Terminal assembly applied to motor stator

Abstract

The present disclosure relates to a terminal assembly applied to a motor stator, and more particularly, to a terminal assembly having improved coupling with an end coil. The terminal assembly of the present disclosure has an effect of enhancing a space utilization rate by applying the terminal assembly to a side surface portion of a coil, and has an effect of process automation and cost reduction by allowing use of a winding of the same type regardless of the position of the winding. And has an effect of improving coupling firmness between the winding and the terminal assembly by including epoxy resin for covering the terminal assembly and the end coil.

Description

Technical Field

[0001] The following disclosure relates to a terminal assembly applied to a motor stator, and more particularly, to a terminal assembly having an improved coupling with an end coil. Background Art

[0002] The conventional stator includes a wound coil, and a terminal bus bar disposed separately from the coil in a crown located at the end of the coil is installed to be spaced apart from the stator in the axial direction to transmit power to the coil. At this time, when the coil is inserted into the hairpin structure, various types of windings must be used.

[0003] More specifically, the hairpin winding method is a method of sequentially inserting a hairpin coil formed to have a U-shape (hairpin shape) into a slot of a stator core in an axial direction and then welding the end of each coil. In this method, there is no need to pre-manufacture a winding bundle, and the process is completed by inserting the hairpin coil between stator shoes, which advantageously simplifies the process, but since the process has a disadvantage in that a protective coating should be stacked after welding the ends of a plurality of hairpin coils, this method is inefficient in terms of manufacturing cost and required time.

[0004] In addition, welding defects inevitably occur due to the presence of multiple welding positions. In addition, in the case of the hairpin winding method, since the end of the hairpin coil to be welded is extended to protrude to the outside of the stator, the axial length of the stator becomes longer. In addition, when the structure of the terminal assembly is mounted on the top of the crown end coil, the overall height of the stator assembly increases, and when the shape of the winding changes, the logic of the winding manufacturing device for each winding should be changed one by one to correspond to the terminal assembly, and the winding in the form corresponding to the position should be inserted, which is disadvantageous in mass production. Utility Model Content

[0005] One embodiment of the present disclosure is directed to providing a terminal assembly which may be applied to a side surface portion of a coil to enhance space utilization.

[0006] Another embodiment of the present disclosure is directed to providing a terminal assembly in which the same type of winding is used regardless of the position of the winding, thereby automating the process and reducing costs.

[0007] Another embodiment of the present disclosure is directed to provide a terminal assembly capable of improving coupling strength between a winding and a terminal assembly by including an epoxy resin for coating the terminal assembly and an end coil.

[0008] In one general aspect, a terminal assembly for a motor stator is provided, the motor stator including a coil assembly having a plurality of windings, the terminal assembly including: a first connecting member, the first connecting member including a first coupling portion and a first bus bar, one end of the first coupling portion being electrically coupled to an end of the winding, the first bus bar being integrally formed with the first coupling portion and being disposed on a radially outer side of the coil assembly; at least one second connecting member, the at least one second connecting member including a second coupling portion and a second bus bar, one end of the second coupling portion being electrically coupled to at least one winding adjacent to the winding coupled to the first bus bar, the second bus bar being integrally formed with the second coupling portion and being disposed on a radially outer side of the coil assembly; and two or more jumpers. wire), each jumper wire includes a third connecting portion and a series connecting portion, one end of the third connecting portion is electrically connected to the end of the winding, the series connecting portion is integrally formed with the third connecting portion and is arranged on the inner side of the coil assembly in the radial direction, wherein the first connecting portion and the second connecting portion extend from the end of the winding toward the motor stator to be parallel to the rotation axis of the motor stator, and the first bus bar and the second bus bar are arranged to be spaced apart from each other by a predetermined distance in the radial direction of the motor stator.

[0009] The first and second bus bars may extend in an arc shape in a circumferential direction of the motor stator, and one surface of each of the first and second bus bars may be parallel to an extending direction of the first and second coupling portions.

[0010] The first connecting member may include a first bent portion, the first bent portion having corresponding ends connected to the first connecting portion and the first bus bar and formed integrally with the first connecting portion and the first bus bar, and the first bent portion extends outward along the radial direction of the motor stator, the second connecting member may include a second bent portion, the second bent portion having corresponding ends connected to the second connecting portion and the second bus bar and formed integrally with the second connecting portion and the second bus bar, and the second bent portion extends outward along the radial direction of the motor stator, and the second bent portion may extend longer than the first bent portion in the radial direction of the motor stator.

