motor

Abstract

One embodiment of the motor of the present invention includes: a rotor capable of rotating about a central axis; a stator disposed radially outward of the rotor; and a first busbar and a second busbar disposed on an axial side of the stator. The stator has: a winding portion having a plurality of conductor connectors formed by connecting a plurality of conductors in series; and a stator core having a plurality of slots through which the conductor connectors pass. The winding portion has a coil end located on an axial side of the stator core. The conductor connectors have a first end portion and a second end portion located radially outward of the coil end portion. The first busbar is connected to the first end portion. The second busbar is connected to the second end portion. The first busbar is located on an axial side of the coil end portion. The second busbar is located radially outward of the coil end portion.

Description

Technical Field

[0001] This invention relates to motors. Background Technology

[0002] With the aim of increasing motor efficiency, winding structures using multiple segmented coils are being researched. A busbar is connected to such a motor to supply current to the stator, which is connected to the segmented coils. Patent Document 1 discloses a busbar module disposed radially outward at the edge of the coil. The connection portion of this busbar module is concentrated radially outward at the edge of the coil, thus simplifying the connection process.

[0003] [Existing Technical Documents]

[0004] [Patent Literature]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 2016-25745

[0006] In recent years, there has been a demand for higher voltage motors, sometimes requiring wider busbars to accommodate the increased current. In existing designs, using wider busbars would result in a larger busbar module radially, extending outwards from the back of the core, potentially leading to a larger motor. Summary of the Invention

[0007] In view of the above circumstances, one of the objectives of this invention is to provide a motor that can be miniaturized.

[0008] One embodiment of the motor of the present invention includes: a rotor rotatable about a central axis; a stator disposed radially outward of the rotor; and a first busbar and a second busbar disposed on an axial side of the stator. The stator has: a winding portion having a plurality of conductor connectors formed by connecting a plurality of conductors in series; and a stator core having a plurality of slots through which the conductor connectors pass. The winding portion has a coil end located on an axial side of the stator core. The conductor connector has a first end portion and a second end portion located radially outward of the coil end portion. The first busbar is connected to the first end portion. The second busbar is connected to the second end portion. The first busbar is located on an axial side of the coil end portion. The second busbar is located radially outward of the coil end portion.

[0009] According to one aspect of the present invention, a motor capable of miniaturization can be provided. Attached Figure Description

[0010] Figure 1 This is a cross-sectional schematic diagram of a motor according to one embodiment.

[0011] Figure 2 It is along Figure 1A cross-sectional view of the motor on line II-II.

[0012] Figure 3 This is a schematic diagram showing a circuit composed of a winding section and a busbar module according to one embodiment.

[0013] Figure 4 This is a schematic diagram showing the winding structure of a conductor connector according to one embodiment.

[0014] Figure 5 This is a perspective view of a stator, phase busbar module, and neutral point busbar module according to one embodiment.

[0015] Figure 6 This is a top view of a stator, phase busbar module, and neutral point busbar module according to one embodiment.

[0016] Figure 7 This is a perspective view of a busbar module according to one embodiment.

[0017] Figure 8 This is a perspective view of a neutral point busbar module in one embodiment.

[0018] Figure 9 yes Figure 5 A magnified view of region IX.

[0019] Figure 10 This is a partial cross-sectional schematic diagram of a modified motor.

[0020] (Symbol Explanation)

[0021] 1…motor;

[0022] 2…Stator;

[0023] 3…rotor;

[0024] 5A… Phase busbar module (first busbar module);

[0025] 5B… Neutral point uses busbar module (second busbar module);

[0026] 10… Neutral point uses a bus bar (second bus bar);

[0027] 11…Second main body (main body);

[0028] 15…Second Control Department;

[0029] 19…Second terminal section;

[0030] 20…stator core;

[0031] 30… Winding section;

[0032] 30e…coil edge;

[0033] 50… conductor;

[0034] 50f…turnaround section;

[0035] 50f…First Turnaround Section (Turnaround Section);

[0036] 50g…Second foldback section (foldback section);

[0037] 60… conductor connector;

[0038] 63…First end portion;

[0039] 64…Second end portion;

[0040] 70, 80, 90… phase busbars (first busbar);

[0041] 71, 81, 91… First main body (main body);

[0042] 75…First Control Department;

[0043] 79, 89, 99… First terminal section;

[0044] J…Central axis;

[0045] S…slot. Detailed Implementation

[0046] The Z-axis direction, appropriately shown in each figure, is a vertical direction with the positive side designated as "upper side" and the negative side as "lower side." The central axis J, appropriately shown in each figure, is an imaginary line parallel to the Z-axis direction and extending vertically. In the following explanation, the axial direction of the central axis J, i.e., the direction parallel to the vertical direction, is sometimes simply referred to as the "axial direction," the upper side as "one side of the axial direction," and the lower side as "the other side of the axial direction." Additionally, the radial direction centered on the central axis J is sometimes simply referred to as the "radial direction." Furthermore, the circumferential direction centered on the central axis J is sometimes simply referred to as the "circumferential direction," the clockwise direction when viewed from above is called "one side of the circumferential direction," and the counterclockwise direction when viewed from above is called "the other side of the circumferential direction."

[0047] Furthermore, the terms "upper and lower," "upper side," and "lower side" are merely names used to describe the configuration relationships of each part; the actual configuration relationships may also be those other than those indicated by these names. Moreover, the effects of the embodiment can be reproduced even if the directions described as one axial side and the other axial side are interchanged. Similarly, the effects of the embodiment can be reproduced even if the directions described as one circumferential side θ1 and the other circumferential side θ2 are interchanged.

[0048] <Motor>

[0049] Figure 1 This is a cross-sectional schematic diagram of motor 1 in this embodiment.

[0050] The motor 1 in this embodiment is an internal rotor type motor. Furthermore, the motor 1 in this embodiment is a three-phase AC motor. The center of the motor 1 is the central axis J.

