Motor and electric compressor including the same

Abstract

The invention provides a motor capable of effectively realizing high-precision positioning of a bus unit and axial separation prevention. The motor includes a stator (21) including an iron core (22) and an insulator (27) around which magnetic wires (23) are wound, and a bus bar unit (26) formed by molding a bus bar with a resin (27), the bus bar electrically connecting the magnetic wires (23) extending from slots (29) of the stator (21) and three-phase terminals (33). The iron core (22) is provided with a key groove (31) formed on the outer periphery, and the bus unit (26) is provided with a claw part (47) which is embedded with the key groove (31) and is positioned relative to the iron core (22) in the circumferential direction; a press-fit prevention section (51) that defines the amount of press-fit of the claw section (47) into the key groove (31); and an anti-falling part which is embedded with the insulator (27) and prevents the insulator (27) from falling off from the iron core (22).

Description

Technical Field

[0001] The present invention relates to a motor formed by connecting magnetic wires extending from each slot of the stator to the three-phase terminals of a busbar unit obtained by resin molding of the busbar, and an electric compressor having the motor. Background Technology

[0002] Traditionally, the motor used to drive the compression element of an electric compressor consists of a stator and a rotor that rotates inside the stator. The stator is composed of an iron core formed by stacking electromagnetic steel plates, multiple teeth protruding from the iron core in the inner diameter direction, and magnetic wire wound and installed on each tooth. However, since the iron core and the magnetic wire need to be insulated, insulation between the iron core and the magnetic wire is achieved by providing an insulator made of insulating resin at the end of the iron core and winding the magnetic wire around the insulator.

[0003] Furthermore, a busbar unit, formed by resin molding metal busbars and three-phase terminals (terminals connected to the inverter), is provided at the end of the stator (lead wire side). Magnetic wires extending from each slot in the stator are electrically connected to the three-phase terminals via the busbar. In this case, conventionally, the busbar unit is fixed to the stator using the fixing force generated by welding the magnetic wires to the busbar. However, this only retains thicker magnetic wires, and the retaining force decreases for thinner magnetic wires.

[0004] Therefore, a structure has been proposed in which the busbar unit (hereinafter referred to as the busbar support) is engaged with the stator core for installation (see, for example, Patent Document 1). According to this structure, compared with the case where the busbar unit (made of resin) is engaged with a resin insulator that accumulates dimensional tolerances, the use of a metal core that can be machined with high dimensional accuracy can be expected to achieve high-precision positioning of the busbar unit in the circumferential direction.

[0005] Patent Document 1: WO2020 / 013078

[0006] However, in the aforementioned patent document 1, although the circumferential positioning of the busbar unit (busbar support) can be achieved, the axial prevention of the busbar unit from detaching can only be achieved by welding the magnetic wire to the busbar. For thin-diameter magnetic wires, there is a risk of the busbar unit detaching axially. Summary of the Invention

[0007] The present invention was proposed to solve the prior art problem, and aims to provide a motor and an electric compressor equipped with the motor that can effectively achieve high-precision positioning of busbar units and axial anti-detachment.

[0008] To solve the above-mentioned problems, the motor of the present invention includes a stator and a busbar unit. The stator includes an iron core and an insulator provided on the iron core and wound with magnetic wire. The busbar unit is formed by molding the busbar with resin. The busbar is electrically connected to the three-phase terminals with magnetic wire extending from each slot of the stator. The iron core has a keyway formed on its outer periphery. The busbar unit is formed with: a claw portion that engages with the keyway for positioning relative to the iron core in the circumferential direction; a pressing-in prevention portion that specifies the pressing amount of the claw portion into the keyway; and an anti-detachment portion that engages with the insulator to prevent detachment from the iron core.

[0009] The motor of the invention of method 2 is based on the invention described above, and has a cut in the claw that cuts from the top to the base.

[0010] The motor of the invention of method 3 is based on the invention of method 1. The bus unit has a ring portion with a busbar and three-phase terminals molded and each three-phase terminal protruding from the resin, and a plurality of feet extending radially outward from the ring portion. A claw portion is formed at the top of each foot portion, and a pressing-in prevention portion is formed at the base of the claw portion of the foot portion. An anti-detachment portion is formed on the inner side of each foot portion.

[0011] The motor of the invention of method 4 is based on the above invention, wherein at least one of the feet is formed to extend outward from the annular portion where the three-phase terminals are provided.

