Rotating electrical machine

Abstract

The rotary motor of the present invention includes: a busbar support (61) disposed axially relative to a stator (21) and a plurality of busbar terminals (71) electrically connecting the stator to a control unit (50). Lead wires (82) extend from lead-out portions (81) toward the axial busbar terminal (71) side, the lead-out portions being located between a plurality of windings (23) disposed on the circumferential circumference of the stator (21) and adjacent to each other on the busbar terminal (71) side. Each busbar terminal (71) has a winding-side terminal portion (72) and a substrate-side terminal portion (77), wherein the winding-side terminal portion includes at least one connecting portion (73), and the substrate-side terminal portion is connected to a substrate (51). The plurality of busbar terminals (71) are concentrated in a portion of the circumference. The lead wires (82) are routed from one of the plurality of lead-out portions (81) distributed on the circumferential circumference to one of the plurality of connecting portions (73).

Description

[0001] Cross-reference to related applications

[0002] This application is based on Japanese Patent Application No. 2021-129608, filed on August 6, 2021, the contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a rotary electric motor. Background Technology

[0004] As a conventional busbar terminal for rotating electric machines, the busbar terminal described in Patent Document 1 is known, for example. The busbar terminal disclosed in Patent Document 1 includes a motor connection component and a terminal component, wherein the motor connection component is electrically connected to the windings of the motor, and the terminal component is composed of a component different from the motor connection component and is electrically connected to an external terminal.

[0005] Patent Document 1: International Publication No. 2020 / 261866

[0006] In Patent Document 1, the motor connection component is formed in a manner corresponding to multiple windings arranged around the entire circumference, and continuously across the approximately entire circumference. Therefore, there is a problem that the busbar terminals become longer, requiring more material. Summary of the Invention

[0007] The purpose of this disclosure is to provide a rotary motor capable of shortening the busbar terminals.

[0008] The rotary electric motor disclosed herein includes: a stator; a rotor configured to rotate relative to the stator; a control unit connected to the stator; a busbar support disposed axially relative to the stator; and a plurality of busbar terminals fixed to the busbar support. The busbar terminals electrically connect the stator and the control unit.

[0009] The stator has a plurality of windings arranged circumferentially. Leads extend from lead-out portions toward the busbar terminal side in the axial direction, wherein the lead-out portions are located among a plurality of windings adjacent to each other in the circumferential direction and on the busbar terminal side. The busbar terminal has a winding-side terminal portion and a substrate-side terminal portion, wherein the winding-side terminal portion includes at least one connecting portion, and the substrate-side terminal portion is connected to the substrate of the control unit. The plurality of busbar terminals are concentrated in a portion of the circumference. The lead-out portions are routed from one of the plurality of lead-out portions distributed throughout the circumferential circumference to one of the plurality of connecting portions.

[0010] Therefore, since it is sufficient to set the busbar terminals only on a portion of the circumference, the busbar terminals can be shortened compared to the conventional method of setting the busbar terminals continuously around the entire circumference. This reduces the material cost of the busbar terminals. Attached Figure Description

[0011] The above-mentioned objects, as well as other objects, features, and advantages of this disclosure, will become clearer from the following detailed description with reference to the accompanying drawings.

[0012] Figure 1 This is a longitudinal sectional view of a rotary electric motor according to one embodiment.

[0013] Figure 2 Viewed from the direction of arrow II Figure 1 The diagram shows the busbar unit, stator, and rotor.

[0014] Figure 3 It means Figure 2 A diagram of the busbar unit.

[0015] Figure 4 It means Figure 2 A cross-sectional view of the stator, rotor, and busbar support protrusions.

[0016] Figure 5 Viewed from the direction of arrow V Figure 2 Side view of the busbar terminal.

[0017] Figure 6 Viewed from the direction of arrow VI Figure 2 A three-dimensional view of the busbar terminals.

[0018] Figure 7 It means Figure 2 The diagram of the busbar unit is a diagram showing the connection part before crimping. Detailed Implementation

[0019] [One implementation method]

[0020] One embodiment of the rotary electric machine will be described with reference to the accompanying drawings. For example... Figure 1 As shown, the motor 10, which is a rotary electric motor, is an electromechanical integrated type in which the rotary machine section 20 and the control section 50 are integrally installed. A busbar unit 60, serving as an electromechanical connection, is provided between the rotary machine section 20 and the control section 50. The control section 50 controls the rotary machine section 20 to generate the desired torque based on information input from the outside and information such as the motor current detected inside the control section 50. The torque of the rotary machine section 20 is output to the outside from the output end of the rotary shaft 32.