[0051] like Figure 1 As shown, the motor 1 includes a rotor 3, a stator 2, a phase busbar module (first busbar module) 5A, a neutral point busbar module (second busbar module) 5B, a bearing retainer 4, and a housing 1a that houses them.

[0052] <Rotor>

[0053] The rotor 3 is capable of rotating about the central axis J. The rotor 3 is arranged radially inside the annular stator 2. That is, the rotor 3 is radially opposite to the stator 2. The rotor 3 has a shaft 3a, a rotor magnet 3b, and a rotor core 3c.

[0054] Shaft 3a extends axially along the central axis J. Shaft 3a is, for example, cylindrical, extending axially around the central axis J. Shaft 3a is supported by two bearings 3p so that it can rotate about the central axis J.

[0055] Figure 2 It is along Figure 1 A cross-sectional view of motor 1 on line II-II.

[0056] The rotor core 3c is constructed by stacking electromagnetic steel plates. The rotor core 3c is cylindrical, extending axially. The inner circumferential surface of the rotor core 3c is fixed to the outer circumferential surface of the shaft 3a. A retaining hole 3h is provided on the rotor core 3c for inserting and fixing the rotor magnet 3b.

[0057] The rotor magnet 3b is radially opposite to the stator 2. The rotor magnet 3b is held embedded in the rotor core 3c. In this embodiment, the rotor magnet 3b is an eight-pole magnet. The number of poles of the rotor 3 is not limited to this embodiment. Alternatively, the rotor magnet 3b may be a ring-shaped magnet or other types of magnets.

[0058] <Stator>

[0059] The stator 2 and rotor 3 are radially opposite each other with a gap between them. In this embodiment, the stator 2 is arranged radially outside the rotor 3. The stator 2 has a stator core 20, a winding portion 30, and a plurality of insulating sheets 6.

[0060] The stator core 20 is annular with the central axis J as its center. The stator core 20 is composed of multiple electromagnetic steel plates stacked axially. The stator core 20 has: a cylindrical core back 21 centered on the central axis J; and multiple pole teeth 22 extending radially inward from the core back 21.

[0061] Multiple pole teeth 22 are arranged at equal intervals in the circumferential direction. An umbrella-shaped portion 22a is provided at the front end of the radially inner side of the pole teeth 22. The umbrella-shaped portion 22a protrudes circumferentially to both sides relative to the pole teeth 22. That is, the circumferential dimension of the umbrella-shaped portion 22a is larger than the circumferential dimension of the pole teeth 22. The radially inner surface of the umbrella-shaped portion 22a faces the outer circumferential surface of the rotor 3 in the radial direction with a gap.

[0062] A winding portion 30 is mounted on the pole tooth portion 22. Slots S are provided between adjacent pole tooth portions 22 in the circumferential direction. That is, a plurality of slots S are provided on the stator core 20 arranged in the circumferential direction.

[0063] The conductor 50 of the winding section 30 is housed in slot S. Additionally, an insulating paper 6 is placed in each slot S. The insulating paper 6 ensures insulation between the winding section 30 and the stator core 20 within the slot S.

[0064] An eight-layer structure is provided in a slot S, arranged radially. A conductor 50 is disposed on each layer within the slot. The eight conductors 50 are arranged in a radial line within the slot S.

[0065] The slot S has an opening 29h that opens radially inward. The opening 29h is located between the umbrella-shaped portions 22a at the front ends of adjacent pole teeth 22. The circumferential width of the opening 29h is smaller than the circumferential dimension of the conductor 50. Therefore, it is difficult for the conductor 50 to pass through the opening 29h, thus preventing the conductor 50 from detaching from the stator core 20.

[0066] In this embodiment, the stator core 20 has forty-eight pole teeth 22. That is, the stator 2 in this embodiment has forty-eight slots. In addition, the number of slots of the stator 2 is appropriately set according to the number of poles of the rotor magnet 3b and the winding method of the winding section 30.

[0067] Figure 3 This is a schematic diagram showing the circuit formed by the winding section 30, the phase busbar module 5A, and the neutral point busbar module 5B of this embodiment.

[0068] The winding section 30 of this embodiment has a plurality of conductor connectors 60 (twelve in this embodiment) to form a segmented coil. The twelve conductor connectors 60 are classified into four U-phase conductor connectors 60U, four V-phase conductor connectors 60V, and four W-phase conductor connectors 60W.

[0069] Additionally, although detailed explanations will follow later, phase bus module 5A has three phase busbars (first busbars) 70, 80, and 90, while neutral point bus module 5B has one neutral point busbar (second busbar) 10. The three phase busbars 70, 80, and 90 are classified as U-phase busbar 70, V-phase busbar 80, and W-phase busbar 90.

[0070] The U-phase conductor connector 60U, V-phase conductor connector 60V, and W-phase conductor connector 60W are Y-connected via the neutral point busbar 10 and phase busbars 70, 80, and 90. In this embodiment, four Y-connections are formed corresponding to the four conductor connectors 60 of each phase, and each Y-connection is connected in parallel. That is, the winding section 30 is 4Y-connected via the phase busbar module 5A and the neutral point busbar module 5B.

[0071] Furthermore, in this embodiment, the case where the winding section 30 has four conductor connectors 60 of the same phase has been described. However, if the winding section 30 has at least two conductor connectors 60 and they form a pair of connectors 69 passing through circumferentially adjacent slots S, the same winding structure as in this embodiment can be used. Therefore, the multiple conductor connectors 60 can be connected in a 2×M Y-connection with M as a natural number (in this embodiment, M=2).

[0072] The conductor connector 60 has a first end portion 63 and a second end portion 64. The first end portion 63 and the second end portion 64 are respectively disposed at one end and the other end of the conductor connector 60. The conductor connector 60 is installed on the stator core 20 between the first end portion 63 and the second end portion 64 to form the coils of each phase. The conductor connector 60 is connected to the phase busbar module 5A and the neutral point busbar module 5B in the first end portion 63 and the second end portion 64.

