Motor unit

Abstract

Multiple first terminals of multiple motor busbars are connected to multiple second terminals of the terminal block. [Solution] The motor unit comprises a motor, a plurality of motor busbars, a plurality of first terminals located at the ends of each, a connecting member connecting the plurality of motor busbars from the base end side of each first terminal, a first guide member fixed to a portion of the plurality of first terminals and at least one of the connecting member and having a first guide surface, a plurality of second terminals to which the plurality of first terminals are fastened using bolts and having a contact surface that contacts one of the corresponding first terminals, a terminal block holding the plurality of second terminals, and a second guide portion provided on the terminal block and having a second guide surface, wherein the first and second guide surfaces may be configured to contact each other when the first terminal approaches the second terminal from a direction parallel to the contact surface, and to prevent contact between the first terminal and the second terminal at least at the timing when the first terminal and the second terminal begin to face each other.

Description

Technical Field

[0001] The technology disclosed in this specification relates to a motor unit.

Background Art

[0002] Patent Document 1 describes a motor unit. In this motor unit, a first terminal is provided at the tip of a motor bus bar. The first terminal of the motor is fastened to the second terminal of a terminal block fixed to the casing and is in contact with the contact surface of the second terminal. A power conversion device is electrically connected to the second terminal, and the motor is electrically connected to the power conversion device via the terminal block.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the motor unit as described above, when the motor is attached to the casing, it is preferable that the first terminals of the plurality of motor bus bars are positioned with respect to the second terminals of the terminal block fixed to the casing. At this time, depending on the design of the motor unit, the plurality of first terminals may approach the plurality of second terminals from a direction parallel to the contact surfaces of the plurality of second terminals. In such a case, since the plurality of first terminals and the plurality of second terminals slide relative to each other, there is a risk of generating conductive foreign matter from the plurality of first terminals and / or the plurality of second terminals. In order to avoid this, it is conceivable to provide a gap between the plurality of first terminals and the plurality of second terminals. However, if a gap is provided between the two terminals, when the plurality of first terminals are respectively fastened to the plurality of second terminals, the motor bus bar is in an elastically deformed state, and an unintended load may act on the stator coil connected to the motor bus bar.

[0005] In view of the above, this specification provides a novel structure for fastening multiple first terminals of multiple motor busbars to multiple second terminals of a terminal block. [Means for solving the problem]

[0006] The technology disclosed herein is embodied in a motor unit. In a first aspect of this technology, the motor unit may include a motor having a stator coil, a plurality of motor busbars connected to the stator coil, a plurality of first terminals located at the ends of the plurality of motor busbars, a connecting member connecting the plurality of motor busbars at a base end closer to each of the first terminals, a first guide member fixed to a portion of the plurality of first terminals and at least one of the connecting member and having a first guide surface, a plurality of second terminals to which the plurality of first terminals are fastened using bolts and each having a contact surface that contacts a corresponding one of the plurality of first terminals fastened to the terminal block, a terminal block holding the plurality of second terminals, and a second guide member provided on the terminal block and having a second guide surface. The first guide surface and the second guide surface are configured to come into contact with each other when the plurality of first terminals approach the plurality of second terminals from a direction parallel to the contact surface, and may have a first profile that prevents contact between the plurality of first terminals and the plurality of second terminals at least at the timing when the plurality of first terminals and the plurality of second terminals begin to face each other.

[0007] In the motor unit described above, when multiple first terminals approach multiple second terminals from a direction parallel to the contact surface, the first guide surface of the first guide member and the second guide surface of the second guide member come into contact with each other. The first guide member is fixed to each of the multiple first terminals directly and / or indirectly via a connecting member. The second guide member is provided on a terminal block that holds the multiple second terminals. That is, the second guide member is fixed to each of the multiple second terminals at least indirectly. Consequently, the multiple first terminals and the multiple second terminals move away from each other or approach each other depending on the respective profiles (surface shapes) of the first guide surface and the second guide surface. In particular, the first guide surface and the second guide surface have a first profile that prevents contact between the multiple first terminals and the multiple second terminals at least at the timing when the multiple first terminals and the multiple second terminals begin to face each other. This prevents, at least partially, the sliding motion between the multiple first terminals and the multiple second terminals when multiple first terminals approach each other from a direction parallel to the contact surface. Consequently, the generation of conductive foreign matter from the multiple first terminals and / or multiple second terminals is prevented or suppressed.

[0008] On the other hand, manufacturing tolerances are expected to occur in the arrangement of the multiple first terminals. Therefore, when the multiple first terminals move to a position where they are fastened to the multiple second terminals, the gap (including contact) between each of the multiple first terminals and the second terminals will not necessarily be constant among all the first terminals. For example, one of the multiple first terminals may be in contact with the second terminal opposite it, while another of the multiple first terminals may be separated from the second terminal with a gap between them. In such a case, if all the first terminals were fixed to the first guide member, the displacement of the first terminal toward the second terminal would be hindered by the first guide member when fastening the first terminals and second terminals that are facing each other with a gap between them. As a result, a large fastening force would be required, and there is a risk that excessive force would be applied to the first guide member and the other first terminals fixed to it. In this regard, in the motor unit described above, not all of the first terminals are fixed to the first guide member. Specifically, the first guide member is fixed to a portion of the plurality of first terminals and to at least one of the connecting members, and is indirectly fixed to at least one of the plurality of first terminals via the connecting member. As a result, the first guide member can appropriately guide all the first terminals according to the profiles of the first guide surface and the second guide surface, while allowing for manufacturing errors in the arrangement of the plurality of first terminals.