[0021] Hereinafter, the direction parallel to the rotation axis O of the rotating machine part 20 will be described as the axial direction. The direction orthogonal to the rotation axis O will be described as the radial direction. The direction about the rotation axis O will be described as the circumferential direction.

[0022] The rotating part 20 is a three-phase brushless motor, comprising a stator 21, a rotor 31, and a housing 41 that houses them. The stator 21 has a stator core 22 fixed to the housing 41 and multiple windings 23 assembled on the stator core 22. The stator core 22 has multiple radially extending pole teeth 24. Insulators 25 are installed on the pole teeth 24. The windings 23 are wound around the insulators 25.

[0023] The rotor 31 has a rotating shaft 32 supported by a rear bearing 45 and a front bearing 46, and a rotor core 33 fixed to the rotating shaft 32. The rotor 31 is located inside the stator 21 and can rotate relative to the stator 21. A permanent magnet 47 is provided at one end of the rotating shaft 32.

[0024] The outer casing 41 has a cylindrical housing 42, a rear frame end 43 disposed at one end of the housing 42, and a front frame end 44 disposed at the other end of the housing 42. A stator core 22 is fixed inside the housing 42. The rear frame end 43 and the front frame end 44 are fastened together by bolts (not shown). The rear frame end 43 also functions as a heat sink for the control unit 50.

[0025] The control unit 50 has a substrate 51, various electronic components, and a cover 55. The substrate 51 is disposed on the rotation axis O and is disposed on the side opposite to the stator 21 relative to the rear frame end 43. Various electronic components are mounted on the substrate 51. The cover 55 is configured to cover the substrate 51 and various electronic components.

[0026] Although the illustrations are omitted, the various electronic components mentioned above include, for example, a rotation angle sensor that detects the rotation angle of the rotating shaft 32, a motor drive element that performs a switching action to switch the energization state of multiple windings 23, and a control circuit that performs calculations based on information from external sources, such as the rotation angle sensor, and issues commands to the motor drive element.

[0027] like Figures 1-6 As shown, the busbar unit 60 includes a busbar bracket 61 and a plurality of busbar terminals 71. The busbar bracket 61 is disposed axially relative to the stator 21 and between the stator 21 and the rear frame end 43. The plurality of busbar terminals 71 are fixed to the busbar bracket 61 and electrically connect the stator 21 to the control unit 50. In one embodiment, one busbar terminal 71 is provided for each of the U-phase, V-phase, and W-phase. That is, three busbar terminals 71 are provided.

[0028] The busbar support 61 is made of an insulating material such as resin and has a partition wall portion 62, a support portion 63, and a plurality of claw portions 64. The partition wall portion 62 is a continuously formed annular portion in the circumferential direction and is disposed between the stator 21 and the rear frame end 43. The support portion 63 protrudes from the partition wall portion 62 in the opposite axial direction and contacts the stator 21. The claw portions 64 protrude from the partition wall portion 62 in the opposite axial direction and engage with the stator 21.

[0029] A partition 62 is disposed between the stator 21 and the busbar terminal 71. The busbar terminal 71 has a winding-side terminal portion 72 including at least one connecting portion 73 and a substrate-side terminal portion 77 connected to the substrate 51. In one embodiment, each busbar terminal 71 is provided with two connecting portions 73.

[0030] The connecting portion 73 is positioned such that at least a portion overlaps with the rotor 31 when viewed from the axial direction. The substrate-side terminal portion 77 is positioned radially outward relative to the connecting portion 73. The two connecting portions 73 provided on each winding-side terminal portion 72 are concentrated in a portion of the circumference and are circumferentially separated from the connecting portions 73 of the other winding-side terminal portions 72.