[0073] The second ends 64 of the four U-phase conductor connectors 60U, the four V-phase conductor connectors 60V, and the four W-phase conductor connectors 60W are connected to a neutral point via a busbar 10. Thus, the second ends 64 of the twelve conductor connectors 60 are at the same potential, forming the neutral point. That is, the neutral point is formed by the busbar 10 in a three-phase circuit.

[0074] The first end portion 63 of the four U-phase conductor connectors 60U is connected to the U-phase busbar 70. The first end portion 63 of the four V-phase conductor connectors 60V is connected to the V-phase busbar 80. The first end portion 63 of the four W-phase conductor connectors 60W is connected to the W-phase busbar 90. Alternating currents with phases staggered by 120° flow through the phase busbars 70, 80, and 90, respectively.

[0075] Two of the four conductor connectors 60 of the same phase are mounted to the stator core 20 through adjacent slots S. In this specification, the two conductor connectors 60 passing through adjacent slots S are referred to as connector pair 69. Furthermore, in the following description, when distinguishing between the two conductor connectors 60 constituting connector pair 69, one will be referred to as first conductor connector 60A and the other as second conductor connector 60B.

[0076] Figure 4 This is a schematic diagram showing the winding structure of the two conductor connectors 60 that constitute the connector pair 69.

[0077] like Figure 4 As shown, the conductor connector 60 is constructed by connecting multiple conductors 50 in series. Each conductor 50 is formed by bending a flat wire. Therefore, compared with the case of using round wire, the duty cycle of the conductors 50 in the slot S can be increased. In addition, in this specification, "flat wire" refers to a wire with a quadrilateral or approximately quadrilateral cross-sectional shape. In this specification, "approximately quadrilateral" includes a rounded quadrilateral with rounded corners. Although the illustration is omitted, in this embodiment, the conductor 50 has a ceramic enamel coating on its surface.

[0078] The multiple conductors 50 constituting the conductor connector 60 are classified as end conductors 51, hairpin conductors 52, first return conductors 54, and second return conductors 55.

[0079] Each conductor 50 has at least straight portions 50a, 50b, and 50c extending linearly along the axial direction (Z direction) and a connecting portion 50j located at the lower end (the other side of the axial direction). The straight portions 50a, 50b, and 50c pass through the slot S. That is, the straight portions 50a, 50b, and 50c of the conductor connector 60 are housed in the slot S. The area of ​​the conductor connector 60, excluding the straight portions 50a, 50b, and 50c, extends towards the upper and lower sides of the stator core 20. The portions extending from the upper and lower sides of the stator core 20 constitute the coil edge 30e of the stator core 20 (see reference). Figure 1 ).

[0080] Furthermore, the straight section 50a is classified into a first straight section 50a, a second straight section 50b, and a third straight section 50c. The first straight section 50a is a straight section connected to the bridging section 50d or the end sections 63 and 64. The second straight section 50b and the third straight section 50c are straight sections connected to one end or the other end of the turning sections 50f and 50g.

[0081] The connecting portion 50j is connected to the connecting portions 50j of other conductors 50. The connecting portions 50j of a pair of conductors 50 are joined together by welding or other joining methods. After the conductor 50 is installed on the stator core 20, the connecting portion 50j is bent circumferentially and welded to the connecting portion 50j of other conductors 50. In the conductors 50 installed before the stator core 20, the connecting portion 50j is a straight line continuous with the straight portions 50a, 50b, and 50c. The conductor 50 is installed on the stator core 20 by inserting the connecting portion 50j and the straight portions 50a, 50b, and 50c into the slot S from the upper side (axial side) of the stator core 20. The connecting portion 50j of the conductor 50 is bent circumferentially and welded to other connecting portions 50j, thereby preventing the conductor 50 from axially detaching from the stator core 20.

[0082] In this embodiment, the stator 2 can be assembled by inserting a plurality of conductors 50 from the top through slots S relative to the stator core 20 and engaging them from the bottom. Therefore, a complex assembly process is not required, and the assembly process can be simplified.

[0083] Next, the various conductors 50 will be described.

[0084] Each of the end conductors 51 has one end portion 63, 64, one straight portion 50a, and one connecting portion 50j. End portions 63 and 64 are located at the upper end of the end conductor 51. End portions 63 and 64 are bent circumferentially relative to the straight portion 50a. In the end conductor 51, the directions in which the end portions 63 and 64 and the connecting portion 50j extend relative to the straight portion 50a are opposite to the circumferential direction. In the end conductor 51, the end portions 63 and 64 extend from the upper end of the straight portion 50a to the other circumferential direction θ1, and the connecting portion 50j extends from the lower end of the straight portion 50a to the other circumferential direction θ2.

[0085] The terminal portions 63 and 64 are connected to any one of the following: a neutral point busbar 10, a U-phase busbar 70, a V-phase busbar 80, and a W-phase busbar 90. The two terminal portions 63 and 64 are respectively located at both ends of the conductor connector 60. One of the two terminal portions 63 and 64 is the first terminal portion 63, and the other is the second terminal portion 64.

[0086] The hairpin conductor 52 has two straight sections 50a, two connecting sections 50j, and one bridging section 50d. The bridging section 50d is disposed at the upper end of the hairpin conductor 52. The bridging section 50d crosses over the two straight sections 50a. That is, in the hairpin conductor 52, the two straight sections 50a are connected to each other via the bridging section 50d. In the hairpin conductor 52, the two connecting sections 50j are respectively connected to the lower ends of different straight sections 50a. A plurality of bridging sections 50d protrude from the upper (axial side) end face of the stator core 20.

