Stator of a rotating electric machine

Abstract

This invention provides a stator for a rotating electric machine that simplifies the structure for installing temperature sensors, thereby reducing costs and improving productivity. [Solution] The device comprises a stator core (73) having a yoke portion (73a) and a plurality of teeth portions (73b), and a coil (20) installed in a slot (73c). The coil (20) is located within the slot (73c) and has coil terminal protrusions (20U1h, 20U2h) protruding from the stator core (73). The device also includes a busbar (240) connecting the plurality of coil terminal protrusions (20U1h, 20U2h), a temperature sensor (160) for measuring the temperature of the coil (20), and a metal fixing part (150) that sandwiches and fixes the temperature sensor (160) between the busbar (240) and the radial direction (X) on the radial side (X1) of the busbar (240).

Description

[Technical Field]

[0001] The present disclosure relates to a stator of a rotating electric machine. [Background Art]

[0002] In a conventional rotating electric machine, when a current flows through a coil wound around a stator core, the temperature of the coil rises due to Joule heat. At this time, if the temperature of the coil rises above a predetermined temperature, some of the components constituting the stator may be damaged by heat. Therefore, for example, as disclosed in Patent Document 1, a temperature sensor is arranged on the stator to manage the temperature, and when the detected temperature reaches or exceeds a predetermined temperature, measures are taken such as cutting off the current supplied to the coil to prevent the temperature of the coil from rising. [Prior Art Literature] [Patent Literature]

[0003] [Patent Document 1] Japanese Patent Laying-Open No. 2022-71979 [Summary of the Invention] [Problem to be Solved by the Invention]

[0004] Conventionally, for example, in the rotating electric machine disclosed in Patent Document 1, the bus bar has a bent portion that sandwiches and holds the temperature sensor. The neutral point bus bar having such a shape has problems of high cost and low productivity due to poor material yield.

[0005] The present disclosure discloses a technique for solving the problems described above, and an object of the present invention is to provide a stator for a rotating electric machine in which the structure for installing a temperature sensor is simplified, cost is reduced, and productivity is improved. [Means for Solving the Problem]

[0006] The stator of the rotating electric machine of the present disclosure is A stator core having a cylindrical yoke portion and a plurality of teeth portions that protrude radially inward from the inner circumferential surface of the yoke portion at circumferential intervals, It has a coil installed in a slot formed between adjacent teeth in the circumferential direction, The coil has a coil body portion arranged in the slot and a coil terminal protrusion portion connected to the coil body portion and protruding from the stator core. A busbar connecting multiple coil terminal protrusions, A temperature sensor for measuring the temperature of the coil, The busbar is provided with a metal fixing component that sandwiches and secures the temperature sensor between the busbar and the busbar in the radial direction, on the radially outer side of the busbar. It is. [Effects of the Invention]

[0007] According to the stator of the rotating electric machine described herein, The structure for installing temperature sensors is simplified, resulting in cost reduction and improved productivity. [Brief explanation of the drawing]

[0008] [Figure 1] This is a cross-sectional view showing the configuration of a rotating electric machine according to Embodiment 1. [Figure 2] Figure 1 is a perspective view showing the configuration of the stator of the rotating electric machine. [Figure 3] Figure 2 is a plan view showing the configuration of the stator core of the stator shown. [Figure 4] Figure 2 is a perspective view showing the configuration of the L-shaped coils that make up the stator coil. [Figure 5] Figure 2 is a partial perspective view showing the configuration of the power supply side of the stator. [Figure 6] Figure 5 is a partial perspective view showing the configuration of the stator before the installation of the busbar unit on the power supply side. [Figure 7] Figure 5 is a perspective view showing the configuration of the stator busbar unit. [Figure 8]It is a perspective view showing the configuration of the busbars of the busbar unit shown in Fig. 7. [Figure 9] It is a perspective view showing the configuration of the fixing component of the busbar unit shown in Fig. 7. [Figure 10] Fig. 10A is a front view showing the configuration of the temperature sensor of the busbar unit shown in Fig. 7, Fig. 10B is a cross-sectional view showing the configuration of a cross section along line A2-A2 of the temperature sensor shown in Fig. 10A, and Fig. 10C is a perspective view showing the configuration of the temperature sensor shown in Fig. 10A. [Figure 11] It is a partial front view showing the configuration of the busbar unit shown in Fig. 7. [Figure 12] It is a cross-sectional view showing the configuration of a cross section along line A1-A1 of the busbar unit shown in Fig. 11. [Figure 13] It is a perspective view showing the configuration of the busbar unit of the stator of the rotating electrical machine according to Embodiment 2. [Figure 14] It is a perspective view showing the configuration of the busbars of the busbar unit shown in Fig. 13. [Figure 15] Fig. 15A is a perspective view showing the configuration of the fixing component of the busbar unit shown in Fig. 13, and Fig. 15B is a perspective view from another direction showing the configuration of the fixing component shown in Fig. 15A. [Figure 16] It is a cross-sectional view showing the manufacturing process of the busbar unit shown in Fig. 13. [Figure 17] It is a cross-sectional view showing the configuration of the busbar unit shown in Fig. 13. [Figure 18] It is a cross-sectional view showing another configuration of the busbar unit shown in Fig. 13. [Figure 19] It is a cross-sectional view showing the configuration of the busbar unit of the stator of the rotating electrical machine according to Embodiment 3. [Figure 20] It is a perspective view showing the configuration of the busbar unit of the stator of the rotating electrical machine according to Embodiment 4. [Figure 21] Fig. 21A is a front view showing the configuration of the temperature sensor of the busbar unit shown in Fig. 20, Fig. 21B is a cross-sectional view showing the configuration of a cross section along line A3-A3 of the temperature sensor shown in Fig. 21A, and Fig. 21C is a perspective view showing the configuration of the temperature sensor shown in Fig. 21A. [Figure 22] It is a perspective view showing a configuration of a busbar unit of a stator of a rotating electrical machine according to Embodiment 5. [Figure 23] It is a front view showing a manufacturing process of a busbar and a fixing component of the busbar unit shown in FIG. 22. [Figure 24] It is a perspective view showing a configuration of a busbar unit of a stator of a rotating electrical machine according to Embodiment 6. [Figure 25] FIG. 25A is a perspective view showing a configuration of a fixing component of the busbar unit shown in FIG. 24, and FIG. 25B is a perspective view from another direction showing the configuration of the fixing component shown in FIG. 25A. MODES FOR CARRYING OUT THE INVENTION