[0009] In a second aspect of this technology, in the first aspect described above, the first guide member may be fixed to at least the connecting member. In this case, the first guide member may be further fixed to some of the plurality of first terminals. Alternatively, the first guide member may not be fixed to any of the plurality of first terminals.

[0010] In a third aspect of this technology, in the first or second aspect described above, the first guide member may be fixed to at least some of the plurality of first terminals. In this case, the first guide member may be further fixed to the connecting member. Alternatively, the first guide member may not be fixed to the connecting member.

[0011] In a fourth aspect of this technology, in the third aspect described above, the plurality of first terminals are arranged along one direction, and the first guide member may be fixed to a first terminal located in the middle portion of the arrangement along the one direction. With this configuration, the first guide member can guide all the first terminals more appropriately than when it is fixed to a first terminal located at one end of the arrangement.

[0012] In a fifth aspect of this technology, in any one of the first to fourth aspects described above, the first guide surface and the second guide surface may have a second profile that allows contact between the plurality of first terminals and the plurality of second terminals when the plurality of first terminals approach the plurality of second terminals from a direction parallel to the contact surface and move to a position where the plurality of first terminals are attached to the terminal block. With such a configuration, when the plurality of first terminals reach the position where they are attached to the terminal block, the plurality of first terminals and the plurality of second terminals can come into contact with each other without being obstructed by the first guide member and the second guide member. Furthermore, even if there are manufacturing errors in the arrangement of the plurality of first terminals and some first terminals are spaced apart from the second terminals, as described above, all first terminals can be easily fastened to the second terminals. [Brief explanation of the drawing]

[0013] [Figure 1] This diagram shows the configuration of the motor unit in Example 1. [Figure 2] This is a cross-sectional view of the first and second terminals along the line II-II in Figure 1. [Figure 3] This is an enlarged cross-sectional view of part III in Figure 2. [Figure 4] This diagram shows the terminal block before it is attached to the casing. [Figure 5] Figures 5(a) to 5(e) are cross-sectional views of the Va-Va line in Figure 4, illustrating in steps the sequence of how multiple first terminals are connected to multiple second terminals. [Figure 6]Figures 6(a)-6(d) show a modified example of the first guide member. [Modes for carrying out the invention]

[0014] (Example) The motor unit 10 of this embodiment will be described with reference to Figure 1-5. As shown in Figure 1, the motor unit 10, together with the inverter 50, constitutes a drive system mounted on an electric vehicle. The motor unit 10 has a motor 20. The motor 20 is a driving motor for the electric vehicle and is a prime mover that drives at least one wheel of the electric vehicle. The motor 20 is, for example, a three-phase motor. Power can be supplied to the motor unit 10 from the battery via the inverter 50.

[0015] The inverter 50 electrically connects the battery mounted on the electric vehicle to the motor unit 10. The inverter 50 converts the DC power supplied from the battery into three-phase AC power. The inverter 50 has a plurality of inverter busbars 52, 54, and 56. The inverter 50 can input and output power to and from the motor unit 10 via the plurality of inverter busbars 52, 54, and 56. The plurality of inverter busbars 52, 54, and 56 include a U-phase inverter busbar 52, a V-phase inverter busbar 54, and a W-phase inverter busbar 56. In Figure 1, each of the plurality of inverter busbars 52, 54, and 56 is simply illustrated with a straight line.

[0016] The motor unit 10 and the inverter 50 are housed in a common casing 60. However, the motor unit 10 and the inverter 50 are not limited to a common casing 60, and may be housed in different casings. The casing 60 is a housing member. The casing 60 has a casing body 62 and a partition wall 64 that separates the motor 20 and the inverter 50 within the casing body 62.

[0017] The motor 20 has a shaft 22, a rotor 24, and a stator 26. The shaft 22 extends along the central axis C of the motor 20. The rotor 24 is generally a cylindrical member. The rotor 24 is fixed to the shaft 22. The rotor 24 rotates together with the shaft 22 about the central axis C as the rotation center.

[0018] Here, in this specification, a cylindrical coordinate system composed of an axial direction, a radial direction, and a circumferential direction is defined based on the central axis C of the motor 20. The axial direction is a direction parallel to the central axis C and is defined by a coordinate axis D1 parallel to the central axis C (see FIG. 2). In this specification, the positive direction of the coordinate axis D1 may be expressed as one side of the axial direction. The negative direction of the coordinate axis D1 may be expressed as the other side of the axial direction. The radial direction is a direction perpendicular to the central axis C and is defined by a coordinate axis D2 with the central axis C as the origin (see FIG. 1). In this specification, the positive direction of the coordinate axis D2 is expressed as the outside in the radial direction, and the negative direction of the coordinate axis D2 may be expressed as the inside in the radial direction. The circumferential direction is a direction perpendicular to the axial direction and the radial direction and is defined by a coordinate axis D3 that circulates around the central axis C (see FIG. 1). In this specification, the positive direction of the coordinate axis D3 is expressed as one side of the circumferential direction, and the negative direction of the coordinate axis D3 may be expressed as the other side of the circumferential direction.