[0087] In the hairpin conductor 52, the two straight sections 50a are arranged relative to each other with a number of slots per pole s. Here, the number of slots per pole s refers to the number of slots S of the stator 2 disposed between one magnetic pole of the rotor 3 in the combination of the rotor 3 and the stator 2. The number of slots per pole s is calculated by (total number of slots of the stator 2) / (number of magnetic poles of the rotor 3). In this embodiment, since the number of magnetic poles of the rotor 3 is 8 and the number of slots of the stator 2 is 48, the number of slots per pole s is 6. In the hairpin conductor 52, the two straight sections 50a are separated from each other by six slots in the circumferential direction.

[0088] In the hairpin conductor 52, the bending directions of the two connecting portions 50j are opposite to each other in the circumferential direction. One of the two connecting portions 50j located on one side θ1 in the circumferential direction extends from the lower end of the straight portion 50a to the other side θ2 in the circumferential direction, and the other side located on the other side θ2 in the circumferential direction extends from the lower end of the straight portion 50a to one side θ1 in the circumferential direction. Twelve hairpin conductors 52 are respectively provided on the first conductor connector 60A and the second conductor connector 60B.

[0089] The first return conductor 54 has two straight portions 50b and 50c, two connecting portions 50j, and a first return portion (return portion) 50f. The second return conductor 55 has two straight portions 50b and 50c, two connecting portions 50j, and a second return portion (return portion) 50g. The first return portion 50f and the second return portion 50g are respectively disposed at the upper end of the first return conductor 54 or the second return conductor 55.

[0090] The first turning-back section 50f and the second turning-back section 50g are installed between the two straight sections 50b and 50c. That is, in the first turning-back conductor 54 and the second turning-back conductor 55, the two straight sections 50b and 50c are connected to each other via the first turning-back section 50f or the second turning-back section 50g, respectively.

[0091] In the first return conductor 54 and the second return conductor 55, the two connecting portions 50j are bent toward one circumferential side θ1. That is, in the first return conductor 54 and the second return conductor 55, the two connecting portions 50j extend from the lower ends of the straight portions 50b and 50c toward one circumferential side θ1, respectively.

[0092] The first return conductor 54 and the second return conductor 55 each have two straight sections 50b and 50c. The one of the two straight sections 50b and 50c located on one circumferential side θ1 is the second straight section 50b, and the one located on the other circumferential side θ2 is the third straight section 50c.

[0093] In the first return conductor 54 and the second return conductor 55, the distances between the two straight sections 50b and 50c are different. In the first return conductor 54, the second straight section 50b and the third straight section 50c are arranged circumferentially with a number of slots per pole s+1 (7 slots in this embodiment). On the other hand, in the second return conductor 55, the second straight section 50b and the third straight section 50c are arranged circumferentially with a number of slots per pole s-1 (5 slots in this embodiment). Therefore, the first return section 50f has a circumferential bridging amount two slots larger than the second return section 50g. A first return conductor 54 is provided on the first conductor connector 60A. On the other hand, a second return conductor 55 is provided on the second conductor connector 60B.

[0094] Next, the winding structure of the first conductor connector 60A and the second conductor connector 60B will be described.

[0095] In the first conductor connector 60A, two end conductors 51 are respectively disposed at both ends of the first conductor connector 60A, and a first fold-back conductor 54 is disposed approximately in the middle. The first conductor connector 60A is wavy-wound every six slots towards the other circumferential side θ2 from the first end portion 63 to the first fold-back portion 50f. Furthermore, the first conductor connector 60A is wavy-wound every six slots towards the other circumferential side θ1 from the first fold-back portion 50f to the second end portion 64.

[0096] Here, in the first conductor connector 60A, the region between the first end portion 63 and the first fold-back portion 50f that is wavy towards the other side θ2 is called the first portion 61. Furthermore, in the first conductor connector 60A, the region between the first fold-back portion 50f and the second end portion 64 that is wavy towards the other side θ1 is called the second portion 62. That is, the first conductor connector 60A has: a first end portion 63; a first portion 61 wavyly wound from the first end portion 63 towards the other side θ2; a first fold-back portion 50f connected to the end of the first portion 61 on the other side θ2; a second portion 62 wavyly wound from the first fold-back portion 50f towards the other side θ1; and a second end portion 64 connected to the end of the second portion 62 on the other side θ1.

[0097] In the second conductor connector 60B, two end conductors 51 are respectively disposed at the ends of both ends of the second conductor connector 60B. The second conductor connector 60B, with a second return conductor 55 disposed approximately in the middle, is wavy wound every six slots from the first end portion 63 to the second return portion 50g (first part 61) toward the other side circumferentially θ2. In addition, the second conductor connector 60B is wavy wound every six slots from the second return portion 50g to the second end portion 64 (second part 62) toward the other side circumferentially θ1. That is, the second conductor connector 60B has: a first end portion 63; a first portion 61 which is wavyly wound from the first end portion 63 toward the other side θ2 in the circumferential direction; a second fold-back portion 50g which is connected to the end of the first portion 61 on the other side θ2 in the circumferential direction; a second portion 62 which is wavyly wound from the second fold-back portion 50g toward one side θ1 in the circumferential direction; and a second end portion 64 which is connected to the end of the second portion 62 on the other side θ1 in the circumferential direction.

[0098] In this embodiment, the conductor connector 60 is wavy-wound in the first portion 61 and the second portion 62 at a number of slots per pole, s. That is, the conductor connector 60 is mounted on the stator core 20 in a full-pitch winding manner. Therefore, according to this embodiment, all the multiple conductors 50 arranged in the same slot S are part of the conductor connector 60 of the same phase. Therefore, according to this embodiment, it is not necessary to insulate conductor connectors 60 of different phases in one slot S, and insulation is easily ensured.