[0012] Based on the invention described above, the motor of Method 5 has three-phase terminals arranged in a circular portion, and feet formed at three locations in the circular portion, two of which are formed to extend outward from the circular portion where the three-phase terminals are located on both sides of the three-phase terminals.

[0013] The motor of invention method 6 is based on the invention of method 3, and has multiple welded connection parts protruding from the resin in the annular part. The magnetic wires extending from each slot of the stator are welded to the welded connection parts for electrical connection.

[0014] The motor of the invention of method 7 houses the motors and compression elements of the above-mentioned inventions in a container, and has an inverter connected to the three-phase terminals.

[0015] According to the present invention, a motor includes a stator and a busbar unit. The stator includes an iron core and an insulator provided on the iron core and wound with magnetic wire. The busbar unit is formed by molding the busbar with resin. The magnetic wire extending from each slot of the stator is electrically connected to a three-phase terminal. In the motor, since a keyway is formed on the outer periphery of the iron core, and a claw portion is formed on the busbar unit to engage with the keyway for positioning relative to the iron core in the circumferential direction, and a pressing-in prevention portion that specifies the pressing amount of the claw portion into the keyway is formed, compared with the case where the busbar unit is positioned using a resin insulator that accumulates dimensional tolerances, the engagement of the keyway formed on the metal iron core, which can be machined with high dimensional accuracy, with the claw portion of the busbar unit enables high-precision positioning of the busbar unit in the circumferential direction.

[0016] In particular, in this invention, since the busbar unit has an anti-detachment part that fits into the insulator to prevent it from falling off the iron core, it is also possible to prevent the busbar unit from falling off axially. As a result, the busbar unit can be fixed to the stator without applying a load to the magnetic wire, and fine-diameter magnetic wire can be used, which is extremely effective for electric compressors such as those of embodiment 7.

[0017] Furthermore, if, as in the invention of method 2, a cut is formed in the claw portion that cuts inward from the top to the base, the claw portion can be made flexible in the circumferential direction, making it easy for the claw portion to fit into the keyway of the iron core.

[0018] In this case, specifically, by means of the invention of method 3, the bus unit is formed with a ring portion having a molded bus and three-phase terminals with each three-phase terminal protruding from the resin, and a plurality of feet extending radially outward from the ring portion, a claw portion is formed at the top of each foot portion, and a pressing-in prevention portion is formed at the base of the claw portion of the foot portion, and an anti-detachment portion is formed on the inner side of each foot portion, thereby simplifying the structure of the bus unit.

[0019] Furthermore, by forming at least one foot of the foot to extend outward from the annular portion where the three-phase terminals are located, as in the invention of method 4, the foot can effectively bear the stress when connecting the inverter of method 7 to the three-phase terminals, and can effectively prevent deformation and damage during connection.

[0020] In this case, when the three-phase terminals are arranged in the annular portion, as in the invention of embodiment 5, feet can be formed in three parts of the annular portion, such that two of the feet are formed to extend outward from the annular portion where the three-phase terminals on both sides of the three-phase terminals are located.

[0021] Furthermore, if, as in the invention of method 6, a plurality of welded connection parts protruding from the resin are provided in the annular portion, and the magnetic wires extending from each slot of the stator are welded to the welded connection parts for electrical connection, then the electrical connection between the magnetic wires and the busbar can also be easily performed. Attached Figure Description

[0022] Figure 1 This is a schematic longitudinal sectional side view of an electric compressor equipped with the motor of the present invention, according to one embodiment. Figure 2 It constitutes Figure 1 A three-dimensional view of the stator and busbar units of the motor. Figure 3 yes Figure 1 Side view of the stator and busbar units. Figure 4 yes Figure 2 Exploded 3D view of the stator and busbar units. Figure 5 yes Figure 2 A three-dimensional view of the busbar unit. Figure 6 yes Figure 3 The main part longitudinal section side view. Detailed Implementation

[0023] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Figure 1 A schematic longitudinal sectional side view of an embodiment of an electric compressor 1 equipped with the motor 4 of the present invention. Figure 2 A perspective view showing the stator 21 and busbar unit 26 of motor 4. Figure 3 This represents its side view. Figure 4 This represents its exploded 3D diagram.

[0024] exist Figure 1 In this embodiment, the electric compressor 1 is an inverter-integrated scroll electric compressor formed by housing a scroll compressor element 3, which serves as a compression element, and the motor 4 of the present invention within a container 2. The scroll compressor element 3 of this embodiment consists of a fixed scroll disk 6 fixed to the container 2 and a movable scroll disk 7 that revolves relative to the fixed scroll disk 6 without rotating, using the rotating shaft 8 of the motor 4. The scroll disk 7 is configured such that the vortex-shaped scroll teeth 11 formed on the fixed scroll disk 6 mesh with the vortex-shaped scroll teeth 12 formed on the movable scroll disk 7.