[0009] In the following description, each direction in the rotating electrical machine 100 is referred to as a circumferential direction Z, an axial direction Y, a radial direction X, an outer side X1 in the radial direction X, and an inner side X2 in the radial direction X, respectively. Further, when referring to "inner side" and "outer side" with respect to the axial direction Y, the center side of the rotating electrical machine 100 is defined as the inner side, and the opposite side is defined as the outer side. Therefore, in the stator 7 and other portions, description will be made with each direction indicated based on this reference direction.

[0010] Embodiment 1. FIG. 1 is a cross-sectional view showing a configuration of a rotating electrical machine according to Embodiment 1. FIG. 2 is a perspective view showing a configuration of a stator of the rotating electrical machine shown in FIG. 1. FIG. 3 is a plan view showing a configuration of a stator core of the stator shown in FIG. 2. FIG. 4 is a perspective view showing a configuration of an L-shaped coil that constitutes a coil of the stator shown in FIG. 2. FIG. 5 is a partial perspective view showing a configuration on a power feeding side of the stator shown in FIG. 2. FIG. 6 is a partial perspective view showing a configuration before installing a busbar unit on the power feeding side of the stator shown in FIG. 5. FIG. 7 is a perspective view showing a configuration of the busbar unit of the stator shown in FIG. 5.

[0011] Figure 8 is a perspective view showing the configuration of the busbars of the busbar unit shown in Figure 7. Figure 9 is a perspective view showing the configuration of the fixing components of the busbar unit shown in Figure 7. Figure 10A is a front view showing the configuration of the temperature sensor of the busbar unit shown in Figure 7, Figure 10B is a cross-sectional view showing the configuration of the temperature sensor shown in Figure 10A along the line A2-A2, and Figure 10C is a perspective view showing the configuration of the temperature sensor shown in Figure 10A. Figure 11 is a partial front view showing the configuration of the busbar unit shown in Figure 7. Figure 12 is a cross-sectional view showing the configuration of the busbar unit shown in Figure 11 along the line A1-A1.

[0012] In Figure 1, the rotating electric machine 100 comprises a housing 1, a power supply bracket 2, an output bracket 3, a stator 7, and a rotor 6. The power supply bracket 2 and the output bracket 3 each have bearings 4. The housing 1 is closed by the power supply bracket 2 and the output bracket 3. The stator 7 is fixed inside the housing 1 by fixing means such as press-fitting or shrink-fitting. The rotor 6 comprises a shaft 5 and permanent magnets 8. The shaft 5 is press-fitted inside the two bearings 4. The permanent magnets 8 are embedded on the outer circumferential surface of the rotor 6 to form magnetic poles. The permanent magnets 8 are arranged at a predetermined pitch in the circumferential direction Z, centered on the axis O.

[0013] Next, the configuration of the stator 7 will be described based on Figure 2. The stator 7 comprises a stator core 73, a coil 20, and a busbar unit 130. The coil 20 is wound around the stator core 73. The portions of the coil 20 that protrude from the axial Y end face of the stator core 73 are the power supply side coil end 71 and the output side coil end 72. Hereafter, the side of the stator core 73's axis O where the power supply coil end 71 is located will be referred to as the power supply side (upper side on the page), and the side where the output coil end 72 is located will be referred to as the output side (lower side on the page).

[0014] As shown in Figure 3, the stator core 73 comprises a yoke portion 73a and a teeth portion 73b. The yoke portion 73a is formed in a cylindrical shape (see Figure 2). Multiple teeth portions 73b are formed on the inner circumferential surface of the yoke portion 73a, protruding inward in the radial direction X X2 and spaced apart in the circumferential direction Z. Slots 73c are formed between each tooth portion 73b in the circumferential direction Z. A coil 20 is installed in the slots 73c, formed by inserting an L-shaped coil 20a, which has its insulating coating peeled off at both ends as shown in Figure 4.

[0015] As shown in Figure 4, the L-shaped coil 20a for forming the coil 20 has coating peeling portions 20a1 and 20a4 at both ends, a hypotenuse portion 20a2, and a straight portion 20a3 as the coil body. The L-shaped coil 20a is first inserted into the slot 73c of the stator core 73 from the coating peeling portion 20a4. In this embodiment 1, the stator core 73 has 48 slots 73c, and four L-shaped coils 20a are inserted into each slot 73c, so a total of 192 L-shaped coils 20a are inserted.