[0019] The stator 26 is generally a cylindrical member. The stator 26 is disposed outside the rotor 24 in the radial direction. The stator 26 has a stator core 28 and a plurality of coils 30U, 30V, 30W. In the motor 20, three-phase AC power of the U phase, V phase, and W phase is input and output to the plurality of coils 30 of the stator 26 from the inverter 50, whereby the rotor 24 and the shaft 22 rotate.

[0020] In FIG. 2, a cross-sectional view of the motor unit 10 is shown, and the illustration of the rotor 24 and the shaft 22 is omitted. The stator core 28 is a cylindrical member. The stator core 28 has one end face 28e located on one side in the axial direction and the other end face (not shown) located on the other side in the axial direction, and extends along the axial direction from the one end face 28e to the other end face. The stator core 28 has an inner peripheral surface 28a. The inner peripheral surface 28a is the radially inner surface of the stator core 28 and extends cylindrically along the circumferential direction. The inner peripheral surface 28a of the stator core 18 defines a through hole that houses at least a part of the rotor 24. A plurality of slots (not shown) are formed on the inner peripheral surface 28a of the stator core 28 along the circumferential direction. The outer peripheral surface 28b of the stator core 28 is the radially outer surface of the stator core 28 and extends cylindrically along the circumferential direction. The inner peripheral surface 28a and the outer peripheral surface 28b extend along the axial direction between the one end face 28e and the other end face (not shown).

[0021] The plurality of coils 30U, 30V, 30W are arranged in the slots of the stator core 18. Specifically, each of the plurality of stator coils 30U, 30V, 30W (hereinafter referred to as each stator coil 30U, 30V, 30W) is arranged across two or more slots. Each stator coil 30U, 30V, 30W is a segment coil and is composed of a conductor wire having a rectangular cross section. The specific configuration of the plurality of coils 30U, 30V, 30W is not particularly limited. For example, the plurality of coils 30U, 30V, 30W may have a concentrated winding configuration or a distributed winding configuration.

[0022] The multiple coils 30U, 30V, and 30W include a U-phase coil 30U, a V-phase coil 30V, and a W-phase coil 30W. The U-phase coil 30U has one end 30Ua on the input / output side and the other end (not shown) on the neutral point side. The V-phase coil 30V has one end 30Va on the input / output side and the other end (not shown) on the neutral point side. The W-phase coil 30W has one end 30Wa on the input / output side and the other end (not shown) on the neutral point side. The other ends of each coil 30U, 30V, and 30W are electrically connected to each other, forming the neutral point in a Y-connection. In other words, the motor 20 in this embodiment is a Y-connection type motor. As shown in Figure 2, one end 30Ua, 30Va, and 30Wa of each coil 30U, 30V, and 30W protrudes from one end face 28e of the stator core 28 toward one side in the axial direction (i.e., the upper side in Figure 2).

[0023] In addition to the motor 20 described above, the motor unit 10 includes a plurality of motor busbars 32, 34, and 36, a busbar holder 38, a plurality of first guide members 39, a terminal block 40, and a plurality of second guide members 47.

[0024] Each of the multiple motor busbars 32, 34, and 36 (hereinafter referred to as each motor busbar 32, 34, and 36) is a plate-shaped member and is formed using a conductive material such as metal. The multiple motor busbars 32, 34, and 36 include a U-phase motor busbar 32, a V-phase motor busbar 34, and a W-phase motor busbar 36. The U-phase motor busbar 32 is connected to one end 30Ua of the U-phase coil 30U. The V-phase motor busbar 34 is connected to one end 30Va of the V-phase coil 30V. The W-phase motor busbar 36 is connected to one end 30Wa of the W-phase coil 30W.

[0025] Each motor busbar 32, 34, and 36 extends from its base to its tip, connected to a corresponding coil 30U, 30V, and 30W. Each of the multiple motor busbars 32, 34, and 36 (hereinafter referred to as their respective first terminals 32a, 34a, and 36a) has a flat first terminal 32a, 34a, and 36a located at its tip. That is, the multiple first terminals 32a, 34a, and 36a include a U-phase first terminal 32a, a V-phase first terminal 34a, and a W-phase first terminal 36a. Each first terminal 32a, 34a, and 36a extends along a planar direction perpendicular to the axial direction. The multiple first terminals 32a, 34a, and 36a are arranged along one direction (in this embodiment, the up-and-down direction in the plane of the paper in Figure 1).

[0026] The busbar holder 38 is a holding member that holds a plurality of motor busbars 32, 34, and 36. The busbar holder 38 connects the plurality of motor busbars 32, 34, and 36 at the base end side of their respective first terminals 32a, 34a, and 36a. The busbar holder 38 is constructed of, for example, a resin material. The busbar holder 38 has a plurality of fixing parts 38f. The busbar holder 38 is fixed to one end face 28e of the stator core 28 at the plurality of fixing parts 38f. Although not particularly limited, the busbar holder 38 may be fastened to the stator core 28 using a plurality of fastening members such as bolts.