[0011] One surface of the second bus bar may be disposed in a position overlapping with one surface of the first bus bar by a predetermined area.

[0012] The second connection member may be provided as two or more connection members, at least one of the second bus bars is provided to cover the upper end of the first bus bar, and at least another one of the second bus bars may be provided to cover the lower end of the first bus bar.

[0013] The first and second bus bars may extend in an arc shape in a circumferential direction of the motor stator, and one surface of each of the first and second bus bars may be perpendicular to an extending direction of the first and second coupling portions.

[0014] The first bus bar and the second bus bar may include protrusions which are provided at the outermost portions and protrude toward opposite sides of the motor stator with respect to the radial direction of the motor stator.

[0015] The series connection portion may be gradually bent in the radial direction of the motor stator.

[0016] The jumpers may be arranged to be spaced a predetermined distance apart from each other in the radial direction of the motor stator, the series connection portions of all the jumpers may be located at the same height based on the axial direction of the motor stator, and a predetermined area of ​​a surface of each of the series connection portions may be in contact with an adjacent one of the series connection portions.

[0017] The terminal assembly may further include a covering portion covering and covering the first connection member, the at least one second connection member, the jumper wire, and an end portion of the coil assembly.

[0018] Other features and aspects will be apparent from the following detailed description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a side view showing a motor stator to which the terminal assembly of the present disclosure is applied.

[0020] Figure 2 1 is a partial top view showing a first connecting member and a second connecting member of the present disclosure.

[0021] Figure 3 is a partial perspective view showing a terminal assembly of the present disclosure.

[0022] Figure 4 is a partial perspective view showing a terminal assembly of the present disclosure.

[0023] Figure 5 is a schematic diagram showing a detailed embodiment of a terminal assembly of the present disclosure.

[0024] Figure 6 is a perspective view showing one embodiment of a jumper of the present disclosure.

[0025] Figure 7 is a perspective view showing another embodiment of a jumper of the present disclosure.

[0026] Figure 8 is a partial perspective view showing the arrangement of the jumper of the present disclosure.

[0027] Fig. 9 is a side view showing the cover portion of the present disclosure.

[0028] Detailed description of the main components

[0029] 1000: Terminal assembly

[0030] 100: First connecting member

[0031] 110: First connecting portion

[0032] 120: First busbar

[0033] 130: First bend

[0034] 200: Second connecting member

[0035] 210: Second connection part

[0036] 220: Second bus bar

[0037] 230: Second bend

[0038] 300: Jumper

[0039] 310: Third connection part

[0040] 320: Series connection part

[0041] 400: protrusion

[0042] 500: Coating

[0043] S: Motor stator

[0044] C: Coil assembly

[0045] W: Winding

[0046] O: Cooling oil DETAILED DESCRIPTION

[0047] Hereinafter, the preferred embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Before the description, it should be understood that the terms used in the specification and the appended claims should not be interpreted as limited to the general meaning and dictionary meaning, but based on the principle of allowing the definition of terms, based on the meaning and concept corresponding to the technical aspects of the present disclosure.

[0048] In the following, reference will be made to Figure 1 and Figure 2 The basic configuration of the terminal assembly 1000 of the present disclosure is described.

[0049] like Figure 1 As shown, the present disclosure can be applied to a motor stator S including a coil assembly C, wherein the coil assembly C includes a plurality of windings W. Figure 2 As shown, the terminal assembly 1000 of the present disclosure may include a first connection member 100, a second connection member 200, and a jumper 300 electrically and physically connected to the winding W. In more detail, the first connection member 100 may include a first coupling portion 110 electrically coupled to an end of the winding W at one end, and may include a first bus bar 120 integrally formed with the first coupling portion 110 and disposed in a radial direction outside the coil assembly C. In addition, the second connection member 200 may include a second coupling portion 210 electrically coupled to at least one winding W adjacent to the winding W coupled to the first connection member 100 at one end, respectively, and may include a second bus bar 220 integrally formed with the second coupling portion 210 and disposed in a radial direction outside the coil assembly C. Two or more second connection members 200 may be provided.