[0016] Furthermore, the insertion of the L-shaped coil 20a is to be performed from the output side (bottom) towards the power supply side (top). When inserted, the orientation of the hypotenuse portion 20a2 is to face the circumferential direction Z of the stator core 73. Of the four L-shaped coils 20a inserted into one slot 73c, they are designated as the 1st, 2nd, 3rd, and 4th from the inside X2 in the radial direction X. Hereafter, they will be abbreviated as 1st, 2nd, 3rd, and 4th. Of the four L-shaped coils 20a inserted into one slot 73c, the orientation of the hypotenuse portion 20a2 of the 1st and 3rd L-shaped coils 20a inserted into the slot 73c is opposite to the orientation of the hypotenuse portion 20a2 of the 2nd and 4th L-shaped coils 20a inserted into the slot 73c. ​​The L-shaped coils 20a inserted into the slot 73c are in the order of 1st, 2nd, 3rd, and 4th.

[0017] On the output side, the first L-shaped coil 20a, bent in the circumferential direction Z, is directly connected to the second L-shaped coil 20a, which is inserted in slot 73c, six slots away in the circumferential direction Z, at their coating stripping portions 20a1. Similarly, the third L-shaped coil 20a, also bent in the circumferential direction Z, is directly connected to the fourth L-shaped coil 20a, which is inserted in slot 73c, six slots away in the circumferential direction Z, at their coating stripping portions 20a1.

[0018] Here, "direct connection" means that, for example, the decoating portions 20a1 are connected to each other by contact without using wires or the like. Resistance welding, ultrasonic bonding, TIG welding, laser welding, etc., are used to connect the decoating portions 20a1 to each other. The slanted portion 20a2, which is inserted and connected in this way, forms the output coil end 72 of the stator 7.

[0019] Then, a portion of the straight section 20a3 is housed in the slot 73c, and a portion of the straight section 20a3 protrudes from the power supply side end face of the stator core 73 in the axial direction Y. The straight section 20a3 protruding from the power supply side end face of the stator core 73 in the axial direction Y is bent into an L shape in the circumferential direction Z to be the same shape as the output side coil end 72, thereby forming the power supply side coil end 71 of the stator 7. However, in the power supply side coil end 71, there is a portion with a different coil shape than the output side coil end 72.

[0020] Specifically, as shown in Figures 5 and 6, the power supply coil end 71 has power supply sections 20U1a, 20U2a, 20V1a, 20V2a, 20W1a, and 20W2a formed from the L-shaped coil 20a inserted into the slot 73c, as well as coil terminal protrusions 20U1h, 20U2h, 20V1h, 20V2h, 20W1h, and 20W2h that connect to the busbar unit 130. Also, for example, at the power supply coil end 71, there is a point where the coil terminal 20U1b of the second L-shaped coil 20a and the coil terminal 20U1c of the third L-shaped coil 20a are connected. Here, the stator 7 has 2 slots per pole per phase and consists of coils 20 for U1 phase, U2 phase, V1 phase, V2 phase, W1 phase, and W2 phase.

[0021] The following describes the conduction path of the U1 phase. The U1 phase is supplied with current from the power supply through the power supply section 20U1a. The supplied current flows counterclockwise in the CCW direction with a gap of 6 slots between the coil 20 in slot 73c, the power supply side coil end 71, and the output side coil end 72, and reaches the coil terminal 20U1b where the coating has been stripped. The coil terminals 20U1b and 20U1c are directly joined, and current flows from coil terminal 20U1b to coil terminal 20U1c.

[0022] Subsequently, the current flows counterclockwise in the CCW direction with a spacing of 6 slots, reaching coil terminal 20U1d, and then flows from coil terminal 20U1d to coil terminal 20U1e, which is directly joined to it. After that, the current flows clockwise in the CW direction with a spacing of 6 slots, reaching coil terminal 20U1f, and then flows from coil terminal 20U1f to coil terminal 20U1g.

[0023] Subsequently, the current flows in a clockwise direction (CW) with a spacing of 6 slots, reaching the coil terminal protrusion 20U1h. The coil terminal protrusion 20U1h is directly connected to the protrusion 40U1 of the busbar 140, and the current flows into the busbar 140. The configuration of the busbar 140 will be described in detail later. In the U2, V1, V2, W1, and W2 phases, the conductive path is the same as that of the U1 phase, with current flowing from the power supply section 20U2a to the protrusion 40U2 in the U2 phase, from the power supply section 20V1a to the protrusion 40V1 in the V1 phase, from the power supply section 20V2a to the protrusion 40V2 in the V2 phase, from the power supply section 20W1a to the protrusion 40W1 in the W1 phase, and from the power supply section 20W2a to the protrusion 40W2 in the W2 phase. Here, the busbar 140 is configured as the neutral point of the stator 7.

[0024] Next, the configuration of the busbar unit 130 will be described. The busbar unit 130 shown in Figure 7 consists of a busbar 140 shown in Figure 8, a fixing component 150 shown in Figure 9, and a temperature sensor 160 shown in Figure 10. As shown in Figure 7, the temperature sensor 160 is sandwiched and fixed between the busbar 140 and the fixing component 150 in the radial direction X. As described above, by attaching the temperature sensor 160 to the busbar 140, which acts as a neutral point, and detecting the temperature, it is possible to detect abnormalities even if an unbalanced current occurs due to a break in the wire or the like, causing abnormal heat generation in one of the phases.

[0025] As shown in Figure 8, the busbar 140 is formed by punching out a sheet metal material to create protrusions 40U1, 40U2, 40V1, 40V2, 40W1, and 40W2 that project outward in the axial direction Y. Furthermore, a sensor mounting section 141 for installing the temperature sensor 160 is formed, along with an outer protrusion 140a projecting outward in the axial direction Y of the sensor mounting section 141, and an inner protrusion 140b projecting inward in the axial direction Y. Subsequently, the busbar is formed by bending, using the bend sections 40p, 40q, 40r, and 40s as bending starting points. As a result, as shown in Figure 5, the protrusions 40U1, 40U2, 40V1, 40V2, 40W1, and 40W2 of the busbar 140 are formed to be connectable to the coil terminal protrusions 20U1h, 20U2h, 20V1h, 20V2h, 20W1h, and 20W1h, respectively, which are spaced apart in the circumferential direction Z.

