar can be as follows: Figure 5 The busbar through holes H13-H19 and H23-H29 shown are located in the wide portion of the busbar, or they can be located near the 1dU and 2dU of the wide portion, as shown by the busbar through holes H11, H12, H21, and H22. By adopting a structure where the busbar through holes are located in the wide portion, the resistance increase of the busbar caused by the through holes is almost eliminated, thus allowing the through holes for inserting the support pins to be positioned in any location.

[0081] In this embodiment, the wide portion 1dV of the first V-phase busbar 341V, the wide portion 2dV of the second V-phase busbar 342V, and the wide portion 1dW of the first W-phase busbar 341W and the wide portion 2dW of the second W-phase busbar 342W are located inside the corners formed by the buckling of each busbar. This structure improves the rigidity of each busbar. It also reduces busbar deflection, thereby increasing the yield of the busbar unit 36 ​​and reducing coil wiring defects.

[0082] In this embodiment, the wide portions 1dV and 1eV of the first V-phase busbar 341V and the wide portions 2dV and 2eV of the second V-phase busbar 342V are located at the two circumferential ends of the first V-phase busbar 341V and the second V-phase busbar 342V, respectively. Similarly, the wide portions 1dW and 1eW of the first W-phase busbar 341W and the wide portions 2dW and 2eW of the second W-phase busbar 342W are located at the two circumferential ends of the first W-phase busbar 341W and the second W-phase busbar 342W, respectively.

[0083] Based on these structures, by providing busbar through holes in the wide portion, the busbar through holes for inserting support pins can be positioned at both ends of the slender busbar, thus ensuring stable holding even for relatively long busbars. This improves the positional accuracy of the busbar during insert molding. It also increases the yield rate of the busbar unit 36 ​​and reduces coil wiring defects.

[0084] In this embodiment, the first U-phase busbar 341U, the second U-phase busbar 342U, the first V-phase busbar 341V, the second V-phase busbar 342V, the first W-phase busbar 341W, and the second W-phase busbar 342W each have external power wiring portions 1cU, 2cU, 1cV, 2cV, 1cW, and 2cW extending in a direction along the first imaginary line VL1, in a portion of their respective main line portions 41U, 42U, 41V, 42V, 41W, and 42W. External power connection terminal portions Te extend from the front end of the external power wiring portions 1cU, 2cU, 1cV, 2cV, 1cW, and 2cW. When viewed axially, the plurality of external power wiring portions 1cU, 2cU, 1cV, 2cV, 1cW, and 2cW are arranged in a direction perpendicular to the first imaginary line VL1. External power supply cabling sections 1cU, 2cU, 1cV, 2cV, 1cW, and 2cW are maintained at... Figures 2-4 The connector portion 353 of the busbar holder 35 shown. The front ends of the external power wiring portions 1cU, 2cU, 1cV, 2cV, 1cW, and 2cW each protrude from the connector portion 353 toward the outer periphery of the busbar unit 36.

[0085] According to this structure, multiple external power wiring portions 1cU, 2cU, 1cV, 2cV, 1cW, and 2cW are housed within a portion of the circumferential area of ​​the busbar holder 35, thus allowing for a compact arrangement of the external power wiring portions. The multiple external power wiring portions are arranged along the first imaginary line VL1, thus enabling the external power wiring portions 1cU, 1cV, and 1cW of the first system busbar group 341 and the external power wiring portions 2cU, 2cV, and 2cW of the second system busbar group 342 to be positioned near the first imaginary line VL1. This allows for a compact configuration of a connector for connecting to external power supplies in both systems.

[0086] like Figure 5 As shown, the external power wiring sections 1cV and 1cW of the first system have wide sections 1eV and 1eW protruding from opposite sides. When viewed from the direction in which the external power wiring sections 1cV and 1cW extend, the two wide sections 1eV and 1eW overlap each other.

[0087] In addition, in the second system, the external power wiring portions 2cV and 2cW have wide portions 2eV and 2eW that protrude from opposite sides, and when viewed from the direction in which the external power wiring portions 2cV and 2cW extend, the two wide portions 2eV and 2eW overlap each other.