[0027] Multiple first terminals 32a, 34a, and 36a are attached to a terminal block 40. In this embodiment, the terminal block 40 is fixed to a through hole 64a formed in a partition wall 64 of the casing 60. The terminal block 40 has a base 41 and multiple terminal block busbars 42, 44, and 46 held by the base 41. The base 41 is made of an insulator, such as a resin material. Each of the multiple terminal block busbars 42, 44, and 46 (hereinafter referred to as each terminal block busbar 42, 44, and 46) is a plate-shaped member and is formed using a conductive material such as metal.

[0028] Each terminal block busbar 42, 44, 46 extends from its base to its tip. The base of each terminal block busbar 42, 44, 46 is connected to a corresponding inverter busbar 52, 54, 56. Each of the terminal block busbars 42, 44, 46 has a flat second terminal 42a, 44a, 46a located at its tip. That is, the multiple second terminals 42a, 44a, 46a include a U-phase second terminal 42a, a V-phase second terminal 44a, and a W-phase second terminal 46a. For example, each of the multiple terminal block busbars 42, 44, 46 is held at the base 41 of the terminal block 40 at its second terminals 42a, 44a, 44b. The multiple second terminals 42a, 44a, 46a extend along the multiple first terminals 32a, 34a, 36a.

[0029] Here, referring to Figures 2 and 3, the configuration of multiple first terminals 32a, 34a, and 36a and multiple second terminals 42a, 44a, and 46a will be explained. In Figures 2 and 3, the V-phase first terminal 34a and the V-phase second terminal 44a are shown. The V-phase second terminal 44a is positioned parallel to the V-phase first terminal 34a. The V-phase second terminal 44a has a contact surface CS that contacts the V-phase first terminal 34a. The V-phase second terminal 44a is fastened to the V-phase first terminal 34a at the contact surface CS using a bolt 48. The bolt 48 passes through the V-phase first terminal 34a and the V-phase second terminal 44a and, in combination with a nut 49 fixed to the V-phase second terminal 44a, fastens the V-phase first terminal 34a and the V-phase second terminal 44a together. Although not shown in Figure 2, the U-phase first terminal 32a and U-phase second terminal 42a, and the W-phase first terminal 36a and W-phase second terminal 46a can be configured in the same way as the V-phase first terminal 34a and V-phase second terminal 44a. The U-phase second terminal 42a has a contact surface that contacts the U-phase first terminal 32a of the U-phase motor busbar 32, and is fastened to the U-phase first terminal 32a at the contact surface using a bolt 48. The W-phase second terminal 46a has a contact surface that contacts the W-phase first terminal 36a of the W-phase motor busbar 36, and is fastened to the W-phase first terminal 36a at the contact surface using a bolt 48. In other words, terminal block 40 connects the second terminals 42a, 44a, and 46a of each terminal block busbar 42, 44, and 46 to the first terminals 32a, 34a, and 36a of the corresponding motor busbar 32, 34, and 36, respectively.

[0030] Multiple first guide members 39 are configured to guide the multiple first terminals 32a, 34a, 36a of the motor busbars 32, 34, 36 when they are connected to the multiple second terminals 42a, 44a, 46a of the terminal block 40, respectively. As an example, the motor unit 10 of this embodiment includes two first guide members 39. One of the two first guide members 39 is located between the U-phase first terminal 32a and the V-phase first terminal 34a, and the other of the two first guide members 39 is located between the V-phase first terminal 34a and the W-phase first terminal 36a. Both first guide members 39 are fixed to the V-phase first terminal 34a. Therefore, each of the two first guide members 39 can guide the V-phase first terminal 34a. On the other hand, one of the two first guide members 39 has a gap between it and the U-phase first terminal 32a and is not directly fixed to the U-phase first terminal 32a. The other of the two first guide members 39 has a gap between it and the W-phase first terminal 36a and is not directly fixed to the W-phase first terminal 36a. Each of the two first guide members 39 is fixed to the busbar holder 38 and is indirectly fixed to the U-phase first terminal 32a and the W-phase first terminal 36a via the busbar holder 38. As a result, each of the two guide members 39 can guide the U-phase first terminal 32a and the W-phase first terminal 36a, as well as the V-phase first terminal 34a.

[0031] For example, each first guide member 39 is constructed using an insulator such as a resin material. Each first guide member 39 is formed integrally with the busbar holder 38. In a modified example, each first guide member 39 may be formed separately from the busbar holder 38.

[0032] The multiple second guide members 47 are configured to contact the multiple first guide members 39 when the multiple first terminals 32a, 34a, and 36a of the motor busbars 32, 34, and 36 are connected to the multiple second terminals 42a, 44a, and 46a of the terminal block 40, respectively. Each of the multiple second guide members 47 (hereinafter referred to as each second guide member 47) is fixed to one or more of the multiple second terminals 42a, 44a, and 46a. As an example, the motor unit 10 of this embodiment includes two second guide members 47. One of the two second guide members 47 is located between the U-phase second terminal 42a and the V-phase second terminal 44a and is fixed to both the U-phase second terminal 42a and the V-phase second terminal 44a. The other of the two second guide members 47 is positioned between the V-phase second terminal 44a and the W-phase second terminal 46a, and is fixed to both the V-phase second terminal 44a and the W-phase second terminal 46a. Each second guide member 47 is also fixed to the base 41 of the terminal block 40. The number of second guide members 47 is not limited to two; there may be one or three or more. One or more second guide members 47 are configured to guide the multiple second terminals 42a, 44a, and 46a. Note that the second guide members 47 do not have to be directly fixed to each of the multiple second terminals 42a, 44a, and 46a, but may be fixed at least indirectly to each of the multiple second terminals 42a, 44a, and 46a via the base 41 of the terminal block 40. As an example, each second guide member 47 is made of an insulator such as a resin material. Each second guide member 47 is formed integrally with the base 41 of the terminal block 40. In the modified example, each second guide member 47 may be formed separately from the base 41 of the terminal block 40.