[0099] In this embodiment, the winding portion 30 has a first end portion 63, a second end portion 64, a bridging portion 50d, and fold-back portions 50f and 50g. The first end portion 63, the second end portion 64, the bridging portion 50d, and the fold-back portions 50f and 50g form a coil edge 30e on the upper side of the stator core 20. On the other hand, the connecting portion 50j forms a coil edge 30e on the lower side of the stator core 20. The first end portion 63 and the second end portion 64 are disposed on the outermost periphery of the coil edge 30e. That is, the first end portion 63 and the second end portion 64 are located radially outside the plurality of bridging portions 50d. The first end portion 63 extends upward (axially) from the stator core 20 and is connected to the phase busbars 70, 80, and 90. Similarly, the second end portion 64 extends upward (axially) from the stator core 20 and is connected to the neutral point busbar 10.

[0100] According to this embodiment, the foldback portions 50f and 50g are disposed at the innermost periphery of the coil edge 30e. That is, the foldback portions 50f and 50g are disposed radially inside the plurality of bridging portions 50d. Therefore, the wiring area of ​​the foldback portions 50f and 50g can be the radially inner area of ​​the coil edge 30e, which allows for miniaturization of the vertical dimension of the coil edge 30e.

[0101] Furthermore, according to this embodiment, by positioning the foldback portions 50f and 50g at the innermost periphery of the coil edge 30e, the two end portions 63 and 64 can be positioned at the outermost periphery of the coil edge 30e. That is, according to this embodiment, the first end portion 63 and the second end portion 64 extend from the outermost layer. Therefore, the connection process between the neutral point busbar 10 and the first end portion 63, and the connection process between the phase busbars 70, 80, and 90 and the second end portion 64, can be performed radially relative to the coil edge 30e, thus simplifying the manufacturing process of the motor 1.

[0102] like Figure 4 As shown, the circumferential order of the grooves S through which the first conductor connector 60A and the second conductor connector 60B pass in their respective fold-back portions 50f and 50g is reversed. The first end portion 63 of the first conductor connector 60A is located on one circumferential side of the first end portion 63 of the second conductor connector 60B. Furthermore, the second end portion 64 of the first conductor connector 60A is located on the other circumferential side of the second end portion 64 of the second conductor connector 60B. The U-phase connector pair 69, the V-phase connector pair 69, and the W-phase connector pair 69 are arranged sequentially facing the other circumferential side θ2.

[0103] <Busbar Module for Phase and Busbar Module for Neutral Point>

[0104] like Figure 1 As shown, the phase busbar module 5A and the neutral point busbar module 5B are disposed on the upper side of the stator 2. More specifically, the phase busbar module 5A is disposed directly above the coil end 30e. Furthermore, the neutral point busbar module 5B is disposed on the upper side of the core back 21 and radially outward of the coil end 30e. Therefore, the phase busbar module 5A is axially opposite to the coil end 30e, and the neutral point busbar module 5B is radially opposite to the coil end 30e.

[0105] Additionally, in this specification, "directly above" means that at least part of the configuration overlaps when viewed from above and in the vertical direction. Therefore, the phase busbar module 5A is configured above the coil edge 30e and overlaps with the coil edge 30e when viewed from the vertical direction.

[0106] Figure 5 This is a perspective view of the stator 2, phase busbar module 5A, and neutral point busbar module 5B of this embodiment. Figure 6 This is a top view of the stator 2, phase busbar module 5A, and neutral point busbar module 5B in this embodiment. Figure 7 This is a 3D view of the 5A busbar module. Figure 8 This is a 3D view of the busbar module 5B at the neutral point. Additionally, in Figure 7 and Figure 8The illustrations of the first retaining member 5c and the second retaining member 5d are omitted in the text.

[0107] like Figure 6 As shown, the phase busbar module 5A and the neutral point busbar module 5B extend circumferentially. The circumferential positions of the phase busbar module 5A and the neutral point busbar module 5B overlap.

[0108] (Using busbar module)

[0109] like Figure 7 As shown, the phase busbar module 5A has phase busbars 70, 80, and 90 and a first retaining member 5c. That is, the motor 1 has phase busbars 70, 80, and 90 and a first retaining member 5c. The phase busbars 70, 80, and 90 are plate-shaped and formed by stamping.

[0110] Phase busbars 70, 80, and 90 each have a first main body portion 71, 81, and 91, input terminal portions 78, 88, and 98, and multiple first terminal portions 79, 89, and 99. The first main body portions 71, 81, and 91 of each phase busbar 70, 80, and 90 have the same shape. Furthermore, the multiple input terminal portions 78, 88, and 98 of each phase busbar 70, 80, and 90 have the same shape. However, the multiple first terminal portions 79, 89, and 99 of each phase busbar 70, 80, and 90 have different shapes.

[0111] The first main body portions 71, 81, and 91 extend in an arc shape along the circumference. Each of the first main body portions 71, 81, and 91 is plate-shaped with its thickness along the axial direction. Phase busbars 70, 80, and 90 are stacked axially within the first main body portions 71, 81, and 91. The three first main body portions 71, 81, and 91 are arranged from top to bottom in the order of U-phase busbar 70, V-phase busbar 80, and W-phase busbar 90. Each of the three first main body portions 71, 81, and 91 extends in an arc shape along the circumference. The three first main body portions 71, 81, and 91 are staggered circumferentially. Therefore, in the phase busbar module 5A, three regions are arranged circumferentially: three stacked regions of the three first main body portions 71, 81, and 91; two stacked regions; and only one region.

[0112] Phase busbars 70, 80, and 90 each have two first terminal portions 79, 89, and 99. The two first terminal portions 79, 89, and 99 are disposed at both ends of the circumferential direction of each phase busbar 70, 80, and 90.

[0113] Two first end portions 63 are respectively connected to a first terminal portion 79, 89, 99. Therefore, four first end portions 63 are connected to a phase busbar 70, 80, 90.