[0031] In one embodiment, the three substrate-side terminal portions 77 corresponding to the U-phase, V-phase, and W-phase are arranged sequentially at intervals in the circumferential direction. Regarding the V-phase busbar terminal 71, the two connecting portions 73 are arranged at intervals in the circumferential direction in a region relatively close to the radially inward side relative to the substrate-side terminal portion 77. Regarding the W-phase busbar terminal 71, the two connecting portions 73 are arranged at intervals in the circumferential direction in a region radially inward side relative to the substrate-side terminal portion 77 and away from the circumferential direction. Regarding the U-phase busbar terminal 71, the two connecting portions 73 are arranged at intervals in the circumferential direction in a region radially inward side relative to the substrate-side terminal portion 77 and away from the circumferential direction.

[0032] Regarding the busbar terminal 71 of the V phase, the winding-side terminal portion 72 has two connecting portions 73, an extending protrusion 74 extending from the substrate-side terminal portion 77 to each connecting portion 73, and a pressing portion 75 that is pressed into the pressing portion 65 of the busbar support 61. Regarding the busbar terminals 71 of the U phase and W phase, the winding-side terminal portion 72 has two connecting portions 73, an extending protrusion 74, a pressing portion 75, and a bent portion 76 connecting the extending protrusion 74 and the connecting portion 73.

[0033] Multiple windings 23 are arranged around the entire circumference. Leads 82 extend from leads 81 towards the axial busbar terminal 71, wherein the leads 81 are located among the multiple windings 23 adjacent to each other in the circumferential direction and on the side of the busbar terminal 71. The multiple leads 81 are distributed across the entire circumference. On the other hand, all connections 73 are concentrated in a portion of the circumference. In one embodiment, all connections 73 are arranged to be housed on approximately half of the circumference. The leads 82 are routed from one of the multiple leads 81 distributed around the entire circumference to one of the multiple connections 73 concentrated in a portion of the circumference. The busbar terminal 71 is housed in approximately half of the circumference and has a relatively short overall length.

[0034] The partition 62 has through holes 66 corresponding to each connecting portion 73. The lead wire 82 extends to the connecting portion 73 through the wiring space 67 between the partition 62 and the stator 21 and the through holes 66. Two lead wires 82 are connected to each connecting portion 73.

[0035] The busbar bracket 61 has at least one protrusion 68 in the wiring space 67, which protrudes axially toward a radially inward portion (hereinafter, inner portion 26) of the insulator 25. The gap between the protrusion 68 and the inner portion 26 is smaller than the wire diameter of the lead wire 82. In one embodiment, five protrusions 68 are arranged circumferentially spaced apart.

[0036] like Figure 7 As shown, the connecting portion 73 before connecting the lead wire 82 is hook-shaped. The hook-shaped connecting portion 73 is connected to the lead wire 82 by crimping while hooking it. All connecting portions 73 before crimping hook the lead wire 82 from one circumferential direction.

[0037] like Figures 1-6 As shown, the extension protrusion 74 is provided slightly axially separated from the partition wall portion 62. The connecting portion 73 is provided at the same axial position as at least a portion of the extension protrusion 74. The press-in portion 65 is formed to protrude from the partition wall portion 62. The press-in portion 75 is formed to protrude axially from the extension protrusion 74 toward the partition wall portion 62 and is pressed into the press-in portion 65. The bend 76 is formed to protrude axially from the extension protrusion 74 toward the partition wall portion 62 and bend into a U-shape toward the side opposite to the partition wall portion 62, and is connected to the connecting portion 73. The bend 76 is provided at the same axial position as at least a portion of the press-in portion 75.

[0038] The substrate-side terminal portion 77 has a wide portion 78 and a narrow portion 79, wherein the wide portion 78 extends axially from the winding-side terminal portion 72 toward the substrate 51, and the narrow portion 79 protrudes from the wide portion 78 into the connection hole 52 of the substrate 51. The area of ​​the cross-section of the wide portion 78 orthogonal to the axial direction is larger than the area of ​​the cross-section of the narrow portion 79 orthogonal to the axial direction.

[0039] (Effect)

[0040] As explained above, in one embodiment, the lead wire 82 is routed from one of a plurality of leads 81 distributed throughout the circumference to one of a plurality of connecting portions 73 concentrated in a portion of the circumference. Therefore, since it is sufficient to provide the busbar terminal 71 only in a portion of the circumference, the busbar terminal 71 can be shortened compared to the conventional method of providing the busbar terminal continuously throughout approximately the entire circumference. This reduces the material cost of the busbar terminal 71.