[0033] Each first guide member 39 has a first guide surface GS1. Each second guide member 47 has a second guide surface GS2. In Figures 2 and 3, only the other of the two first guide members 39 and the other of the two second guide members 47 are shown. The two first guide members 39 can be configured similarly to each other, and the two second guide members 47 can be configured similarly to each other. Hereafter, each of the two first guide members 39 will be simply referred to as the first guide member 39, and each of the two second guide members 47 will be simply referred to as the second guide member 47, and they will be described accordingly.

[0034] As shown in Figure 3, the first guide surface GS1 has a convex shape GS11 and a concave shape GS12. The convex shape GS11 is located on the tip side of the first guide member 39, and the concave shape GS12 is located on the base side of the first guide member 39. The convex shape GS11 protrudes toward the second guide surface GS2. The convex shape GS11 is an example of the first profile in this technology. The convex shape GS11 comprises a top surface 100 and a tapered surface 102. The top surface 100 is a plane and extends parallel to the longitudinal direction of the V-phase first terminal 34a. The tapered surface 102 extends from the top surface 100 toward the tip of the first guide member 39. In the tapered surface 102, the height of the convex shape GS11 gradually decreases toward the tip of the first guide member 39. The tapered surface 102 may be a plane or a curved surface. The concave GS12 refers to the portion that is recessed relative to the convex GS11. The concave GS12 is planar and extends parallel to the longitudinal direction of the V-phase first terminal 34a. The concave GS12 is an example of the second profile in this technology.

[0035] The second guide surface GS2 has a convex shape GS21 and a concave shape GS22. The convex shape GS21 is located on the tip side of the second guide member 47, and the concave shape GS22 is located on the base side of the second guide member 47. The convex shape GS21 protrudes toward the first guide surface GS1. The convex shape GS21 is an example of the first profile in this technology. The convex shape GS11 has a top surface 104 and a tapered surface 106. The top surface 104 is flat and extends parallel to the longitudinal direction of the second terminal 44a. The tapered surface 106 extends from the top surface 104 toward the tip of the second guide member 47. In the tapered surface 106, the height of the convex shape GS21 gradually decreases toward the tip of the second guide member 47. The tapered surface 106 may be flat or curved. The concave shape GS22 means the portion that is recessed relative to the convex shape GS21. The concave GS22 is planar and extends parallel to the longitudinal direction of the V-phase second terminal 44a. The concave GS22 is an example of a second profile in this technology.

[0036] With multiple first terminals 32a, 34a, and 36a connected to multiple second terminals 42a, 44a, and 46a respectively, the convex shape GS11 of the first guide surface GS1 faces the concave shape GS22 of the second guide surface GS2. Also, the concave shape GS12 of the first guide surface GS1 faces the convex shape GS21 of the second guide surface GS2. In this case, the convex shape GS11 of the first guide surface GS1 and the concave shape GS22 of the second guide surface GS2 are not in contact with each other. That is, a gap is formed between the convex shape GS11 and the concave shape GS22. Similarly, the concave shape GS12 of the first guide surface GS1 and the convex shape GS21 of the second guide surface GS2 are not in contact with each other. That is, a gap is formed between the concave shape GS12 and the convex shape GS21.

[0037] As shown in Figure 3, in the direction perpendicular to the contact surface CS, the convex shape GS11 of the first guide member 39 protrudes by a dimension d1 relative to the surface of the V-phase first terminal 34a. On the other hand, the convex shape GS21 of the second guide member 47 is recessed by a dimension d2 relative to the surface of the V-phase second terminal 44a. Here, it is preferable that the dimension d1 by which the convex shape GS11 of the first guide member 39 protrudes is greater than the dimension d2 by which the convex shape GS21 of the second guide member 47 is recessed. As will be explained in more detail later, with this relationship, when the V-phase first terminal 34a is connected to the V-phase second terminal 44a, unnecessary contact between the V-phase first terminal 34a and the V-phase second terminal 44a can be avoided.

[0038] Next, referring to Figures 4 and 5(a)-5(e), we will explain how multiple first terminals 32a, 34a, and 36a are connected to multiple second terminals 42a, 44a, and 46a. In Figures 4 and 5(a)-5(e), the V-phase first terminal 34a and V-phase second terminal 44a are shown as representative examples. In the following explanation, we will use the V-phase first terminal 34a and V-phase second terminal 44a as examples, but the same applies to all first terminals 32a, 34a, and 36a and all second terminals 42a, 44a, and 46a.