[0050] At this time, the first connecting portion 110 and the second connecting portion 210 may extend from the end of the winding W toward the motor stator S so as to be parallel to the rotation axis of the motor stator S. Therefore, the axial length of the entire motor including the motor stator S, the coil assembly C and the terminal assembly 1000 may be reduced, and the space utilization rate may be improved. In addition, the first bus bar 120 and the second bus bar 220 may be formed to extend in an arc shape in the circumferential direction of the motor stator S, and may be spaced apart from each other by a predetermined interval in the radial direction of the motor stator S. That is, the first external extension portion and the second external extension portion may not contact each other, but may be arranged to form a separate layer in the radial direction of the motor stator S. Therefore, the first bus bar 120 and the second bus bar 220 may be insulated from each other.

[0051] In addition, the terminal assembly 1000 of the present disclosure may include a plurality of jumpers 300, and the jumper 300 may include a third coupling portion 310 electrically coupled to an end of the winding W at one end and a series connection portion 320 integrally formed with the third coupling portion 310 and disposed inside the coil assembly C in a radial direction. That is, the jumper 300 may be disposed on opposite sides of the first bus bar 120 and the second bus bar 220 relative to the coil assembly C. Each jumper 300 is connected in series to electrically connect the plurality of windings W to each other. The plurality of jumpers 300 may all be formed into a single shape, and the jumper 300 may have a shape extending along the side of the coil assembly C.

[0052] In this way, even if the shapes of all windings W are uniform, the coil assembly C can be easily connected to the outside by simply changing the arrangement of the first connection member 100, the second connection member 200, and the jumper wire 300 connected to each winding W. In addition, since the jumper wire 300 connected to each winding W is formed in the same shape, automation of the process can be achieved.

[0053] In the following, reference will be made to Figure 3 The first embodiment of the terminal assembly 1000 of the present disclosure is described in more detail.

[0054] like Figure 3 As shown, one surface of each of the first bus bar 120 and the second bus bar 220 may be parallel to the extension direction of the first coupling portion 110 and the second coupling portion 210. At this time, one surface of each of the first bus bar 120 and the second bus bar 220 may be a surface perpendicular to the radial direction of the motor stator S, and one surface of each of the first bus bar 120 and the second bus bar 220 may be formed to be flat. The first bus bar 120 and the second bus bar 220 may be formed so that one surface thereof has the largest area among the other surfaces.

[0055] In this manner, one surface having the largest area of ​​the first bus bar 120 and the second bus bar 220 is formed parallel to the rotation axis of the motor stator S, thereby reducing the radial thickness of the terminal assembly 1000. A space can be formed between the side surface of the motor stator S and the outermost portion of the terminal assembly 1000, and the terminal formed of the PPS material can be easily connected.

[0056] In addition, the first connection member 100 may include a first bent portion 130, both ends of which are connected to and integrally formed with the first coupling portion 110 and the first bus bar 120, and the first bent portion 130 extends outward in the radial direction of the motor stator S. The second connection member 200 may include a second bent portion 230, both ends of which are connected to and integrally formed with the second coupling portion 210 and the second bus bar 220, and the second bent portion 230 extends outward in the radial direction of the motor stator S. The second bent portion 230 may extend longer than the first bent portion 130 in the radial direction of the motor stator S. At this time, considering the thickness of the first bus bar 120 and the second bus bar 220, the second bent portion 230 may extend to have a length such that the first bus bar 120 and the second bus bar 220 do not contact each other. Therefore, the first outer extension portion and the second outer extension portion may not contact each other and may be arranged to form separate layers in the radial direction of the motor stator S, and the first bus bar 120 and the second bus bar 220 may be insulated from each other.

[0057] At this time, one surface of the second bus bar 220 may be arranged in a position overlapping a predetermined area with one surface of the first bus bar 120. Therefore, space utilization can be improved. In addition, two or more second connecting members 200 may be provided, and at least one of the second bus bars 220 may be arranged to cover the upper end of the first bus bar 120, and at least another of the second bus bars 220 may be arranged to cover the lower end of the first bus bar 120. At this time, each of the second bus bars 220 covering the upper and lower ends of the first bus bar 120 may be spaced apart from each other by a predetermined distance in the axial direction of the motor stator S. That is, there may be an area of ​​the first bus bar 120 that does not overlap with the second bus bar 220, so the first bus bar 120 may be partially exposed to the outside. Therefore, in the process of adding external components later, the area may be used as a pin space to support the position of the first bus bar 120 and the second bus bar 220.