[0025] Refrigerant is introduced into container 2 through a refrigerant inlet channel (not shown) and drawn in from the outside into the compression chamber formed between the two scroll teeth 11 and 12. Because the compression chamber narrows towards the center due to the revolution of the movable scroll plate 7, the drawn-in refrigerant is compressed and ejected from the center through the ejection chamber 14 and the refrigerant ejection channel (not shown). Furthermore, because the pressure inside container 2 becomes low, the refrigerant also passes around the motor 4, thus cooling the motor 4.

[0026] like Figure 1 As shown, an inverter chamber 17 is formed at the end of the container 2 located opposite to the scroll compressor element 3. The inverter chamber 17 houses the inverter 16 for driving the motor 4. The three-phase terminal 33 of the bus unit 26, which will be described in detail later, penetrates the bottom wall of the inverter chamber 17, with its top end facing into the inverter chamber 17 and connected to the connection terminal 18 provided on the inverter 16. The connection terminal 18 is pressed into the three-phase terminal 33, thereby electrically connecting the motor 4 to the inverter 16 and supplying power to the motor 4 from the inverter 16.

[0027] Next, the motor 4 of the present invention will be described. The motor 4 of the embodiment is a permanent magnet synchronous motor, which is composed of a stator 21 and a rotor 24 with built-in magnets. The stator 21 is composed of an iron core 22 formed by stacking multiple electromagnetic steel plates, a thin-diameter magnetic wire 23 (winding), and insulators 25 and 27. The rotor 24 (which is also formed by stacking multiple electromagnetic steel plates) is fixed to the rotating shaft 8 and rotates inside the stator 21.

[0028] like Figure 2 As shown, the stator 21's core 22 has a plurality of teeth 28 (the number corresponding to the number of poles; in this embodiment, 12), and the slots 29 between each tooth 28 are open towards the center. Insulators 25 are mounted on the end of the core 22 located on the side of the scroll compressor element 3, and insulators 27 are mounted on the end of the core 22 located on the side of the inverter chamber 17. Magnetic wire 23 is wound around these insulators 25 and 27. Furthermore, in... Figure 4 In the middle, 30A and 30B are insulating papers inserted into each slot 29 between the magnetic wire 23 and the iron core 22, and between each magnetic wire 23.

[0029] Thus, insulators 25 and 27 are fixed to the iron core 22, and insulators 25 and 27 and insulating papers 30A and 30B are located between the iron core 22 and the magnetic wire 23 for insulation. Furthermore, in this embodiment, insulators 25 and 27 are formed into a ring shape by injection molding with insulating synthetic resins such as LCP, PPS, or PBT.

[0030] Multiple keyways 31 (three locations in this embodiment) extending axially along the stator 21 are formed on the outer peripheral surface of the iron core 22. Figures 2-4 , Figure 6 In addition, such as Figure 6 As shown, an anti-detachment support portion 32 is formed in the outer surface of the insulator 27 at the position corresponding to each keyway 31.

[0031] Next, the bus unit 26, which is fixed to the inverter compartment 17 side of the stator 21, will be described. The bus unit 26 is a connecting member used to collect and electrically connect the magnetic wires 23 extending from the slots 29 of the stator core 22 and the aforementioned three-phase terminals 33. Figure 5 The metal (conductive component) busbar 36 is obtained by molding resin 37 (insulating rigid resin) of the shape shown.

[0032] In this embodiment, the busbar 36 is annular and integrally includes a plurality of welded connection portions 41 protruding outward from the circle. Each welded connection portion 41 is formed at 24 locations corresponding to the number 24 of magnetic wires 23 extending from each slot 29 in this embodiment. Furthermore, the aforementioned three-phase terminals 33 are arranged in an arc along the busbar 36, and their bases are in communication with the busbar 36.

[0033] Furthermore, the busbar 36 and the three-phase terminals 33 are molded (embedded) from resin 37, forming a busbar unit 26 integrating the busbar 36, the three-phase terminals 33, and the resin 37. In this case, the busbar 36 is embedded within the annular portion 42 of the busbar unit 26, and each welded connection portion 41 protrudes radially along the circle of the annular portion 42, protruding from the resin 37. Additionally, only the bases of the three three-phase terminals 33 are embedded in the resin 37, protruding axially along the circle of the annular portion 42, with their top ends protruding from the resin 37. Figure 5 ).