[0026] Furthermore, as shown in Figure 10, the temperature sensor 160 has a main body 161 formed in the shape of a rectangular parallelepiped. As shown in Figure 10B, the cross-section of the main body 161 perpendicular to the circumferential direction Z is formed in the shape of a rectangle. Thus, the main body 161 has an outer upper surface 161a in the axial direction Y, an inner lower surface 161b in the axial direction Y, an outer surface 161c in the radial direction X1, and an inner surface 161d in the radial direction X2. In addition, the upper and lower corners of the radial direction X1 in the axial direction Y are designated as corners 161e and 161f.

[0027] Furthermore, as shown in Figure 9, the fixing part 150 is manufactured by punching out a sheet metal material and then bending it so that it can accommodate the radial length 160X and axial length 160Y (see Figure 10B) of the main body 161 of the temperature sensor 160, which is formed in the rectangular parallelepiped. Then, an outer joint portion 150a on the outside in the axial direction Y and an inner joint portion 150b on the inside in the axial direction Y are formed.

[0028] If the corners 161e and 161f of the temperature sensor 160 interfere with the fixing part 150, the contact area between the temperature sensor 160 and the fixing part 150 will decrease. For this reason, as shown in Figure 12, the corners 161e and 161f of the temperature sensor 160 are formed with a rounded chamfer. In this rounded chamfer, the radius 160R of the corners 161e and 161f of the temperature sensor 160 is processed to be larger than the bending radius 150R of the fixing part 150. As a result, a gap is formed between the corners 161e and 161f of the temperature sensor 160 and the fixing part 150.

[0029] As described above, the fixing component 150 and the temperature sensor 160 are formed with a radius relationship of 150R < radius 160R. Therefore, the inner surface 161d of the temperature sensor 160 on the inner side X2 in the radial direction X contacts the sensor mounting portion 141 of the busbar 140, and the upper surface 161a, lower surface 161b, and outer surface 161c of the temperature sensor 160 can contact the fixing component 150, respectively. Although the case of rounded chamfering of the corners 161e and 161f of the temperature sensor 160 is shown here, similar effects can be obtained with other chamfering methods such as rounded chamfering.

[0030] Subsequently, the busbar unit 130 is manufactured by assembling the outer joint portion 150a and the outer protrusion portion 140a, and the inner joint portion 150b and the inner protrusion portion 140b, respectively, using metal joining such as laser welding or ultrasonic bonding. Furthermore, as shown in Figure 11, the relationship between the axial length 150Y of the outer joint portion 150a and the inner joint portion 150b of the fixing part 150 in the axial Y direction and the axial length 140Y of the outer protrusion portion 140a and the inner protrusion portion 140b of the busbar 140 is formed such that length 150Y ≤ length 140Y.

[0031] As a result, when the busbar unit 130 is formed, the axial Y position of the end of the outer projection 140a of the busbar 140 is the same as or outside the axial Y position of the end of the outer joint 150a of the fixing part 150, and the axial Y position of the end of the inner projection 140b of the busbar 140 is the same as or inside the axial Y position of the end of the inner joint 150b of the fixing part 150. By forming it in this way, it is possible to suppress the increase in the axial Y of the busbar unit 130 when the temperature sensor 160 is attached.

[0032] Furthermore, the top surface 161a, bottom surface 161b, and outer surface 161c of the temperature sensor 160 are in contact with the fixing component 150, and the inner surface 161d is in contact with the bus bar 140, thereby fixing the temperature sensor 160 in position and reducing manufacturing variations. The fixing component 150 has high thermal conductivity, and the heat from the bus bar 140 is smoothly transferred to the fixing component 150. In addition, since the four surfaces of the temperature sensor 160 are in contact with the bus bar 140 and the fixing component 150, the heat from the bus bar unit 130 is transferred from all four surfaces, improving the temperature detection accuracy of the temperature sensor 160.

[0033] According to the stator of the rotating electric machine of Embodiment 1 configured as described above, A stator core having a cylindrical yoke portion and a plurality of teeth portions that protrude radially inward from the inner circumferential surface of the yoke portion at circumferential intervals, It has a coil installed in a slot formed between adjacent teeth in the circumferential direction, The coil has a coil body portion arranged in the slot and a coil terminal protrusion portion connected to the coil body portion and protruding from the stator core. A busbar connecting multiple coil terminal protrusions, A temperature sensor for measuring the temperature of the coil, The busbar is provided with a metal fixing component that sandwiches and secures the temperature sensor between the busbar and the busbar in the radial direction, on the radially outer side of the busbar. Therefore, The temperature sensor is sandwiched between two parts: a busbar connected to the coil and a fixing part connected to the busbar. Compared to a configuration where the temperature sensor is sandwiched between a single part, the shape and molding method of the busbar can be simplified, resulting in higher material yield, cost reduction, and improved productivity. Furthermore, sandwiching the radial outer and inner surfaces of the temperature sensor between metal busbars and fixing components improves the temperature detection accuracy of the temperature sensor. Furthermore, because the busbar and the fixing component are directly joined, there is no need to fix the temperature sensor with resin or the like. This reduces heat transfer to the resin and transmits the heat from the coil to the temperature sensor without dispersion, improving temperature detection accuracy. In addition, the elimination of the need for resin fixing reduces costs. Furthermore, since the temperature sensor is sandwiched between two parts, a busbar and a fixing component, the molding of the busbar for fixing the temperature sensor is unnecessary, simplifying the busbar molding process. This ensures high positional accuracy of the busbar connected to the coil end, improving productivity.