[0058] In the following, reference will be made to Figure 4 and Figure 5 The second embodiment of the terminal assembly 1000 of the present disclosure is described in more detail.

[0059] like Figure 4 As shown, in the second embodiment of the terminal assembly 1000 of the present disclosure, the first bus bar 120 and the second bus bar 220 may extend in an arc shape along the radial direction of the motor stator S, and one surface of each of the first bus bar 120 and the second bus bar 220 may be formed to be perpendicular to the extension direction of the first coupling portion 110 and the second coupling portion 210. At this time, one surface of each of the first bus bar 120 and the second bus bar 220 may be a surface perpendicular to the radial direction of the motor stator S, and one surface of each of the first bus bar 120 and the second bus bar 220 may be formed to be flat. The first bus bar 120 and the second bus bar 220 may be formed so that the area of ​​one surface is the largest among the other surfaces.

[0060] In this way, since a surface with the largest area of ​​the first bus bar 120 and the second bus bar 220 is formed to be perpendicular to the rotation axis of the motor stator S, the cooling oil O for cooling the coil assembly C can be retained on a surface of each of the first bus bar 120 and the second bus bar 220, and the cooling efficiency of the coil assembly C can be improved.

[0061] In addition, if Figure 5As shown, the first bus bar 120 and the second bus bar 220 may include a protrusion 400 formed at the outermost portion and protruding toward the opposite side of the motor stator S relative to the radial direction of the motor stator S. Alternatively, one surface of each of the first bus bar 120 and the second bus bar 220 may be formed as a curved surface having a predetermined curvature to play the same role as the above-mentioned protrusion 400. Therefore, the cooling oil O cooling the coil assembly C may stay on one surface of each of the first bus bar 120 and the second bus bar 220 for a longer time, and the cooling efficiency of the coil assembly C may be improved.

[0062] In the following, reference will be made to Figures 6 to 8 The jumper 300 of the present disclosure is described in more detail.

[0063] like Figure 6 and Figure 7 As shown, the terminal assembly 1000 of the present disclosure may include a jumper 300 disposed on the radial inner side of the coil assembly C, and the series connection portion 320 of the jumper 300 is preferably formed to be gradually bent in the radial direction of the stator S of the motor. Figure 6 1 shows a case where the contact surface of each jumper wire 300 (the largest surface of the outer surface of the jumper wire 300) is arranged in a direction parallel to the axial direction of the motor stator S, while Figure 7 A case where the contact surface of each jumper wire 300 (the largest surface of the outer surface of the jumper wire 300 ) is disposed in a direction perpendicular to the axial direction of the stator S of the motor is shown.

[0064] At this time, the bend may be equal to the gap between the windings W, and the radial height difference at the bend may be proportional to the thickness of the jumper 300. Therefore, a plurality of jumpers 300 formed in the same shape may be sequentially stacked according to coupling positions and may be connected to each other in series.

[0065] That is, Figure 8 As shown, the jumper wires 300 may be arranged to be spaced apart from each other by predetermined distances (positions depending on the windings W to be connected) in the radial direction of the motor stator S, respectively, and all the jumper wires 300 may be located at the same height based on the axial direction of the motor stator S, and predetermined areas of one surface thereof may contact each other. Therefore, the jumper wires 300 may connect each winding W in series.

[0066] In the following, reference will be made to Fig. 9 The cover 500 of the present disclosure is described in more detail.

[0067] like Fig. 9As shown, the terminal assembly may further include a coating 500 covering and encapsulating the first connecting member 100, the second connecting member 200, the jumper 300, and the end of the coil assembly C. The coating 500 may include an epoxy material or may be a spray-coated coating. Since the terminal assembly 1000 of the present disclosure includes the coating 500, the first connecting member 100, the second connecting member 200, and the jumper 300 may be insulated from the outside, and the connection rigidity between the terminal assembly 1000 and the coil assembly C may be increased.

[0068] The terminal assembly of the present disclosure configured as described above has an effect of enhancing space utilization by applying the terminal assembly to the side surface portion of the coil.

[0069] Furthermore, by allowing the same type of winding to be used regardless of the position of the winding, there is an effect of automating the process and reducing costs.