[0039] As shown in Figure 4, when manufacturing the motor unit 10, the terminal block 40 is inserted into the through hole 64a of the casing 60. At this time, the motor 20 is pre-installed in the casing 60, and the multiple first terminals 32a, 34a, and 36a of the motor 20 are waiting inside the casing 60. As shown in Figures 5(a) to 5(b), as the terminal block 40 is inserted into the through hole 64a of the casing 60, the V-phase first terminal 34a and the V-phase second terminal 44a approach each other along a direction parallel to the contact surface CS. At this time, the first guide surface GS1 and the second guide surface GS2 begin to make contact with each other before the V-phase first terminal 34a and the V-phase second terminal 44a make contact with each other. Subsequently, as shown in Figure 5(c), the V-phase first terminal 34a and the V-phase second terminal 44a begin to face each other in a direction perpendicular to the contact surface CS. At this time, the convex shape GS11 of the first guide surface GS1 (particularly the tapered surface 102 shown in Figure 3) and the convex shape GS21 of the second guide surface GS2 (particularly the tapered surface 106 shown in Figure 3) are in contact, causing the first guide member 39 and the second guide member 47 to be displaced so as to move away from each other. As a result, the V-phase first terminal 34a fixed to the first guide member 39 and the V-phase second terminal 44a fixed to the second guide member 47 are also guided to move away from each other. In other words, at this stage, contact between the V-phase first terminal 34a and the V-phase second terminal 44a is prohibited.

[0040] Subsequently, as shown in Figure 5(d), the first guide surface GS1 and the second guide surface GS2 slide against each other on the top surfaces 100 and 104 (see Figure 3) of their respective convex shapes GS11 and GS21. While the first guide surface GS1 and the second guide surface GS2 are sliding against each other, the first V-phase terminal 34a and the second V-phase terminal 44a remain separated from each other. Subsequently, as shown in Figure 5(e), the first V-phase terminal 34a reaches the position where it is fastened to the second V-phase terminal 44a of the terminal block 40. When the first V-phase terminal 34a reaches the position where it is fastened to the second V-phase terminal 44a, the convex shape GS11 of the first guide surface GS1 is accommodated in the concave shape GS22 of the second guide surface GS2. Also, the convex shape GS21 of the second guide surface GS2 is accommodated in the concave shape GS12 of the first guide surface GS1. As a result, the first V-phase terminal 34a and the second V-phase terminal 44a come into contact with each other.

[0041] In the motor unit 10 of this embodiment, as described above, when the multiple first terminals 32a, 34a, and 36a approach the multiple second terminals 42a, 44a, and 46a from a direction parallel to the contact surface CS, the first guide surface GS1 of the first guide member 39 (one or the other of the two first guide members 39) and the second guide surface GS2 of the second guide member 47 (one or the other of the two second guide members 47) come into contact with each other. The first guide member 39 is directly fixed to the V-phase first terminal 34a among the multiple first terminals 32a, 34a, and 36a, and is indirectly fixed to the other terminals 32a, 36a among the multiple first terminals 32a, 34a, and 36a via the busbar holder 38. The second guide member 47 is directly fixed to the multiple second terminals 42a, 44a, and 46a. Accordingly, the multiple first terminals 32a, 34a, 36a and the multiple second terminals 44a move away from or approach each other according to the respective profiles (i.e., each convex shape GS11, GS21) of the first guide surface GS1 and the second guide surface GS2. In particular, the first guide surface GS1 and the second guide surface GS2 have a first profile that prohibits contact between the V-phase first terminal 34a and the V-phase second terminal 44a at the timing when the multiple first terminals 32a, 34a, 36a and the multiple second terminals 42a, 44a, 46a begin to face each other. As a result, when the multiple first terminals 32a, 34a, 36a approach the multiple second terminals 42a, 44a, 46a from a direction parallel to the contact surface CS, sliding between the multiple first terminals 32a, 34a, 36a and the multiple second terminals 42a, 44a, 46a is at least partially avoided. Therefore, the generation of conductive foreign matter from multiple first terminals 32a, 34a, 36a and / or multiple second terminals 42a, 44a, 46a is prevented or suppressed.

[0042] On the other hand, manufacturing tolerances are expected to occur in the arrangement of the multiple first terminals 32a, 34a, and 36a. Therefore, when the multiple first terminals 32a, 34a, and 36a move to a position where they are fastened to the multiple second terminals 42a, 44a, and 46a, the gap (including contact) between each of the multiple first terminals 32a, 34a, and 36a and the second terminals 42a, 44a, and 46a will not necessarily be constant among all the first terminals 32a, 34a, and 36a. For example, one of the multiple first terminals 32a, 34a, and 36a (e.g., 34a) may be in contact with the opposing second terminal (e.g., 44a), while another of the multiple first terminals 32a, 34a, and 36a (32a or 36a) may be separated from the opposing second terminal (42a or 46a) with a gap between them. In such a case, if all the first terminals 32a, 34a, and 36a were fixed to the first guide member 39, when fastening the opposing first terminals 32a, 34a, and 36a with the second terminals 42a, 44a, and 46a with a gap between them, the displacement of the first terminals 32a, 34a, and 36a toward the second terminals 42a, 44a, and 46a would be obstructed by the first guide member 39. As a result, a large fastening force would be required, and there is a risk that excessive force would be applied to the first guide member 39 and the other first terminals (32a or 36a) fixed to it. In this regard, in the motor unit 10 of this embodiment, all the first terminals 32a, 34a, and 36a are not fixed to the first guide member 39. Specifically, the first guide member 39 is fixed to the U-phase first terminal 32a of the multiple first terminals 32a, 34a, and 36a and to the busbar holder 38, and is indirectly fixed to the U-phase first terminal 32a and W-phase first terminal 36a of the multiple first terminals 32a, 34a, and 36a via the busbar holder 38. As a result, the first guide member 39 can appropriately guide all the first terminals 32a, 34a, and 36a according to the profiles of the first guide surface GS1 and the second guide surface GS2, while allowing for manufacturing errors that occur in the arrangement of the multiple first terminals 32a, 34a, and 36a.