[0034] Furthermore, according to the stator of the rotating electric machine of Embodiment 1 configured as described above, The temperature sensor has a rectangular cross-section perpendicular to the circumferential direction of the main body, and the two corners of the rectangle on the side away from the busbar are chamfered. There is a gap between the corner of the temperature sensor and the fixing part. Therefore, By avoiding point contact between the corners of the temperature sensor and the fixing component, and allowing surface contact between the temperature sensor and the fixing component, the contact area between the temperature sensor and the fixing component can be increased, making it easier to transfer heat to the temperature sensor and thus improving the temperature detection accuracy.

[0035] Furthermore, according to the stator of the rotating electric machine of Embodiment 1 configured as described above, The temperature sensor has a main body formed in the shape of a rectangular parallelepiped. The axial end faces and radial outer surface of the main body of the temperature sensor are in contact with the fixing part. The radial inner surface of the main body of the temperature sensor is in contact with the busbar, The position of the temperature sensor is restricted. Therefore, Increasing the contact area between the temperature sensor, the mounting components, and the busbar improves the temperature detection accuracy of the temperature sensor. Additionally, the axial position of the temperature sensor is restricted, improving the fixing force.

[0036] Furthermore, according to the stator of the rotating electric machine of Embodiment 1 configured as described above, The busbar has a sensor mounting section for installing the temperature sensor, The sensor mounting portion has an outer projection that protrudes outward in the axial direction and an inner projection that protrudes inward in the axial direction. The fixing component has an outer joint that connects to the outer protrusion of the busbar and an inner joint that connects to the inner protrusion of the busbar. The axial position of the end of the outer projection of the busbar is the same as or axially outward the axial position of the end of the outer joint of the fixing part. The axial position of the end of the inner projection of the busbar is the same as or axially inward of the end of the inner joint of the fixing component. Therefore, Since the fixing components are installed within the axial length of the busbar, it is possible to prevent the busbar and fixing components from becoming larger.

[0037] Furthermore, according to the stator of the rotating electric machine of Embodiment 1 configured as described above, The busbar is connected to the three-phase coil terminal protrusions and serves as the neutral point. Therefore, Even if an unbalanced current occurs due to a broken wire or other issue, causing abnormal heat generation in one of the phases, this device has the effect of detecting the abnormality.

[0038] Embodiment 2. Figure 13 is a perspective view showing the configuration of the busbar unit of the stator of a rotating electric machine according to Embodiment 2. Figure 14 is a perspective view showing the configuration of the busbars of the busbar unit shown in Figure 13. Figure 15A is a perspective view showing the configuration of the fixing parts of the busbar unit shown in Figure 13, and Figure 15B is a perspective view from another direction showing the configuration of the fixing parts shown in Figure 15A. Figure 16 is a cross-sectional view showing the manufacturing process of the busbar unit shown in Figure 13. Figure 17 is a cross-sectional view showing the configuration of the busbar unit shown in Figure 13. Figure 18 is a cross-sectional view showing other configurations of the busbar unit shown in Figure 13. In the figures, parts the same as those in Embodiment 1 are denoted by the same reference numerals and their description is omitted.

[0039] The following describes the busbar unit of the stator of a rotating electric machine according to Embodiment 2, focusing on the differences from Embodiment 1 described above. The busbar unit 230 shown in Figure 13 is formed from the busbar 240 shown in Figure 14, the fixing part 250 shown in Figure 15, and the temperature sensor 160. As shown in Figure 14, the busbar 240 has a sensor mounting section 241 for installing the temperature sensor 160. The sensor mounting section 241 has outer protrusions 240a and 240c that protrude outward in the axial direction Y, and inner protrusions 240b and 240d that protrude inward in the axial direction Y. In total, there are four outer protrusions 240a and 240c and four inner protrusions 240b and 240d on the outer and inner sides of the axial direction Y.

[0040] As shown in Figure 15, the fixing part 250 has outer joints 250a and 250c at two locations projecting outward in the axial direction Y, and inner joints 250b and 250d at two locations projecting inward in the axial direction Y. The fixing part 250 also has a curved portion 250e on its outer surface X1 in the radial direction X, which curves inward from the outer X1 to the inner X2 in the radial direction X, and this curved portion 250e is elastic from the outer X1 to the inner X2 in the radial direction X.

[0041] A method for manufacturing a busbar unit of a stator of a fixed electric machine of Embodiment 2 configured as described above, in which a temperature sensor 160 is installed on the busbar 240 using a fixing part 250, will be explained with reference to Figures 14, 16, and 17. First, as shown in Figure 16, the temperature sensor 160 is attached by sandwiching it between both end faces in the axial direction Y of the fixing part 250 and pressing it against the busbar 240. In this state, it is desirable that the relationship between the radial length 250X of the part of the fixing part 250 that houses the temperature sensor 160 and the radial length 160X of the temperature sensor 160 is such that length 250X < length 160X.

[0042] Next, as shown in Figure 17, the curved portion 250e of the fixing part 250 is pressed against the busbar 240, causing the curved portion 250e to bend, and the temperature sensor 160 is pressed against the busbar 240 from the outside X1 to the inside X2 in the radial direction X using the curved portion 250e of the fixing part 250. In this state, as shown in Figure 14, the outer protrusions 240a, 240c and inner protrusions 240b, 240d of the busbar 240 are joined to the outer joints 250a, 250c and inner joints 250b, 250d of the fixing part 250, respectively.