[0070] Furthermore, since the epoxy resin for covering the terminal assembly and the end coil is included, there is an effect of improving the coupling firmness between the winding and the terminal assembly.

[0071] The present disclosure should not be construed as being limited to the above exemplary embodiments. The present disclosure can be applied to various fields and can be variously modified by those skilled in the art without departing from the scope of the present disclosure. Therefore, it is obvious to those skilled in the art that these changes and modifications fall within the scope of the present disclosure.

[0072] CROSS-REFERENCE TO RELATED APPLICATIONS

[0073] This application claims the priority of Korean Patent Application No. 10-2023-0129344 filed in the Korean Intellectual Property Office on September 26, 2023, the disclosure of which is incorporated herein by reference in its entirety.

Claims

1. A terminal assembly for a motor stator, the motor stator comprising a coil assembly having a plurality of windings, characterized in that: The terminal assembly comprises: a first connection member including a first coupling portion and a first bus bar, one end of the first coupling portion being electrically coupled to an end of the winding, the first bus bar being integrally formed with the first coupling portion and disposed on a radially outer side of the coil assembly; at least one second connection member, the at least one second connection member including a second coupling portion and a second bus bar, one end of the second coupling portion being electrically coupled to at least one winding adjacent to the winding coupled to the first bus bar, the second bus bar being integrally formed with the second coupling portion and disposed on an outer side of the coil assembly in a radial direction; and two or more jumpers, each jumper including a third coupling portion and a series connection portion, one end of the third coupling portion being electrically coupled to an end of the winding, the series connection portion being integrally formed with the third coupling portion and being disposed on an inner side of the coil assembly in a radial direction, wherein the first coupling portion and the second coupling portion extend from an end of the winding toward the motor stator to be parallel to a rotation axis of the motor stator, and The first bus bar and the second bus bar are arranged to be spaced apart from each other by a predetermined distance in a radial direction of the motor stator.

2. The terminal assembly for a motor stator according to claim 1, characterized in that: The first bus bar and the second bus bar extend in an arc shape in a circumferential direction of the motor stator, and One surface of each of the first bus bar and the second bus bar is parallel to an extending direction of the first coupling portion and the second coupling portion.

3. The terminal assembly for a motor stator according to claim 2, characterized in that: the first connecting member includes a first bent portion having respective ends connected to and integrally formed with the first coupling portion and the first bus bar, and the first bent portion extends outwardly in the radial direction of the motor stator, The second connecting member includes a second bent portion having respective ends connected to and integrally formed with the second coupling portion and the second bus bar, and the second bent portion extends outward in the radial direction of the motor stator, and The second bent portion extends longer than the first bent portion in the radial direction of the motor stator.

4. The terminal assembly for a motor stator according to claim 3, characterized in that: One surface of the second bus bar is disposed in a position overlapping with one surface of the first bus bar by a predetermined area.

5. The terminal assembly for a motor stator according to claim 4, characterized in that: The second connecting member is provided as two or more connecting members, At least one of the second bus bars is arranged to cover an upper end portion of the first bus bar, and At least another one of the second bus bars is provided to cover a lower end portion of the first bus bar.

6. The terminal assembly for a motor stator according to claim 1, characterized in that: The first bus bar and the second bus bar extend in an arc shape in a circumferential direction of the motor stator, and One surface of each of the first bus bar and the second bus bar is perpendicular to an extending direction of the first coupling portion and the second coupling portion.

7. The terminal assembly for a motor stator according to claim 6, characterized in that: The first bus bar and the second bus bar include protrusions which are provided at outermost portions and protrude toward opposite sides of the motor stator with respect to the radial direction of the motor stator.

8. The terminal assembly for a motor stator according to claim 1, characterized in that: The series connection portion is gradually bent along the radial direction of the motor stator.

9. The terminal assembly for a motor stator according to claim 8, characterized in that: The jumper wires are arranged to be spaced apart from each other by a predetermined distance in the radial direction of the motor stator, The series connection parts of all the jumper wires are located at the same height based on the axial direction of the motor stator, and A predetermined area of ​​one surface of each of the series connection portions is in contact with an adjacent one of the series connection portions.

10. The terminal assembly for a motor stator according to claim 1, characterized in that: The terminal assembly also includes: A covering portion covers and covers the first connection member, the at least one second connection member, the jumper wire, and an end portion of the coil assembly.

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