[0043] Furthermore, in this embodiment, the first guide surface GS1 has a convex shape GS11 that protrudes toward the second guide surface GS2 as a first profile. The second guide surface GS2 also has a convex shape GS21 that protrudes toward the first guide surface GS1 as a first profile. With this configuration, the multiple first terminals 32a, 34a, and 36a are guided by the convex shape GS21 of the second guide surface GS2 so as to be separated from the multiple second terminals 42a, 44a, and 46a, and the multiple second terminals 42a, 44a, and 46a are guided by the convex shape GS11 of the first guide surface GS1 so as to be separated from the multiple first terminals 32a, 34a, and 36a. This prevents the multiple first terminals 32a, 34a, 36a and the multiple second terminals 42a, 44a, 46a from coming into contact with each other when they reach a position where they face each other. The first profile of the first guide surface GS1 (here, the convex shape GS11) and the first profile of the second guide surface GS2 (here, the convex shape GS21) function complementaryly. For this reason, it is preferable that the first profile of the first guide surface GS1 and the first profile of the second guide surface GS2 be designed as an integral part of the design.

[0044] Furthermore, in this embodiment, the first guide surface GS1 and the second guide surface GS2 have concave shapes GS12 and GS22 as second profiles. The concave shapes GS12 and GS22 accommodate the convex shapes GS21 and GS11 respectively when the V-phase first terminal 34a moves to the position where it is fastened to the V-phase second terminal 44a, thereby allowing contact between the multiple first terminals 32a, 34a, 36a and the multiple second terminals 42a, 44a, 46a. With this configuration, when the multiple first terminals 32a, 34a, 36a reach the position where they are fastened to the multiple second terminals 42a, 44a, 46a, the multiple first terminals 32a, 34a, 36a and the multiple second terminals 42a, 44a, 46a can contact each other without being obstructed by the multiple first guide members 39 and the multiple second guide members 47. Furthermore, even if manufacturing errors occur in the arrangement of multiple first terminals 32a, 34a, and 36a, causing some first terminals (e.g., 32a and 36a) to be spaced apart from the second terminals (e.g., 42a and 46a), as described above, all first terminals 32a, 34a, and 36a can be easily fastened to the second terminals 42a, 44a, and 46a.

[0045] Furthermore, in this embodiment, the two first guide members 39 are fixed to the first terminal (i.e., the V-phase first terminal 34a) located in the middle portion of the arrangement of the multiple first terminals 32a, 34a, and 36a along one direction. With this configuration, all of the first terminals 32a, 34a, and 36a can be guided more appropriately.

[0046] Furthermore, in this embodiment, the first guide member 39 and the second guide member 47 are made of resin material. With this configuration, conductive foreign matter is not generated by contact between the first guide member 39 and the second guide member 47. In a modified example, it is sufficient if either the first guide member 39 or the second guide member 47 is made of resin material. In another modified example, neither the first guide member 39 nor the second guide member 47 is made of resin material. For example, the first guide member 39 and the second guide member 47 may be made of a conductive material such as metal.

[0047] Here, the U-phase first terminal 32a, the V-phase first terminal 34a, and the W-phase first terminal 36a are examples of "first terminals" related to this technology, and the U-phase second terminal 42a, the V-phase second terminal 44a, and the W-phase second terminal 46a are examples of "second terminals" related to this technology. The busbar holder 38 is an example of a "connecting member" related to this technology.

[0048] Although specific examples of the technology disclosed herein have been described in detail above, these are merely illustrative and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes to the specific examples described above.