[0034] Furthermore, by utilizing the integral molding of resin, a plurality of feet 43 (three portions in the embodiment) are formed on the annular portion 42 of the busbar unit 26, extending radially outward from the outer side of the circle of the annular portion 42. In this case, one foot 43 ( Figure 5 (represented by (43A)) is formed by extending outward from the circle of the annular portion 42 on the side opposite to the three-phase terminal 33, and the remaining two legs 43 ( Figure 5 (43B) and (43C) are used to represent the three-phase terminals on both sides of the three-phase terminal 33. Figure 5 The annular portion 42, which is located at the position indicated by (33A) and (33C), extends outward.

[0035] Each foot 43 is bent at a right angle in the direction opposite to the three-phase terminal 33, and a claw 47 is formed at its top. Each claw 47 has a cut 48 that cuts in from the top toward the base. The base of the claw 47 is narrower than the width of the foot 43, thereby forming a pressing-in prevention part 51 extending from the claw 47 along its width direction at the base of each claw 47.

[0036] Furthermore, anti-detachment portions 52 are formed protruding from the inner side of each bent foot 43. Here, the aforementioned keyway 31 of the iron core 22 is formed at a position corresponding to each claw portion 47 of the busbar unit 26, and the aforementioned anti-detachment support portion 32 of the insulator 27 is formed at a position corresponding to each anti-detachment portion 52 of the busbar unit 26. In addition, the width dimension of the keyway 31 is the same as the width dimension of the claw portion 47.

[0037] According to the above structure, when the busbar unit 26 is installed onto the stator 21, the claws 47 of each foot 43 of the busbar unit 26 are axially inserted into the keyway 31 of the core 22 and engaged. At this time, because the claws 47 have cutouts 48 formed therein, and are flexible in the circumferential direction, they can easily engage with the keyway 31 of the core 22. Thus, the busbar unit 26 is positioned relative to the core 22 in the circumferential direction.

[0038] With the claw portion 47 engaged with the keyway 31 as described above, the claw portion 47 cannot be further pressed in because the pressing-in prevention portion 51 abuts against the end face of the core 22, thus defining the amount of pressing into the keyway 31. Furthermore, when the claw portion 47 is engaged with the keyway 31, the busbar unit 26 will not detach from the core 22 because the anti-detachment portion 52 on the inner side of each foot portion 42 engages with the upper wall 32A of the anti-detachment support portion 32 of the insulator 27.

[0039] By utilizing the engagement of the claw 47 with the keyway 31, the engagement of the anti-disengagement part 52 with the anti-disengagement support part 32, and the abutment of the pressing-in prevention part 51 with the iron core 22, movement of the busbar unit 26 in the circumferential and axial directions is prevented, while simultaneously achieving the positioning and fixation of the busbar unit 26 relative to the stator 21. After positioning and fixing the busbar unit 26 to the iron core 22 in this way, the magnetic wires 23 extending from each slot 29 ( Figure 3 , Figure 6 (represented by 23A) Welded connection 41 to busbar 36.

[0040] As detailed above, in this invention, since a keyway 31 is formed on the outer periphery of the core 22, and a claw portion 47 is formed on the bus unit 26 to engage with the keyway 31 for positioning relative to the core 22 in the circumferential direction, and a pressing-in prevention portion 51 that specifies the pressing amount of the claw portion 47 into the keyway 31 is formed, compared with the case where the bus unit 26 is positioned using a resin insulator 27 that accumulates dimensional tolerances, the engagement of the keyway 31 formed on the metal core 22, which can be machined with high dimensional accuracy, with the claw portion 47 of the bus unit 26 enables the bus unit 26 to be positioned in the circumferential direction with high precision.

[0041] In particular, in this invention, since the busbar unit 26 has an anti-detachment portion 52 that engages with the insulator 27 to prevent it from falling off the iron core 22, it is also possible to prevent the busbar unit 26 from falling off in the axial direction. As a result, the busbar unit 26 can be fixed to the stator 21 without applying a load to the magnetic wire 23, and a fine-diameter magnetic wire 23 can be used, which is extremely effective for the electric compressor 1 in the embodiment.

[0042] Furthermore, in the embodiment, since a cutout 48 is formed on the claw portion 47 that cuts inward from the top to the base, the claw portion 47 is made flexible in the circumferential direction, which allows the claw portion 47 to easily fit into the keyway 31 of the iron core 22.