[0114] First terminal portions 79, 89, and 99 extend radially outward and upward from the outer edges of the first main body portions 71, 81, and 91. The upper ends of the first terminal portions 79, 89, and 99 of the three phase busbars 70, 80, and 90 are positioned identically. As described above, the positions of the first main body portions 71, 81, and 91 of the three phase busbars 70, 80, and 90 in the vertical direction are different. Therefore, the vertical protrusion dimensions of the first terminal portions 79 of the phase busbars 70, 80, and 90 are different. That is, the vertical protrusion dimensions of the first terminal portions 79 of the U-phase busbar 70, V-phase busbar 80, and W-phase busbar 90 increase sequentially.

[0115] Figure 9 yes Figure 5 A magnified view of region IX.

[0116] based on Figure 9 The structure of the first terminal portion 99 will be described. Furthermore, although the illustrations are omitted, the first terminal portions 79 and 89 of the other phase busbars 70 and 80 also have the same characteristics. Figure 9 It has the same structure as the first terminal portion 99 shown.

[0117] The first terminal portion 99 has an extension portion 74 extending from the first main body portion 91 and a terminal body 76 located at the upper end of the extension portion 74. The terminal body 76 is a strip-shaped plate portion extending circumferentially in the axial (vertical) direction as the width direction of the plate. The two circumferential ends of the terminal body 76 are bent radially outward into a U-shape. The bent portions at both circumferential ends of the terminal body 76 constitute the first gripping portions 75. That is, the first terminal portion 99 has two U-shaped first gripping portions 75 that are open to each other respectively.

[0118] The first gripping part 75 clamps the first end part 63 into the opening from both radial sides. The first gripping part 75 and the first end part 63 are welded together. Thus, the first end part 63 is electrically connected to the phase busbars 70, 80, and 90.

[0119] In this embodiment, two first end portions 63 are connected to each first terminal portion 99. Figure 9 The two conductor connectors 60 connected by the first terminal portion 99 of the busbar 90 shown are the first end portions 63 of the two conductor connectors 60 of the W phase installed on the stator core 20 through adjacent slots S in the circumferential direction. Similarly, for the U phase and V phase, the first terminal portions 79, 89, and 99 are connected to the two first end portions of the same phase extending from the adjacent slots S in the circumferential direction.

[0120] According to this embodiment, the first terminal portion 99 is connected to the first end portion 63 at two opposing first gripping portions 75 with circumferential openings. Therefore, the two first gripping portions 75 can be simultaneously clamped from both radial sides using electrodes for resistance welding. By resistance welding, the first gripping portions 75 and the first end portions 63 can be welded at two locations simultaneously, simplifying the connection process.

[0121] like Figure 5 As shown, according to this embodiment, two first end portions 63 of the same phase can be connected to a first terminal portion 79, 89, 99. Therefore, in the phase busbars 70, 80, 90, the number of first terminal portions 79, 89, 99 can be reduced, and the shape of the phase busbars 70, 80, 90 can be simplified. Furthermore, by arranging the two first end portions 63 close to each other as a whole, the phase busbars 70, 80, 90 can be miniaturized in the circumferential direction.

[0122] like Figure 7 As shown, the input terminal portions 78, 88, and 98 of the phase busbars 70, 80, and 90 extend upward from the inner edge of their respective first main body portions 71, 81, and 91. Furthermore, the input terminal portions 78, 88, and 98 are connected to the inverter (not shown) via other separately prepared busbars (not shown). In each phase busbar 70, 80, and 90, the input terminal portions 78, 88, and 98 are arranged circumferentially between two first terminal portions 79, 89, and 99.

[0123] The first retaining member 5c is made of an insulating resin component. The first retaining member 5c is formed by embedding a portion of the phase busbars 70, 80, and 90. Thus, the first retaining member 5c retains the three phase busbars 70, 80, and 90.

[0124] The first retaining member 5c is embedded in the first main body portions 71, 81, and 91 of the phase busbars 70, 80, and 90, exposing the first terminal portions 79, 89, and 99 and the input terminal portions 78, 88, and 98. The resin component of the first retaining member 5c is inserted between the first main body portions 71, 81, and 91 of the phase busbars 70, 80, and 90. That is, an insulating resin component is sandwiched between the first main body portions 71, 81, and 91 stacked axially. Therefore, even if the first main body portions 71, 81, and 91 are arranged close to each other, insulation between the first main body portions 71, 81, and 91 can be ensured.

[0125] The first retaining member 5c has three first legs (legs) 5f and one second leg (leg) 5g extending downward (to the other axial side) from portions embedded in the first main bodies 71, 81, and 91. The first legs 5f are located radially outward relative to the first main bodies 71, 81, and 91. The lower end of the first leg 5f contacts the upper surface (facing the axial side) of the core back 21. The second leg 5g is located radially inward relative to the first main bodies 71, 81, and 91. The lower end of the second leg 5g is located on the upper surface of the pole tooth portion 22. Thus, the phase busbar module 5A is mounted on the stator core 20.

[0126] (Use busbar module for neutral point)

[0127] like Figure 8 As shown, the neutral point busbar module 5B includes a neutral point busbar 10 and a second retaining member 5d. That is, the motor 1 includes the neutral point busbar 10 and the second retaining member 5d. The neutral point busbar 10 is a plate-shaped component formed by stamping. The neutral point busbar 10 has a second main body portion 11 and a plurality of second terminal portions 19. The second main body portion 11 extends in an arc shape in the circumferential direction. The second main body portion 11 is a plate-shaped component with the radial direction being the thickness direction.

[0128] The neutral point busbar 10 has six second terminal portions 19. Two second end portions 64 are connected to each second terminal portion 19. Therefore, twelve second end portions 64 are connected to the neutral point busbar 10. The six second terminal portions 19 are arranged at equal intervals along the circumference of each phase busbar 70, 80, 90. The second terminal portions 19 extend upward from the upper edge of the second main body portion 11. The upper ends of the six neutral point busbars 10 are positioned symmetrically.