[0049] The configuration of the first guide member 39 is not limited to the configuration of the embodiment described above. The number of first guide members 39 is not limited to two, but may be one or three or more. At least one first guide member 39 needs to be fixed to some of the multiple first terminals 32a, 34a, 36a and at least one of the busbar holder 38. For example, in a modified example, as shown in Figure 6(a), the first guide member 39 (one of the two first guide members 39 and / or the other) does not have to be directly fixed to the busbar holder 38. In this case, the first guide member 39 may be fixed to some of the multiple first terminals 32a, 34a, 36a (for example, the V-phase first terminal 34a). Even with such a configuration, the first guide member 39 can be indirectly fixed to the other first terminals 32a, 36a that are not directly fixed, via the directly fixed V-phase first terminal 34a and the busbar holder 38. In another modification, as shown in Figure 6(b), the first guide member 39 does not have to be directly fixed to any of the multiple first terminals 32a, 34a, and 36a. Even with this configuration, the first guide member 39 can be indirectly fixed to all of the multiple first terminals 32a, 34a, and 36a via the busbar holder 38. In yet another modification, as shown in Figure 6(c), the first guide member 39 does not have to be directly fixed to the V-phase first terminal 34a, which is located in the middle portion of the arrangement of the multiple first terminals 32a, 34a, and 36a along one direction. In this case, the first guide member 39 may be directly fixed to, for example, the W-phase first terminal 36a (or the U-phase first terminal 32a), which is located at the end portion of the arrangement of the multiple first terminals 32a, 34a, and 36a along one direction. Even with this configuration, the first guide member 39 can be indirectly fixed to the other first terminals 32a and 34a that are not directly fixed to the first guide member 39, via the busbar holder 38 and the W-phase first terminal 36a located at the end portion. In another modified example, as shown in Figure 6(d), the first guide member 39 does not have to be adjacent to the multiple first terminals 32a, 34a, and 36a. Specifically, it does not have to be located between two adjacent first terminals among the multiple first terminals 32a, 34a, and 36a.In other words, the first guide member 39 may be located away from the multiple first terminals 32a, 34a, and 36a. For example, the distance between the multiple first terminals 32a, 34a, and 36a and the first guide member 39 may be greater than the distance between two adjacent first terminals. In this case, the first guide member 39 may be directly fixed to the busbar holder 38. Even with this configuration, the first guide member 39 can be indirectly fixed to all of the multiple first terminals 32a, 34a, and 36a via the busbar holder 38. The arrangement of the second guide member 47 may be appropriately changed to match that of the first guide member 39.

[0050] In the embodiment described above, the motor unit 10 includes three first terminals 32a, 34a, and 36a and three second terminals 42a, 44a, and 46a. The number of each of the first terminals 32a, 34a, and 36a and the second terminals 42a, 44a, and 46a is not limited to three. In a modified example, in addition to the three first terminals 32a, 34a, and 36a and the three second terminals 42a, 44a, and 46a, the motor unit 10 may further include a fourth first terminal and a second terminal for connecting a charging power source and a neutral point. In another modified example, the motor unit 10 may further include three first terminals 32a, 34a, 36a and three second terminals 42a, 44a, 46a for connecting one end 30Ua, 30V, 30W of each phase coil 30U, 30V, 30W of the motor 20 to the inverter 50, as well as three additional first and second terminals for connecting the other end of each phase coil 30U, 30V, 30W of the motor 20 to the second inverter.

[0051] The technical elements described herein or in the drawings demonstrate technical usefulness individually or in various combinations, and are not limited to the combinations described in the claims at the time of filing. Furthermore, the technologies illustrated herein or in the drawings achieve multiple objectives simultaneously, and achieving even one of these objectives constitutes technical usefulness in itself. [Explanation of Symbols]

[0052] 10: Motor unit, 20: Motor, 22: Shaft, 24: Rotor, 26: Stator, 28: Stator core, 30U, 30V, 30W: Stator coil, 32, 34, 36: Motor busbar, 32a, 34a, 36a: First terminal, 38: Busbar holder, 39: First guide member, 40: Terminal block, 42, 44, 46: Terminal block busbar, 42a, 44a, 46a: Second terminal, 47: Second guide member, CS: Contact surface, GS1: First guide surface, GS11: Convex shape, GS12: Concave shape, GS2: Second guide surface, GS21: Convex shape, GS22: Concave shape

Claims

1. A motor unit, A motor having a stator coil, Multiple motor busbars connected to the stator coil, Multiple first terminals located at the ends of multiple motor busbars, A connecting member that connects multiple motor busbars at the base end side of each of the first terminals, A first guide member is fixed to a portion of the plurality of first terminals and to at least one of the connecting members and has a first guide surface, Each of the aforementioned multiple first terminals is fastened using bolts, and each of the multiple second terminals has a contact surface that contacts one of the corresponding first terminals, A terminal block holding the plurality of second terminals, A second guide member is provided on the terminal block and has a second guide surface, Equipped with, The first guide surface and the second guide surface are configured to come into contact with each other when the plurality of first terminals approach the plurality of second terminals from a direction parallel to the contact surface, and have a first profile that prevents contact between the plurality of first terminals and the plurality of second terminals at least at the timing when the plurality of first terminals and the plurality of second terminals begin to face each other. Motor unit.

2. The motor unit according to claim 1, wherein the first guide member is fixed to the connecting member.

3. The motor unit according to claim 1, wherein the first guide member is fixed to a portion of the plurality of first terminals.

4. The plurality of first terminals are arranged along one direction, The motor unit according to claim 3, wherein the first guide member is fixed to a first terminal located in the middle portion of the arrangement of the plurality of first terminals along the one direction.

5. The motor unit according to claim 1, wherein the first guide surface and the second guide surface have a second profile that allows contact between the plurality of first terminals and the plurality of second terminals when the plurality of first terminals approach the plurality of second terminals from a direction parallel to the contact surface and move to a position where the plurality of first terminals are fastened to the plurality of second terminals, respectively.

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