[0041] In one embodiment, the connecting portion 73 is positioned where at least a portion overlaps with the rotor 31 when viewed from the axial direction. Therefore, the space on the side of the rotor 31 closer to the axial direction can be effectively utilized to configure the connecting portion 73.

[0042] In one embodiment, the substrate-side terminal portion 77 is disposed radially outward relative to the connecting portion 73. The plurality of connecting portions 73 disposed on each winding-side terminal portion 72 are concentrated in a portion in the circumferential direction, and are circumferentially separated from the connecting portions 73 of other winding-side terminal portions 72. Therefore, each winding-side terminal portion 72 can be configured so that it does not intersect with other winding-side terminal portions 72 when viewed axially. Thus, compared to a configuration where the plurality of winding-side terminal portions intersect when viewed axially, the axial height of the three winding-side terminal portions 72 can be reduced.

[0043] In one embodiment, the busbar support 61 has at least one protrusion 68 in the wiring space 67 for wiring the lead wire 82, with a portion protruding axially toward the radially inward side of the insulator 25. The gap between the protrusion 68 and the insulator 25 is smaller than the wire diameter of the lead wire 82. Thus, when the lead wire 82 attempts to move toward the rotor 31, the protrusion 68 acts as a wall, preventing the lead wire 82 from moving. Therefore, when the motor 10 is operating, it is possible to prevent the lead wire 82 from getting caught in the rotor 31.

[0044] In one embodiment, the connecting portion 73 is positioned at the same axial location as at least a portion of the extended protrusion 74. The bent portion 76 is positioned at the same axial location as at least a portion of the press-in portion 75. Thus, compared to the case where the bent portion 76 is positioned at a different axial location than the press-in portion 75, the axial height of the winding-side terminal portion 72 can be reduced.

[0045] In one embodiment, all the connecting portions 73 before crimping hook the lead wire 82 from one circumferential direction. This improves the assemblability when connecting the lead wire 82 to the connecting portions 73.

[0046] In one embodiment, the busbar support 61 has an insulating partition 62 disposed between the stator 21 and the busbar terminal 71. This ensures insulation.

[0047] In one embodiment, two or more leads 82 are connected to each connection portion 73. As a result, manufacturing time can be reduced by decreasing the number of connections between the connection portion 73 and the leads 82.

[0048] Here, a problem concerning the busbar terminal 71 connecting the rotating machine section 20 and the control section 50 will be explained. The busbar terminal 71 carries a larger current than the signal lines within the control section 50, thus increasing heat generation. Therefore, to reduce resistance, the busbar terminal 71 is generally thickened. However, when the busbar terminal 71 is bonded to the substrate 51 of the control section 50 via soldering, the increased thickness of the busbar terminal 71 increases the area for soldering, making soldering more difficult. Therefore, it is required to reduce the difficulty of soldering the busbar terminal 71 and suppress heat generation.

[0049] In this respect, in one embodiment, the substrate-side terminal portion 77 has a wide portion 78 and a narrow portion 79, wherein the wide portion 78 extends axially from the winding-side terminal portion 72 toward the substrate 51, and the narrow portion 79 protrudes from the wide portion 78 into the connection hole 52 of the substrate 51. The area of ​​the cross-section of the wide portion 78 orthogonal to the axial direction is larger than the area of ​​the cross-section of the narrow portion 79 orthogonal to the axial direction. Therefore, the difficulty of soldering can be reduced by soldering the relatively thin narrow portion 79 to the substrate 51, and by placing the relatively larger wide portion 78 next to the narrow portion 79, resistance can be reduced and self-heating suppressed.

[0050] [Other Implementation Methods]

[0051] In other embodiments, the number of busbar terminals is not limited to three. The winding is not limited to one system, but may include two or more systems. The connection method between the lead and the connector is not limited to crimping; for example, welding or other methods may be used.

[0052] In other embodiments, the busbar bracket may also be fixed to a location other than the stator. The fixing method of the busbar bracket is not limited to claw-based engagement; for example, it may use other methods such as screws. The partition portion of the busbar bracket is not limited to annular shape; it may also be formed as a circumferential portion.