[0129] like Figure 9 As shown, the second terminal portion 19 has the same shape as the first terminal portion 99. The second terminal portion 19 has an extension portion 14 extending from the second main body portion 11 and a terminal body 16 located at the upper end of the extension portion 14. The terminal body 16 is a strip-shaped plate portion extending circumferentially in the axial (vertical) direction as its width. The two circumferential ends of the terminal body 16 are bent radially inward into a U-shape. The bending direction of the terminal body 16 of the second terminal portion 19 is radially opposite to the bending direction of the first terminal portion 99. The bent portions at both circumferential ends of the terminal body 16 constitute second gripping portions 15. That is, the second terminal portion 19 has two U-shaped second gripping portions 15 that open towards each other.

[0130] The second gripping portion 15 clamps the second end portion 64 into the opening from both radial sides. The second gripping portion 15 and the second end portion 64 are welded together. Thus, the second end portion 64 is electrically connected to the neutral point via the busbar 10. Like the first terminal portion 79, the second terminal portion 19 can simultaneously clamp both second gripping portions 15 from both radial sides using electrodes for resistance welding. Therefore, the second gripping portion 15 and the second end portion 64 can be welded at two locations simultaneously, simplifying the connection process.

[0131] In this embodiment, two second end portions 64 are connected to a second terminal portion 19. The two conductor connectors 60 connected to the second terminal portion 19 are two conductor connectors 60 of the same phase installed in the stator core 20 through adjacent circumferential slots S. Figure 4 The second end portion 64 of the connector pair 69 shown. That is, according to this embodiment, two second end portions 64 of the same phase can be connected to a second terminal portion 19. Therefore, in the neutral point busbar 10, the number of second terminal portions 19 can be reduced, and the shape of the neutral point busbar 10 can be simplified. Furthermore, by arranging the two second end portions 64 close to each other as a whole, the neutral point busbar 10 can be miniaturized in the circumferential direction.

[0132] like Figure 6 As shown, the first terminal portions 79, 89, and 99 of the phase busbars 70, 80, and 90 are connected to the first end portion 63 from the radially inner side. Furthermore, the second terminal portion 19 of the neutral point busbar 10 is connected to the second end portion 64 from the radially outer side. That is, the first terminal portions 79, 89, 99 and the second terminal portion 19 are connected from radially opposite sides relative to the end portions 63 and 64. According to this embodiment, it is possible to prevent the first terminal portions 79, 89, and 99 from being too close to the second terminal portion 19, and to easily ensure insulation between the first terminal portions 79, 89, and 99 and the second terminal portion 19. Furthermore, it is easy to arrange the connection positions of the first terminal portions 79, 89, and 99 to the first end portion 63 and the connection positions of the second terminal portion 19 to the second end portion 64 on the same circumference centered on the central axis J, which simplifies the connection process.

[0133] According to this embodiment, the first terminal portions 79, 89, 99 and the second terminal portion 19 are arranged alternately in the circumferential direction. Therefore, it is easy to arrange the first terminal portions 79, 89, 99 in a configuration that is sufficiently separated from each other in the circumferential direction, and it is easy to ensure the insulation between the first terminal portions 79, 89, 99 and each other.

[0134] like Figure 5As shown, according to this embodiment, the first end portion 63 and the second end portion 64 extend upward and are connected to the first terminal portion 79, 89, 99 or the second terminal portion 19 at their upper ends, respectively. Furthermore, the connection position between the first end portion 63 and the first terminal portions 79, 89, 99 is located higher than the connection position between the second end portion 64 and the second terminal portion 19. Therefore, even if the first terminal portions 79, 89, 99 and the second terminal portion 19 are arranged close together in the circumferential direction, their axial separation ensures a sufficient straight-line distance between them. This ensures insulation between the first terminal portions 79, 89, 99 and the second terminal portion 19.

[0135] The second retaining member 5d is made of an insulating resin component. The second retaining member 5d is formed by embedding a portion of the neutral point busbar 10. Thus, the second retaining member 5d retains the neutral point busbar 10. The second retaining member 5d is in contact with the upper surface (the surface facing the axial side) of the core back 21. That is, the neutral point busbar module 5B is mounted on the stator core 20.

[0136] The second retaining member 5d has two fixing parts 5e protruding radially outward. The two fixing parts 5e are arranged circumferentially. The fixing parts 5e are fixed to a housing (not shown) of the motor 1. Figure 6 As shown, the fixing part 5e protrudes radially outward from the outer edge of the back of the core 21 when viewed from the axial direction.

[0137] According to this embodiment, the phase busbar module 5A is located on the upper side of the coil end 30e. That is, the phase busbars 70, 80, and 90 are located on the upper side of the coil end 30e. Furthermore, the neutral point busbar module 5B is located radially outward of the coil end 30e. That is, the neutral point busbar 10 is located radially outward of the coil end 30e. In this embodiment, the phase busbars 70, 80, and 90 and the neutral point busbar 10 are separately arranged on the radially outward and upper side of the coil end 30e. Therefore, compared to the case where the phase busbars 70, 80, and 90 and the neutral point busbar 10 are all arranged on the upper side or radially outward of the coil end 30e, the motor 1 can be miniaturized in both the axial and radial directions.

[0138] In particular, in this embodiment, the radial thickness of the neutral point busbar module 5B located radially outward of the coil edge 30e can be made smaller than the radial thickness of the core back surface 21. Therefore, as... Figure 6 As shown, the projected area of ​​the phase busbar module 5A and the neutral point busbar module 5B from the axial direction of the stator core 20 can be suppressed, resulting in the miniaturization of the motor 1.