[0088] Based on these structures, two wide portions 1eV and 1eW are arranged between adjacent external power wiring portions 1cV and 1cW. Two wide portions 2eV and 2eW are arranged between external power wiring portions 2cV and 2cW. Because the wide portions 1eV, 1eW, 2eV, and 2eW can be arranged efficiently, a connector for connecting to an external power source can be compactly constructed. Furthermore, the widths of the external power wiring portions do not become excessively large, thus suppressing resin molding defects that may occur in the gaps between the external power wiring portions.

[0089] In this embodiment, a wide portion 1dU of a first U-phase busbar 341U is disposed between adjacent external power wiring sections 1cU and 1cV. A wide portion 2dU of a second U-phase busbar 342U is disposed between adjacent external power wiring sections 2cU and 2cV. With this structure, it is possible to prevent excessive expansion of the gaps between adjacent external power wiring sections 1cU and 1cV, and between adjacent external power wiring sections 2cU and 2cV, thereby suppressing poor resin molding in the gaps between the external power wiring sections.

[0090] Busbar unit 36 ​​has a shield 37 that overlaps with busbar assembly 34 when viewed axially. When viewed axially, shield 37 is a thin, annular metal plate. Shield 37 is located on the upper side (+Z side) of busbar assembly 34. That is, shield 37 is located axially between busbar assembly 34 and rotary transformer stator 62. Shield 37 shields the rotary transformer stator 62, which is part of the electronic circuitry of rotational position detection unit 60, from the magnetic field generated from busbar assembly 34.

[0091] like Figure 6 and Figure 7 As shown, when viewed axially, the inner periphery of the shield 37 is located slightly radially inward than the inner periphery of the busbar body 1aW of the first W-phase busbar 341W and the inner periphery of the busbar body 2aW of the second W-phase busbar 342W. When viewed axially, the outer periphery of the shield 37 substantially overlaps with the inner periphery of the busbar body 1aU of the first U-phase busbar 341U and the inner periphery of the busbar body 2aU of the second U-phase busbar 342U, as well as the inner periphery of the busbar body 1aG of the first neutral point busbar 341G and the inner periphery of the busbar body 2aG of the second neutral point busbar 342G.

[0092] like Figure 7As shown, the shield 37 covers from above the main body 1aV of the first V-phase busbar 341V, the main body 2aV of the second V-phase busbar 342V, the main body 1aW of the first W-phase busbar 341W, and the main body 2aW of the second W-phase busbar 342W. The shield 37 can be configured to cover a portion of the first U-phase busbar 341U, the second U-phase busbar 342U, the first neutral point busbar 341G, and the second neutral point busbar 342G.

[0093] Figures 8 to 12 This is an explanatory diagram of the manufacturing process of busbar unit 36. Figures 8 to 12 The cross-sectional views of the busbar and shield shown are respectively along... Figure 7 The cross-sectional view showing the positions of lines VIII-VIII, IX-IX, XX, XI-XI, and XII-XII has the right side corresponding to the central axis J side.

[0094] Busbar unit 36 ​​is manufactured by inserting busbar assembly 34 and shield 37 together into busbar holder 35. Most of busbar assembly 34 is embedded in busbar holder 35, with only the end connection terminals Tc, Te and their peripheral portions exposed from busbar holder 35. Shield 37 is substantially entirely embedded inside busbar holder 35.

[0095] The manufacturing process of busbar unit 36 ​​includes the following steps: a preparation step, which involves preparing a mold 200 (see reference) for insert molding of busbar assembly 34 and shield 37. Figure 8 The first step involves positioning the busbar assembly 34 and the shield 37 within the mold 200; and the second step involves injecting resin into the mold 200 after the first step to form the busbar retainer 35.

[0096] like Figure 8 As shown, the mold 200 has an upper mold 201 and a lower mold 202 arranged vertically. In this embodiment, the lower mold 202 has an upwardly opening recess 202a. The upper mold 201 is plate-shaped, covering the opening of the recess 202a from above. The mold 200 can seal the opening of the recess 202a by contacting the lower surface 201a of the upper mold 201 with the upper end surface 202b of the lower mold 202. The internal space 203 of the mold 200, which is surrounded by the upper mold 201 and the lower mold 202, is filled with a resin material that forms a busbar retainer 35.