[0043] In Embodiment 1 described above, there were two joints between the busbar and the fixing part. However, in Embodiment 2, the number of joints is increased to four by connecting the outer protrusions 240a, 240c and inner protrusions 240b, 240d of the busbar 240 with the outer joints 250a, 250c and inner joints 250b, 250d of the fixing part 250. This makes it possible to prevent heat dissipation in the circumferential Z direction when joining by laser welding, for example. In other words, the heat applied by the laser to the outer protrusions 240a, 240c and inner protrusions 240b and 240d of the busbar 240, and the outer joints 250a, 250c and inner joints 250b and 250d of the fixing part 250, remains at these points, making them easier to melt and thus improving welding productivity. Furthermore, this reduces the energy required during welding, thus lowering the cost of production equipment.

[0044] Furthermore, as shown in Figure 17, when the curved portion 250e is formed, the outer and inner sides of the fixing part 250 in the axial direction Y are bent outward in the radial direction X1, and the outer and inner sides of the fixing part 250 in the axial direction Y are formed as corners that bulge outward in the radial direction X1. As a result, the fixing part 250 has a horizontal M-shape in the cross section perpendicular to the circumferential direction Z, and the fixing part 250 has elasticity inward in the radial direction X2.

[0045] Furthermore, the elasticity of the curved portion 250e of the fixing part 250 presses the temperature sensor 160 from the outside X1 to the inside X2 in the radial direction X, improving the fixing force for installing the temperature sensor 160 on the busbar 240. Also, similar to Embodiment 1 above, the temperature sensor 160 is fixed by contacting and fixing it on a total of four surfaces: the top surface 161a, the bottom surface 161b, the outer surface 161c of the temperature sensor 160 with the fixing part 250 (3 surfaces), and the inner surface 161d with the busbar 240 (1 surface).

[0046] Furthermore, another example of joining with the busbar 240 when a curved portion 250e is formed on the fixing part 250 will be described. For example, as shown in Figure 18, the fixing part 250 may be fixed to the busbar 240 in a case where the outer and inner sides of the axial direction Y of the cross section perpendicular to the circumferential direction Z are in a horizontal V shape.

[0047] The stator of the rotating electric machine of Embodiment 2, configured as described above, provides the same effects as Embodiment 1, The outer joint and the inner joint of the aforementioned fixing component are each formed in two locations. The fixing component is joined and fixed at two locations on the outer protrusion of the busbar and at two locations on the inner protrusion of the busbar. Therefore, By dividing the connection points between the busbar and the fixing component into multiple locations, heat loss from the weld points during welding of the fixing component and the busbar is suppressed, improving welding productivity. Furthermore, it becomes possible to reduce the energy required during welding, thereby lowering production equipment costs.

[0048] Furthermore, the stator of the rotating electric machine of Embodiment 2 configured as described above provides the same effects as Embodiment 1, The aforementioned fixing component includes an elastic curved portion that presses the radial outer surface from the radial outside to the inside, The curved portion presses the temperature sensor from the radial outside to the inside, and holds the temperature sensor by clamping it with the busbar. Therefore, The fixing force of the temperature sensor by the fixing component is improved. In addition, because the temperature sensor is in contact with the busbar while being pressed against it, variations in the contact state between the temperature sensor and the busbar are suppressed, improving the measurement accuracy of the temperature sensor.

[0049] Embodiment 3. Figure 19 is a cross-sectional view showing the configuration of the busbar unit of the stator of a rotating electric machine according to Embodiment 3. In the figure, parts that are the same as those in each of the above embodiments are denoted by the same reference numerals and their descriptions are omitted.

[0050] The following describes the busbar unit of the stator of a rotating electric machine according to Embodiment 3, focusing on the differences from the above embodiments. As shown in Figure 19, the temperature sensor 160 has a rectangular cross-section perpendicular to the circumferential direction Z of the main body 161. The corners 350a and 350b of the fixing part 350, corresponding to the positions of the corners 161g and 161h of the temperature sensor 160, are formed to bulge outwards in the axial direction Y and inwards, respectively. The axial length 350Y2 of the fixing part 350 that sandwiches the upper surface 161a and lower surface 161b of the temperature sensor 160 in the axial direction Y is smaller than the axial length 350Y1 between the bulging corners 350a and 350b of the fixing part 350 in the axial direction Y.

[0051] In this way, by forming the fixing part 350 such that length 350Y1 > length 350Y2, interference between the corners 350a and 350b of the fixing part 350 can be avoided regardless of the shape of the corners 161g and 161h of the temperature sensor 160. As a result, the fixing part 350 can reliably contact the upper surface 161a on the outside in the axial direction Y, the lower surface 161b on the inside in the axial direction Y, and the outer surface 161c on the outside X1 in the radial direction X of the temperature sensor 160. This ensures reliable contact between the busbar 240 and the inner surface 161d of the temperature sensor 160, and between the fixing part 350 and the upper surface 161a, lower surface 161b, and outer surface 161c of the temperature sensor 160, for a total of four surfaces. Heat can be transferred to the temperature sensor 160 through these surfaces, improving the temperature detection accuracy.

[0052] The stator of the rotating electric machine of Embodiment 3, configured as described above, provides the same effects as those of each of the embodiments described above, The temperature sensor has a rectangular cross-section perpendicular to the circumferential direction of the main body, and the corners of the fixing component corresponding to the two corners of the rectangle away from the busbar are formed with a bulge on the axial outer side and the axial inner side, respectively. The axial distance of the fixing component that clamps both axial ends of the temperature sensor is Smaller than the axial distance between the bulging corners of the aforementioned fixing part Therefore, Regardless of the shape of the corners of the temperature sensor, surface contact between the fixing component and the temperature sensor is facilitated.