[0043] In this case, in the embodiment, since the bus unit 26 is formed with a ring portion 42 in which a bus 36 and a three-phase terminal 33 are molded and each three-phase terminal 33 protrudes from the resin 37, and a plurality of feet 43 extending radially outward from the ring portion 42, a claw portion 47 is formed at the top of each foot 43, and a pressing-in anti-detour portion 51 is formed at the base of the claw portion 47, and an anti-detachment portion 52 is formed on the inner side of each foot 43, the structure of the bus unit 26 can be simplified.

[0044] Furthermore, in the embodiment, since the two feet of the foot 43 are formed to extend outward from the annular portion 42 where the three-phase terminal 33 is located, the foot 43 can effectively bear the stress when the connection terminal 18 of the inverter 16 is connected to the three-phase terminal 33, and can effectively prevent deformation and damage of components such as the three-phase terminal 33 during connection.

[0045] In particular, when the three-phase terminals 33 are arranged in the annular portion 42 as in the embodiment, feet 43 are formed in three parts of the annular portion 42, and two of the feet (43B) and (43C) are formed to extend outward from the annular portion 42 where the three-phase terminals (33A) and (33C) are located on both sides of the three-phase terminals 33.

[0046] Furthermore, in this embodiment, since a plurality of welded connection portions 41 protruding from the resin 37 are provided in the annular portion 42, and the magnetic wires 23A extending from each slot 29 of the stator 21 are welded to the welded connection portions 41 for electrical connection, the magnetic wires 23A and the busbar 36 can also be easily electrically connected.

[0047] In addition, in the embodiment, feet 43 are formed in three locations, two of which (43B) and (43C) are formed to extend outward from the annular portion 42 where the three-phase terminals (33A) and (33C) are located. However, the invention is not limited to this in other than embodiment 5. Even if one of the feet 43 is formed to extend outward from the annular portion 42 where the three-phase terminals 33 are located, the effect can still be expected.

[0048] Furthermore, in this embodiment, the invention is applied to the motor 4 of the electric compressor 1, but it is not limited to this in inventions other than embodiment 7. The invention is effective for various motors with bus units. Explanation of reference numerals in the attached figures

[0049] 1 Electric compressor 2 containers 3. Scroll compressor element 4 motors 8 Rotation axis 21 Stator 22 Iron Core 23. (23A) Magnetic lines 24 rotors 26 busbar units 25, 27 Insulators 29 slots 31 keyways 32 Anti-detachment support section 33, (33A), (33C) Three-phase terminals 36 busbars 37 Resin 41 Welded joint 42. Circular section 43. (43A), (43B), (43C) Feet 47 claws 48 Incisions 51. Indentation Prevention Section 52. Anti-hair loss section.

Claims

1. A motor comprising a stator and a busbar unit, the stator having an iron core and an insulator disposed thereon and wound with magnetic wire, the busbar unit being formed by molding a busbar with resin, the busbar electrically connected to three-phase terminals via magnetic wire extending from slots in the stator. The motor is characterized in that... The iron core has keyways formed on its outer periphery. The busbar unit includes: a claw portion that engages with the keyway for positioning relative to the core in the circumferential direction; a pressing-in prevention portion that specifies the amount of pressing of the claw portion into the keyway; and an anti-detachment portion that engages with the insulator to prevent detachment from the core.

2. The motor according to claim 1, characterized in that, A cut is formed in the claw portion, extending from the tip toward the base.

3. The motor according to claim 1, characterized in that, The bus unit has a ring portion molded with the bus and the three-phase terminals, each of which protrudes from the resin, and a plurality of feet extending radially outward from the ring portion. A claw portion is formed at the top of each foot portion, and a pressing-in prevention portion is formed at the base of the claw portion of the foot portion. An anti-detachment portion is formed on the inner side of each foot portion.

4. The motor according to claim 3, characterized in that, At least one of the feet is formed to extend outward from the annular portion where the three-phase terminals are located.

5. The motor according to claim 4, characterized in that, The three-phase terminals are arranged in the annular portion, and The feet are formed at three locations of the annular portion, two of which are formed to extend outward from the annular portion at the positions of the three-phase terminals on both sides of the three-phase terminals.

6. The motor according to claim 3, characterized in that, The annular portion is provided with multiple welded joints protruding from the resin. The magnetic wires extending from each slot of the stator are welded to the welded connection for electrical connection.

7. An electric compressor, characterized in that, The container houses the motor and compression element as described in any one of claims 1 to 6, and includes an inverter connected to the three-phase terminals.

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