[0097] In the first process, a busbar assembly 34 and a shielding member 37 are arranged in the recess 202a of the lower mold 202. For example... Figures 8 to 12As shown, a busbar assembly 34 is disposed on the bottom side of the recess 202a, and a shielding member 37 is disposed on the upper side of the busbar assembly 34. The busbar assembly 34 and the shielding member 37 are fixed in a predetermined position within the internal space 203 by a plurality of locating pins extending upward from the bottom surface 202c of the lower mold 202 and a plurality of locating pins extending downward from the lower surface 201a of the upper mold 201.

[0098] Mold 200 has Figure 8 The first locating pin 211 extends upward from the bottom surface 202c of the lower mold 202, and the second locating pin 212 extends downward from the lower surface 201a of the upper mold 201. Figure 10 The third locating pin 213 extends downward from the lower surface 201a of the upper mold 201, as shown. Figure 9 The fourth locating pin 214 extends upward from the bottom surface 202c of the lower mold 202, as shown. Figure 10 The fifth locating pin 215 extending upward from the bottom surface 202c of the lower mold 202, as shown, and Figure 12 The sixth locating pin 216 extends upward from the bottom surface 202c of the lower mold 202.

[0099] The mold 200 has six types of positioning pins, namely the first positioning pin 211 to the sixth positioning pin 216.

[0100] First positioning pins 211 are inserted into the busbar through holes H11-H19 and H21-H29 of the busbar assembly 34 located in the recess 202a. The first positioning pins 211 are cylindrical. The first positioning pins 211 pass through the busbar through holes H11-H19 and H21-H29 from the bottom to the top. The upper end of the first positioning pins 211 protrudes upward from the upper end of the busbar through holes H11-H19 and H21-H29.

[0101] A portion of the busbars in busbar group 34 were Figure 10 The fifth locating pin 215 shown is supported from below. The fifth locating pin 215 is cylindrical, extending vertically. (As shown...) Figure 6 As shown, the fifth positioning pin 215 supports the lower surfaces of the first V-phase busbar 341V, the first W-phase busbar 341W, the second V-phase busbar 342V, and the second W-phase busbar 342W from the lower side.

[0102] The fifth positioning pin 215 is disposed in the central part of the arc-shaped busbar body 1aV and 2aV in the V phase busbar.

[0103] The fifth positioning pin 215 is disposed at two locations on each of the arc-shaped busbar main bodies 1aW and 2aW in the W-phase busbar. In the busbar main body 1aW, the fifth positioning pin 215 is positioned at the midpoint between the wide portion 1dW and the wide portion 1fW, and at the midpoint between the wide portion 1eW and the wide portion 1fW. In the busbar main body 2aW, the fifth positioning pin 215 is positioned at the midpoint between the wide portion 2dW and the wide portion 2fW, and at the midpoint between the wide portion 2eW and the wide portion 2fW.

[0104] First positioning pins 211 are inserted into the through holes H11-H19 and H21-H29 of the eight busbars, and each busbar has two or more through holes. Through this structure, each busbar is positioned by the first positioning pins 211 in the horizontal direction perpendicular to the vertical direction.

[0105] After the busbar assembly 34 is provided in the recess 202a, a shield 37 is provided on the upper side of the busbar assembly 34. The shield 37 is supported by a first positioning pin 211, a fourth positioning pin 214, a sixth positioning pin 216 extending upward from the bottom surface of the lower mold 202, and a second positioning pin 212 extending downward from the upper surface of the upper mold 201.

[0106] like Figure 8 As shown, the first locating pin 211 contacts the lower surface 37a of the shield 37 from below. Specifically, through... Figure 7 The six first positioning pins 211 of the busbar through holes H13 and H14 of the first V phase busbar 341V, the busbar through hole H15 of the first W phase busbar 341W, the busbar through holes H23 and H24 of the second V phase busbar 342V, and the busbar through hole H25 of the second W phase busbar 342W support the shield 37 from the bottom.

[0107] In this embodiment, the six first positioning pins 211 supporting the shield 37 are arranged relatively dispersedly in the circumferential direction. Viewed from above, the positions of the two first positioning pins 211 entering the busbar through holes H15 and H25 are located on the opposite side of the positions of the two first positioning pins 211 entering the busbar through holes H14 and H24, separated by the central axis J. The two first positioning pins 211 entering the busbar through holes H13 and H23 are arranged circumferentially at positions relatively far from the four first positioning pins 211 entering the busbar through holes H15, H25, H14, and H24. With this structure, the first positioning pins 211 supporting the shield 37 from the lower side are arranged spaced apart without shifting in the circumferential direction, thus suppressing tilting or deflection of the shield 37.