[0053] Embodiment 4. Figure 20 is a perspective view showing the configuration of the busbar unit of the stator of a rotating electric machine according to Embodiment 4. Figure 21A is a front view showing the configuration of the temperature sensor of the busbar unit shown in Figure 20, Figure 21B is a cross-sectional view showing the configuration of the temperature sensor shown in Figure 21A along the line A3-A3, and Figure 21C is a perspective view showing the configuration of the temperature sensor shown in Figure 21A. In the figures, parts that are the same as those in each of the above embodiments are denoted by the same reference numerals and their descriptions are omitted.

[0054] The following describes the busbar unit of the stator of a rotating electric machine according to Embodiment 4, focusing on the differences from the above embodiments. As shown in Figure 21, the temperature sensor 460 of Embodiment 4 has a main body portion 461 formed as a rectangular parallelepiped, an outer projection 460a that protrudes outward in the axial direction Y, and an inner projection 460b that is on the inside in the axial direction Y.

[0055] As shown in Figure 20, the busbar unit 430 is formed from a busbar 240, a fixing part 250, and a temperature sensor 460. The outer protrusion 460a of the temperature sensor 460 is positioned between the outer joint 250a and outer joint 250c of the fixing part 250 in the circumferential direction Z. The inner protrusion 460b of the temperature sensor 460 is positioned between the inner joint 250b and inner joint 250d of the fixing part 250 in the circumferential direction Z. This prevents the temperature sensor 160 from coming loose in the circumferential direction Z, and also allows the temperature sensor 460 to be positioned radially in the X direction, axially in the Y direction, and circumferentially in the Z direction, thereby reducing manufacturing variations.

[0056] Embodiment 5. Figure 22 is a perspective view showing the configuration of the busbar unit of the stator of a rotating electric machine according to Embodiment 5. Figure 23 is a front view showing the manufacturing process of the busbar and fixing parts of the busbar unit shown in Figure 22. In the figures, parts that are the same as those in each of the above embodiments are denoted by the same reference numerals and their description is omitted.

[0057] The following describes the busbar unit of the stator of a rotating electric machine according to Embodiment 5, focusing on the differences from the above embodiments. For example, in Embodiment 1, the busbar 140 and the fixing part 150 of the busbar unit 130 are shown to be processed from separate plate-shaped materials. In Embodiment 5, the fixing parts 550 and 551 are made using leftover material from the processing of the busbar 240.

[0058] Specifically, as shown in Figure 23, when processing the busbar 240, the fixing parts 550 and 551 are punched out from the excess material between the protrusions 40W1 and 40V2. In order to utilize the excess material in this way, at the time of punching in Figure 23, the relationship between the axial length 550X of the fixing parts 550 and 551 and the axial length 250Y of the protrusion 40W1 of the busbar 240 is 550X < 250Y. By manufacturing the fixing parts 550 and 551 from the excess material during the processing of the busbar 240 in this way, the material yield during the processing of the busbar 240 is increased, and the cost of the product can be reduced.

[0059] As shown in Figure 22, the busbar unit 530 is formed from a busbar 240, a fixing part 550, a fixing part 551, and a temperature sensor 460. The fixing part 550 is joined to the outer projection 240a of the busbar 240 by its bent outer joint 550a, and to the inner projection 240b of the busbar 240 by its bent inner joint 550b. The fixing part 551 is joined to the outer projection 240c of the busbar 240 by its bent outer joint 551c, and to the inner projection 240d of the busbar 240 by its bent inner joint 551d.

[0060] Then, the outer protrusion 460a of the temperature sensor 460 is positioned between the outer joint 550a and the outer joint 551c in the circumferential direction Z. In addition, the inner protrusion 460b of the temperature sensor 460 is positioned between the inner joint 550b and the inner joint 551d in the circumferential direction Z. This prevents the temperature sensor 160 from coming loose in the circumferential direction Z, and also allows the temperature sensor 460 to be positioned radially in the X direction, axially in the Y direction, and circumferentially in the Z direction, thereby reducing manufacturing variations.

[0061] The stator of the rotating electric machine of Embodiment 5, configured as described above, provides the same effects as those of each of the embodiments described above, The aforementioned fixing component is formed of the same material and with the same plate thickness as the busbar. Therefore, By using leftover material from busbar processing to manufacture fixing parts, material yield can be improved, and product costs can be reduced.

[0062] Embodiment 6. Figure 24 is a perspective view showing the configuration of the busbar unit of the stator of a rotating electric machine according to Embodiment 6. Figure 25A is a perspective view showing the configuration of the fixing components of the busbar unit shown in Figure 24, and Figure 25B is a perspective view from another direction showing the configuration of the fixing components shown in Figure 25A. In the figures, parts that are the same as those in each of the above embodiments are denoted by the same reference numerals and their descriptions are omitted.

[0063] The following describes the busbar unit of the stator of the rotating electric machine according to Embodiment 6, focusing on the parts that differ from the above embodiments. As shown in Figure 25, the fixing part 650 has two outer joints 250a and 250c that protrude outward in the axial direction Y, and two inner joints 250b and 250d that protrude inward in the axial direction Y, as well as locking parts 650e and 650f that protrude on both sides in the circumferential direction Z and engage with both sides of the temperature sensor 160 in the circumferential direction Z, respectively.

[0064] As shown in Figure 24, the busbar unit 630 is formed from a busbar 240, a fixing part 650, and a temperature sensor 160. Two sides of the temperature sensor 160 in the circumferential direction Z can be brought into contact with the locking parts 650e and 650f, respectively. This reliably prevents the temperature sensor 160 from coming out of the busbar unit 630 in the circumferential direction Z. Therefore, the position of the temperature sensor 160 is restricted in the radial direction X, axial direction Y, and circumferential direction Z, thus reducing manufacturing variations.