[0139] According to this embodiment, the phase busbars 70, 80, and 90, which are arranged axially relative to the coil edge 30e, are arranged axially in the thickness direction of the first main body portions 71, 81, and 91. Therefore, the increase in the axial dimension of the motor 1 can be effectively suppressed. Furthermore, the neutral point busbar 10, which is arranged radially relative to the coil edge 30e, is arranged radially in the thickness direction of the second main body portion 11. Therefore, the increase in the radial dimension of the motor 1 can be effectively suppressed.

[0140] According to this embodiment, the multiple phase busbars 70, 80, and 90 of the phase busbar module 5A are stacked axially in the first main body portions 71, 81, and 91. Therefore, even though the phase busbar module 5A, which is axially arranged relative to the coil edge 30e, has multiple U-phase busbars 70, 80, and 90, it is difficult to increase its axial size. As a result, the axial size of the motor 1 can be suppressed.

[0141] Alternatively, the configuration of the phase busbar module 5A and the neutral point busbar module 5B relative to the coil edge 30e can also be reversed compared to this embodiment. Regarding this case, Figure 10 This will be used as a basis for explanation, with variations as examples.

[0142] <Variation Example>

[0143] Figure 10 This is a cross-sectional schematic diagram showing a portion of a modified motor 101.

[0144] like Figure 10 As shown, the modified motor 101 has a neutral point busbar (first busbar module) 105A and a phase busbar module (second busbar module) 105B. The neutral point busbar module 105A is located on the upper side of the coil end 30e, and the phase busbar module 105B is located on the radially outer side of the coil end 30e.

[0145] The neutral point busbar module 105A includes a neutral point busbar 110. The neutral point busbar 110 has a plate-shaped main body 111 with the axial direction being the thickness direction and a first terminal portion 119.

[0146] On the other hand, the phase busbar module 105B has a plurality of (three in this embodiment) phase busbars 170, 180, and 190. Each phase busbar 170, 180, and 190 has a plate-shaped main body portion 171, 181, and 191 with the radial direction being the thickness direction, and a second terminal portion 179. The plurality of phase busbars 170, 180, and 190 are radially stacked in the main body portion 171, 181, and 191.

[0147] According to this modification, the number of busbars arranged radially outward on the coil edge 30e is three, and the number of busbars arranged on the upper side of the coil edge 30e is one. Therefore, compared with the above embodiment, a motor 10 with a larger radial size and a smaller axial size can be provided. The neutral point busbar module 105A and the phase busbar module 105B of this modification are suitable for motors 101 with a relatively large radial dimension of the core back 21 and space constraints on the upper side of the coil edge 30e.

[0148] The above describes embodiments and variations of the present invention. However, each embodiment and variation, as well as the structures and combinations thereof, are merely examples. Additions, omissions, substitutions, and other modifications to the structure are possible without departing from the spirit of the invention. Furthermore, the present invention is not limited to the embodiments described above. For example, in the above embodiments, a three-phase motor is described, but other motors, such as a five-phase motor, are also possible.

Claims

1. A motor, wherein, The motor includes: A rotor capable of rotating around its central axis; The stator disposed radially outside the rotor; and The first busbar and the second busbar are configured on one axial side of the stator. The stator has: A winding section, the winding section having multiple conductor connectors formed by connecting multiple conductors in series; and The stator core has multiple slots through which the conductor connectors pass. The winding section has a coil end located on one axial side of the stator core. The conductor connector has a first end portion and a second end portion located on the radial outermost periphery of the coil edge. The first busbar is connected to the first end portion. The second busbar is connected to the second end portion. The first busbar is located on one axial side of the coil end. The second busbar is located radially outward from the edge of the coil. The first busbar has a plate-shaped first main body portion with the axial direction being the thickness direction. The second busbar has a plate-shaped second main body portion with the radial direction as the plate thickness direction.

2. The motor as claimed in claim 1, wherein, The first busbar has a first terminal portion that connects to the first end portion from the radially inward side. The second busbar has a second terminal portion that connects to the second end portion from the radially outer side. The first terminal portion and the second terminal portion are arranged alternately in the circumferential direction.

3. The motor as claimed in claim 2, wherein, The first end portion and the second end portion extend axially to one side and are respectively connected to the first terminal portion or the second terminal portion at their upper ends. The connection position between the first end portion and the first terminal portion is located on the axial side compared to the connection position between the second end portion and the second terminal portion.

4. The motor as claimed in claim 1, wherein, The motor has multiple first busbars. Multiple first busbars are stacked axially at the first main body portion.

5. The motor as claimed in any one of claims 1 to 4, wherein, The conductor connector has a folded-back portion located at the innermost circumference of the coil edge.

6. The motor as claimed in claim 5, wherein, The winding section is connected in a 4Y configuration via the first busbar and the second busbar.

7. The motor as claimed in claim 6, wherein, Two conductor connectors of the same phase in the plurality of conductor connectors pass through adjacent slots in the circumferential direction. The first busbar has a first terminal portion, which is connected to two first end portions of the same phase extending from circumferentially adjacent slots. The second busbar has a second terminal portion, which is connected to two second end portions of the same phase extending from adjacent slots in the circumferential direction.

8. The motor as claimed in claim 7, wherein, The first terminal portion has two U-shaped first gripping portions that open opposite each other, each first gripping portion clamping the first terminal portion within the opening. The second terminal portion has two U-shaped second gripping portions that open opposite each other, each second gripping portion clamping the second terminal portion within the opening.

9. The motor as claimed in claim 8, wherein, The first gripping part and the first end part are welded together. The second gripping part and the second end part are welded together.

10. The motor as claimed in any one of claims 1 to 4, wherein, The motor has a first retaining member for maintaining the insulation of the first busbar. The first retaining member has a plurality of legs that extend axially to the other side and contact the axially facing surface of the stator core.

11. The motor as claimed in any one of claims 1 to 4, wherein, The motor has a second retaining member to maintain the insulation of the second busbar. The second retaining member is in contact with the surface facing the axial side of the stator core.

Images