[0108] Furthermore, in this embodiment, the external power wiring portions 1cU, 1cV, 1cW, 2cU, 2cV, and 2cW have busbar through holes H11, H12, H14, H16, H21, H22, H24, and H26. According to this structure, when manufacturing the busbar unit 36, the external power wiring portions 1cU, 1cV, 1cW, 2cU, 2cV, and 2cW are fixed horizontally in the direction by inserting first positioning pins 211 into the busbar through holes H11, H12, H14, H16, H21, H22, H24, and H26. Therefore, the positional accuracy of the external power wiring portions 1cU, 1cV, 1cW, 2cU, 2cV, and 2cW, which serve as connection terminals for connecting to an external power source, can be improved. This allows for the manufacture of a busbar unit 36 ​​that is less prone to poor connection with the external power source.

[0109] In this embodiment, the busbar constituting the busbar assembly 34 may also have a busbar through-hole within ±45 degrees of the center position of the connector portion 353, which is provided with a plurality of external power wiring portions 1cU, 1cV, 1cW, 2cU, 2cV, 2cW, centered on the central axis J. In this embodiment, the central axis J is aligned with the central axis of the inner hole 35a of the busbar holder 35. Figure 4 The diagram shows a second imaginary line VL2 connecting the central axis J and the connector portion 353 at its circumferential center position, and a range α of ±45° circumferentially relative to the second imaginary line VL2. As long as in Figure 4 By configuring busbar through holes within the range α shown, the positional accuracy of multiple external power wiring sections 1cU, 1cV, 1cW, 2cU, 2cV, and 2cW can be improved by using the first positioning pin 211.

[0110] When viewed from above and below, at the position where the first positioning pin 211 supports the shielding member 37 from below, the shielding member 37 covers the busbar through holes H13, H14, H15, H23, H24, and H25. That is, the shielding member 37 has multiple through hole covering portions that overlap with the multiple busbar through holes H13, H14, H15, H23, H24, and H25 when viewed from above and below. Furthermore, the through hole covering portions of the shielding member 37 that cover the busbar through holes H14 and H24 are located in the external power wiring portions 1cV and 2cV, while the through hole covering portions that cover the other busbar through holes H13, H15, H23, and H25 are located in the busbar body portions 1aV, 1aW, 2aV, 2aW or the coil wiring portions 1bV, 1bW, 2bV, 2bW.

[0111] The fourth locating pin 214 is inserted into Figure 6 and Figure 7The shielding component through-hole 37d is shown. The shielding component through-hole 37d is a hole that penetrates the shielding component 37 along the vertical direction. The shielding component through-hole 37d is positioned so as not to overlap with the busbar assembly 34 when viewed from the vertical direction. The fourth locating pin 214 is cylindrical. (The text repeats itself here.) Figure 9 As shown, the fourth locating pin 214 extends upward from the bottom surface 202c of the lower mold 202 and is inserted into the shielding through hole 37d from the bottom. The upper end of the fourth locating pin 214 protrudes upward beyond the upper surface of the shielding member 37. In this embodiment, the shielding member 37 has two shielding through holes 37d.

[0112] like Figure 6 As shown, the sixth locating pin 216 is located at three points on the lower surface of the shielding member 37. The sixth locating pin 216 is cylindrical. Figure 12 As shown, the sixth locating pin 216 extends upward from the bottom surface 202c of the lower mold 202 and contacts the lower surface 37a of the shield 37. The sixth locating pin 216, together with the first locating pin 211, supports the shield 37 from below. That is, the shield 37 is supported from below by a total of nine locating pins. The sixth locating pin 216 is positioned where the circumferential spacing between the six first locating pins 211 supporting the shield 37 increases. The sixth locating pin 216 facilitates holding the shield 37 in a horizontal position.

[0113] After the busbar assembly 34 and the shield 37 are installed in the recess 202a, the upper mold 201 is moved downwards and positioned in the closed position. The closed position is the position where the lower surface 201a of the upper mold 201 abuts against the upper end surface 202b of the lower mold 202. By positioning the upper mold 201 in the closed position, the opening of the recess 202a is closed.