[0053] In other embodiments, the control unit is not limited to being disposed on one side of the axial direction relative to the rotating part; for example, it may also be disposed on the radially outer side. Correspondingly, the substrate-side terminal part may also be formed to extend in a direction other than the axial direction.

[0054] This disclosure is not limited to the embodiments described above, and can be implemented in various ways without departing from its spirit.

[0055] This disclosure has been described in accordance with embodiments. However, this disclosure is not limited to these embodiments and structures. This disclosure also includes various modifications and equivalent variations. In addition, various combinations and methods, further including only one of their elements, or other combinations and methods with more or fewer elements, are also included in the scope and spirit of this disclosure.

Claims

1. A rotary electric motor, comprising: stator; The rotor is configured to rotate relative to the stator described above; The control unit is connected to the stator mentioned above; The busbar bracket is positioned axially relative to the stator described above; and Multiple busbar terminals are fixed to the busbar bracket, electrically connecting the stator and the control unit. The stator described above has multiple windings arranged around the entire circumference. A lead wire extends from the lead-out portion towards the axial side of the aforementioned busbar terminal, wherein... The aforementioned lead wire is located in the aforementioned windings on the side of the aforementioned busbar terminal and between multiple aforementioned windings that are adjacent in the circumferential direction. The aforementioned busbar terminal has a winding-side terminal portion and a substrate-side terminal portion, wherein the winding-side terminal portion includes at least one connecting portion, and the substrate-side terminal portion is connected to the substrate of the aforementioned control unit. Multiple of the aforementioned busbar terminals are concentrated in a portion of the circumference. The aforementioned lead wire wiring extends from one of the aforementioned lead parts distributed around the circumference to one of the aforementioned connection parts.

2. The rotary motor according to claim 1, wherein, The aforementioned connecting portion is positioned at a location where, when viewed from the axial direction, at least a portion overlaps with the aforementioned rotor. The aforementioned substrate-side terminal portion is disposed radially outward relative to the aforementioned connecting portion. The plurality of connecting portions provided on each of the aforementioned winding-side terminals are concentrated in a portion of the circumferential direction, and are arranged separately in the circumferential direction from the connecting portions of the other winding-side terminals.

3. The rotary motor according to claim 1 or 2, wherein, The aforementioned busbar bracket has at least one protrusion in the space for the aforementioned lead wire wiring, and the portion of at least one of the aforementioned protrusions toward the radially inner side of the insulator of the stator protrudes axially. The gap between the protrusion and the insulator is smaller than the diameter of the lead wire.

4. The rotary motor according to claim 1 or 2, wherein, The winding-side terminal portion has a connecting portion, an extending protrusion, a pressing portion, and a bending portion. The extending protrusion extends from the substrate-side terminal portion toward the connecting portion. The pressing portion is pressed into the busbar support. The bending portion connects the extending protrusion and the connecting portion. The aforementioned connecting portion is located at at least a portion of the aforementioned extended protrusion at the same axial position. The aforementioned curved portion is located at at least a portion of the aforementioned pressed portion in the same axial position.

5. The rotary motor according to claim 1 or 2, wherein, The connecting part before the aforementioned lead wire is hook-shaped. The hook-shaped connecting portion is connected to the lead wire by crimping it while the lead wire is hooked. Before crimping, all of the above-mentioned connecting parts hook the above-mentioned lead wire from one side in the circumferential direction.

6. The rotary electric motor according to claim 1 or 2, wherein, The aforementioned busbar support has an insulating partition portion, which is disposed between the aforementioned stator and the aforementioned busbar terminal.

7. The rotary electric motor according to claim 1 or 2, wherein, Each of the aforementioned connection points has two or more of the aforementioned lead wires connected to it.

8. The rotary electric motor according to claim 1 or 2, wherein, The aforementioned substrate-side terminal portion has a wide portion and a narrow portion, wherein the wide portion extends axially from the aforementioned winding-side terminal portion toward the aforementioned substrate, and the narrow portion protrudes from the aforementioned wide portion into the connection hole of the aforementioned substrate. The area of ​​the cross section orthogonal to the axial direction of the aforementioned wide section is larger than the area of ​​the cross section orthogonal to the axial direction of the aforementioned narrow section.

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