[0114] like Figures 8 to 11 As shown, the upper mold 201 has a second positioning pin 212 and a third positioning pin 213. Both the second positioning pin 212 and the third positioning pin 213 are cylindrical pins extending downward from the lower surface 201a of the upper mold 201.

[0115] like Figure 8 and Figure 12 As shown, the second positioning pin 212 is positioned to overlap with the first positioning pin 21 and the sixth positioning pin 216 that support the shield 37 from below when viewed from above. Figure 8 and Figure 12 As shown, the shielding member 37 is clamped between the second positioning pin 212 and the first positioning pin 211, and between the second positioning pin 212 and the sixth positioning pin 216, and the shielding member 37 is fixed in the vertical direction. Therefore, the process of positioning the upper mold 201 in the closed position is as follows: the second positioning pin 212 is brought into contact with the upper surface 37b of the shielding member 37, and the shielding member 37 is positioned in the vertical direction.

[0116] like Figure 7 As shown, the third positioning pin 213 is positioned relative to the fifth positioning pin 215 (see reference) when viewed from above, which supports the shield 37 from below. Figure 6 The overlapping position. The third positioning pin 213 passes through the shielding notch 37c obtained by cutting through the shielding member 37 from top to bottom. In this embodiment, the shielding notch 37c is a notch that opens radially inward. Figure 10 As shown, the busbar is clamped between the third positioning pin 213 and the fifth positioning pin 215 and fixed in the vertical direction. Therefore, the process of positioning the upper mold 201 in the closed position is as follows: the third positioning pin 213 is brought into contact with the upper surface of the busbar to position the busbar in the vertical direction.

[0117] Through the first process described above, the busbar assembly 34 and the shield 37 are fixed in a positioned state within the internal space of the mold 200. In the subsequent second process, resin is injected into the mold 200 to form the busbar retainer 35. Through the above processes, the busbar unit 36 ​​is manufactured.

[0118] According to the manufacturing method of the busbar unit 36 ​​of this embodiment, the busbar assembly 34 and the shield 37 can be positioned in the vertical and horizontal directions using positioning pins provided on the upper mold 201 and the lower mold 202. The busbar unit 36, which can accurately position the busbar assembly 34 and the shield 37 without using dedicated components for positioning insert parts, can be easily manufactured.

[0119] In this embodiment, a structure capable of positioning in both the vertical and horizontal directions has been described for both the busbar assembly 34 and the shield 37. However, a structure without a horizontal positioning mechanism for the shield 37 can also be used. That is, the busbar unit 36 ​​can be manufactured using a mold 200 that does not have a fourth positioning pin 214 for positioning the shield 37 in the horizontal direction. As long as a shield 37 that is large enough when viewed from the vertical direction is used, even if the horizontal position of the shield 37 is slightly offset, the magnetism generated from the busbar assembly 34 can be shielded.

[0120] like Figures 2 to 4 As shown, the busbar unit 36 ​​obtained by the manufacturing method of this embodiment has a plurality of pin insertion holes that open on the upper or lower surface of the busbar holder 35.

[0121] like Figure 4As shown, the busbar retainer 35 has a plurality of first pin insertion holes Hp1 that open on the lower surface of the busbar retainer 35 and extend upward. The first pin insertion holes Hp1 are formed during the manufacturing process of the busbar unit 36 ​​by means of the first positioning pin 211. Therefore, the first pin insertion holes Hp1 are holes that reach the lower surface of the shield 37 through the busbar through hole.

[0122] like Figure 3 As shown, the busbar holder 35 has a plurality of second pin insertion holes Hp2 that open on the upper surface of the busbar holder 35 and extend downward. The second pin insertion holes Hp2 are formed during the manufacturing process of the busbar unit 36 ​​by means of second positioning pins 212. The second positioning pins 212 are pins that press the shield 37 from above at a position overlapping in the vertical direction with the first positioning pin 211 and the sixth positioning pin 216 that support the shield 37 from below. Therefore, the second pin insertion holes Hp2 are holes that extend downward from the upper surface of the busbar holder 35 and reach the upper surface 37b of the shield 37.

[0123] like Figure 3 As shown, the busbar retainer 35 has a plurality of third pin insertion holes Hp3 that open on the upper surface of the busbar retainer 35 and extend downward. The third pin insertion holes Hp3 are holes formed during the manufacturing process of the busbar unit 36 ​​by means of third locating pins 213. As... Figure 10 and Figure 11 As shown, the third locating pin 213 clamps and holds the busbar between the fifth locating pin 215 extending from the lower mold 202. Therefore, the third pin insertion hole Hp3 is a hole that extends from the upper surface of the busbar holder 35 downwards and reaches the upper surface of the busbar.

[0124] like Figure 3 and Figure 4 As shown, the busbar retainer 35 has multiple fourth pin insertion holes Hp4 extending vertically through the busbar retainer 35. The fourth pin insertion holes Hp4 are formed during the manufacturing process of the busbar unit 36 ​​using fourth locating pins 214. (As shown...) Figure 9 As shown, the fourth locating pin 214 extends upward from the lower mold 202 and reaches the upper mold 201 through the shielding through hole 37d. Therefore, the fourth pin insertion hole Hp4 is a hole that extends upward from the lower surface of the busbar holder 35 and protrudes into the upper surface of the busbar holder 35 through the shielding through hole 37d. Alternatively, the fourth locating pin 214 may not reach the upper mold 201; in this case, the fourth pin insertion hole Hp4 only opens on the lower surface of the busbar holder 35.

[0125] like Figure 4As shown, the busbar retainer 35 has a plurality of fifth pin insertion holes Hp5 that open on the lower surface of the busbar retainer 35 and extend upward. The fifth pin insertion holes Hp5 are formed during the manufacturing process of the busbar unit 36 ​​by means of fifth locating pins 215. Figure 10 and Figure 11 As shown, the fifth locating pin 215 and the third locating pin 213 clamp and hold the busbar together. Therefore, the fifth pin insertion hole Hp5 is a hole that extends upward from the lower surface of the busbar holder 35 and reaches the lower surface of the busbar.

[0126] like Figure 4 As shown, the busbar retainer 35 has a plurality of sixth pin insertion holes Hp6 that open on the lower surface of the busbar retainer 35 and extend upward. The sixth pin insertion holes Hp6 are holes formed during the manufacturing process of the busbar unit 36 ​​by means of sixth locating pins 216. As... Figure 12 As shown, the sixth positioning pin 216 clamps and holds the busbar between the second positioning pin 212. Therefore, the sixth pin insertion hole Hp6 extends upward from the lower surface of the busbar holder 35 and reaches the hole on the lower surface 37a of the shield 37.

[0127] By having the aforementioned multiple pin insertion holes, the busbar unit obtained by the manufacturing method of this embodiment can be determined. Furthermore, in the manufacturing process of the busbar unit 36, the fourth positioning pin 214, the fifth positioning pin 215, and the sixth positioning pin 216 are used as needed. In a busbar unit obtained by a manufacturing method that does not use any one or more of the fourth positioning pin 214, the fifth positioning pin 215, and the sixth positioning pin 216, it naturally also lacks a structure with pin insertion holes corresponding to the unused positioning pins.

Claims

1. A manufacturing method of a bus bar unit which is applicable to connection of a coil in a motor and an external power supply, wherein the bus bar unit has: a plurality of bus bars which are constituted by a plate-shaped conductive body; a thin plate-shaped shield which shields a magnetic field generated from the bus bars; and a bus bar holder which holds the bus bars and the shield, the plurality of bus bars each have: a bus bar main body portion which is held in the bus bar holder in a posture with a plate face facing upward and downward directions; a plurality of bus bar through holes which penetrate the bus bars in a plate thickness direction; a coil wiring portion and an external power supply wiring portion which respectively extend from mutually different end portions of the bus bar main body portion; and a wide portion which protrudes in a width direction from a side face of the bus bar, the external power supply wiring portions of the plurality of bus bars extend in a straight line shape from end portions of the bus bar main body portions toward an outer peripheral side when viewed in the upward and downward directions, and are arranged in a width direction of the external power supply wiring portions, the external power supply wiring portion of the plurality of external power supply wiring portions which is arranged at an end in a direction in which the plurality of external power supply wiring portions are arranged has a first wide portion which protrudes from a side face opposite to an adjacent external power supply wiring portion, the two external power supply wiring portions of the plurality of external power supply wiring portions which are not arranged at the end in the direction in which the plurality of external power supply wiring portions are arranged but are arranged adjacent to each other in the width direction each have a second wide portion which protrudes from a side face opposite to each other, the second wide portions which protrude from the mutually opposite side faces overlap each other when viewed in a direction in which the external power supply wiring portions extend, the shield has a portion which overlaps the plurality of bus bar through holes when viewed in the upward and downward directions, the manufacturing method of the bus bar unit has the following steps: a step of preparing a mold into which the bus bars and the shield are insert-molded; a first step of positioning the bus bars and the shield in the mold; and a second step of injecting resin into the mold after the first step to mold the bus bar holder, the first step has the following steps: the first positioning pins which extend upward from a lower mold upper surface of the mold are inserted into the plurality of bus bar through holes so that the first positioning pins hold the bus bars; the shield is arranged in the mold in a state in which a lower surface of the shield is in contact with a front end of the first positioning pin; a second positioning pin which extends downward from an upper mold lower surface of the mold is brought into contact with an upper surface of the shield to position the shield in the upward and downward directions; and a third positioning pin which extends downward from the upper mold lower surface is brought into contact with an upper surface of the bus bar to position the bus bar in the upward and downward directions.

2. The manufacturing method of the bus bar unit according to claim 1, wherein a plurality of through holes are provided in the second wide portion.

3. The manufacturing method of the bus bar unit according to claim 1 or 2, wherein ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The shield has a shield through-hole that penetrates the shield in a plate thickness direction, The mold has a fourth positioning pin that extends upward from the lower mold upper surface or downward from the upper mold lower surface, The first process has a process of inserting the fourth positioning pin into the shield through-hole.

4. The busbar unit manufacturing method according to claim 1 or 2, wherein The busbar has the busbar through-hole at each of both ends of the busbar body portion.

5. The busbar unit manufacturing method according to claim 1 or 2, wherein The busbar has a coil wiring portion and an external power supply wiring portion that extend from mutually different end portions of the busbar body portion, respectively, When viewed in the up-down direction, the external power supply wiring portion extends in a straight line from the end portion of the busbar body portion to the outer peripheral side, and is arranged in the width direction of the external power supply wiring portion, The busbar has a busbar through-hole that penetrates the external power supply wiring portion in a plate thickness direction.

6. The busbar unit manufacturing method according to claim 5, wherein The busbar holder is ring-shaped with an inner hole that extends in the up-down direction, The busbar has the busbar through-hole within ±45 degrees of the central position with respect to a connector portion in which a plurality of the external power supply wiring portions are arranged, in a circumferential direction centered on the central axis of the inner hole.

7. The busbar unit manufacturing method according to claim 1 or 2, wherein The busbar has a wide portion that protrudes in the width direction from a side surface of the busbar.

8. The busbar unit manufacturing method according to claim 7, wherein The busbar has the busbar through-hole at the wide portion.

9. The busbar unit manufacturing method according to claim 7, wherein The busbar has the wide portion at a portion where the busbar is bent.

10. A busbar unit that can be applied to connection of a coil and an external power supply in a motor, wherein The busbar unit has: a plurality of busbars composed of a plate-shaped conductive body; a thin plate-shaped shield that shields a magnetic field generated from the busbar; and a busbar holder that holds the busbar and the shield, The plurality of busbars each has: a busbar body portion that is held in the busbar holder in a posture with a plate surface facing in an up-down direction; a plurality of busbar through-holes that penetrate the busbar in a plate thickness direction; a coil wiring portion and an external power supply wiring portion that extend from mutually different end portions of the busbar body portion, respectively; and a wide portion that protrudes in the width direction from a side surface of the busbar, When viewed in the up-down direction, the external power supply wiring portions of the plurality of busbars extend in a straight line from the end portions of the busbar body portions to the outer peripheral side, and are arranged in the width direction of the external power supply wiring portions, The external power supply wiring portion arranged at the end in the direction in which the plurality of external power supply wiring portions are arranged among the plurality of external power supply wiring portions arranged in the width direction has a first wide portion protruding from the side surface opposite to the adjacent external power supply wiring portion, The two external power supply wiring portions arranged adjacent to each other in the width direction among the plurality of external power supply wiring portions arranged in the width direction do not have a portion arranged at the end in the direction in which the plurality of external power supply wiring portions are arranged, and each has a second wide portion protruding from the side surface opposite to each other, The second wide portions protruding from the side surfaces opposite to each other overlap each other when viewed in the direction in which the external power supply wiring portions extend, The shield has a portion overlapping the plurality of bus bar through holes when viewed in the up-down direction, The bus bar holder has: a plurality of first pin insertion holes that are opened at the lower surface of the bus bar holder and extend upward, reaching the lower surface of the shield through the bus bar through hole; a second pin insertion hole that is opened at the upper surface of the bus bar holder and extends downward, reaching the upper surface of the shield; and a third pin insertion hole that is opened at the upper surface of the bus bar holder and extends downward, reaching the upper surface of the bus bar.

11. The bus bar unit according to claim 10, wherein the plurality of bus bars include: a first U-phase bus bar and a second U-phase bus bar that constitute a U-phase bus bar group; a first V-phase bus bar and a second V-phase bus bar that constitute a V-phase bus bar group; and a first W-phase bus bar and a second W-phase bus bar that constitute a W-phase bus bar group.

12. A motor having: a rotor rotatable about a center axis extending in an up-down direction; a ring-shaped stator located radially outward of the rotor; and a rotation position detection unit located on the upper side of the stator, detecting a rotation position of the rotor, wherein the stator has: a stator main body having a coil and a stator core; and the bus bar unit according to claim 10 or 11 is located between the stator core and the rotation position detection unit.

13. A motor having: a rotor rotatable about a center axis extending in an up-down direction; a ring-shaped stator located radially outward of the rotor; and a rotation position detection unit located on the upper side of the stator, detecting a rotation position of the rotor, wherein the stator has: a stator main body having a coil and a stator core; and a bus bar unit located between the stator core and the rotation position detection unit, the bus bar unit has: a plurality of bus bars composed of plate-shaped conductive bodies; a thin plate-shaped shield that shields a magnetic field generated from the bus bars; and a bus bar holder that holds the bus bars and the shield, the plurality of bus bars each have: ​ The bus bar main body portion is held in the bus bar holder in a posture with the plate surface facing in the up-down direction. A plurality of bus bar through holes that penetrate the bus bar in the plate thickness direction; A coil wiring portion and an external power supply wiring portion that respectively extend from mutually different end portions of the bus bar main body portion; And A wide portion that protrudes in the width direction from the side surface of the bus bar, When viewed in the up-down direction, the external power supply wiring portion extends in a straight line shape from the end portion of the bus bar main body portion to the outer peripheral side, and is arranged in the width direction of the external power supply wiring portion, When viewed in the up-down direction, the external power supply wiring portion of the plurality of bus bars extends in a straight line shape from the end portion of the bus bar main body portion to the outer peripheral side, and is arranged in the width direction of the external power supply wiring portion, The external power supply wiring portion, which is arranged at the end in the direction in which the plurality of external power supply wiring portions are arranged, among the plurality of external power supply wiring portions arranged in the width direction, has a first wide portion that protrudes from the side surface opposite the adjacent external power supply wiring portion, The two external power supply wiring portions, which are not arranged at the end in the direction in which the plurality of external power supply wiring portions are arranged, among the plurality of external power supply wiring portions arranged in the width direction, are respectively arranged adjacent to each other in the width direction, and each have a second wide portion that protrudes from the side surface opposite the other, The second wide portions that protrude from the mutually opposite side surfaces overlap each other when viewed in the direction in which the external power supply wiring portion extends, The shield has a plurality of through hole shielding portions that respectively overlap the plurality of bus bar through holes when viewed in the up-down direction, A portion of the plurality of through hole shielding portions is located in the external power supply wiring portion, and another portion of the plurality of through hole shielding portions is located in the bus bar main body portion or the coil wiring portion.

14. The motor according to claim 13, wherein The bus bar holder is ring-shaped with an inner hole extending in the up-down direction, In the circumferential direction centered on the central axis of the inner hole, the through hole shielding portion is located within a range of ±45 degrees from the central position of a connector portion in which the plurality of external power supply wiring portions are arranged.

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