[0065] The stator of the rotating electric machine of Embodiment 6, configured as described above, provides the same effects as those of each of the embodiments described above, The fixing component is equipped with locking portions that engage with both circumferential sides of the temperature sensor. Therefore, This reliably prevents the temperature sensor from coming loose in the circumferential direction, thereby reducing manufacturing variations.

[0066] While this disclosure describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but are applicable individually or in various combinations to the embodiments. Accordingly, countless variations not illustrated are conceivable within the scope of the art disclosed in this specification. These include, for example, modifying, adding or omitting at least one component, or even extracting at least one component and combining it with components of other embodiments.

[0067] The various aspects of this disclosure are summarized below as an appendix.

[0068] (Note 1) A stator core having a cylindrical yoke portion and a plurality of teeth portions that protrude radially inward from the inner circumferential surface of the yoke portion at circumferential intervals, It has a coil installed in a slot formed between adjacent teeth in the circumferential direction, The coil has a coil body portion arranged in the slot and a coil terminal protrusion portion connected to the coil body portion and protruding from the stator core. A busbar connecting multiple coil terminal protrusions, A temperature sensor for measuring the temperature of the coil, A stator for a rotating electric machine, comprising a metal fixing component that sandwiches and fixes the temperature sensor between the busbar and the busbar in the radial direction, on the radially outer side of the busbar. (Note 2) The temperature sensor has a rectangular cross-section perpendicular to the circumferential direction of the main body, and the two corners of the rectangle on the side away from the busbar are chamfered. A stator of a rotating electric machine as described in Appendix 1, having an air gap between the corner portion of the temperature sensor and the fixing component. (Note 3) The temperature sensor has a main body formed in the shape of a rectangular parallelepiped. The axial end faces and radial outer surface of the main body of the temperature sensor are in contact with the fixing part. The radial inner surface of the main body of the temperature sensor is in contact with the busbar, A stator of a rotating electric machine as described in Appendix 1 or Appendix 2, in which the position of the temperature sensor is restricted. (Note 4) The busbar has a sensor mounting section for installing the temperature sensor, The sensor mounting portion has an outer projection that protrudes outward in the axial direction and an inner projection that protrudes inward in the axial direction. The fixing component has an outer joint that connects to the outer protrusion of the busbar and an inner joint that connects to the inner protrusion of the busbar. The axial position of the end of the outer projection of the busbar is the same as or axially outward the axial position of the end of the outer joint of the fixing part. The stator of a rotating electric machine according to any one of the appendices 1 to 3, wherein the axial position of the end of the inner projection of the busbar is the same as or axially inward of the end of the inner joint of the fixing part. (Note 5) The outer joint and the inner joint of the aforementioned fixing component are each formed in two locations. The stator of the rotating electric machine described in Appendix 4 is joined and fixed at two locations on the outer protrusions of the busbar and at two locations on the inner protrusions of the busbar, respectively. (Note 6) The aforementioned fixing component includes an elastic curved portion that presses the radial outer surface from the radial outside to the inside, The curved portion presses the temperature sensor from the radial outside to the inside, and holds the temperature sensor by clamping it with the busbar, as described in any one of Appendix 1 to Appendix 5, for the stator of a rotating electric machine. (Note 7) The temperature sensor has a rectangular cross-section perpendicular to the circumferential direction of the main body, and the corners of the fixing component corresponding to the two corners of the rectangle away from the busbar are formed with a bulge on the axial outer side and the axial inner side, respectively. The axial distance of the fixing component that clamps both axial ends of the temperature sensor is A stator for a rotating electric machine according to any one of the appendices 1 to 6, wherein the distance between the bulging corners of the fixed component is smaller than the axial distance between them. (Note 8) The fixing component is a stator of a rotating electric machine according to any one of the appendices 1 to 7, which has locking parts that engage with both circumferential sides of the temperature sensor. (Note 9) The busbar is connected to the three-phase coil terminal protrusions and serves as the neutral point in the stator of the rotating electric machine described in any one of Appendix 1 to Appendix 8. (Note 10) The aforementioned fixing component is formed of the same material and thickness as the busbar, and is a stator for a rotating electric machine as described in any one of Appendix 1 to Appendix 9. [Explanation of Symbols]

[0069] 100 rotating electric machines, 130 busbar units, 140 busbars, 150 Fixing part, 140a outer protrusion, 140b inner protrusion, 141 Sensor installation part, 150a outer joint part, 150b inner joint part, 160 temperature sensor, 161 main body, 161a top surface, 161b bottom surface, 161c outer surface, 161d inner surface, 161e corner, 161f corner, 2 Power supply bracket, 20 coil, 20a L-shaped coil, 20a1 coating stripping portion, 20a2 Hypotenuse section, 20a3 Straight section, 20a4 Coating removal section, 20U1a Power supply section, 20U2a power supply unit, 20V1a power supply unit, 20V2a power supply unit, 20W1a power supply unit, 20W2a Power supply unit, 20U1b Coil terminal, 20U1c Coil terminal, 20U1d coil terminal, 20U1e coil terminal, 20U1f coil terminal, 20U1g coil terminal, 20U1h coil terminal protrusion, 20U2h coil terminal protrusion, 20V1h coil terminal protrusion, 20V 2h coil terminal protrusion, 20W 1h coil terminal protrusion, 20W2h coil terminal protrusion, 20U2a power supply section, 20V1a power supply section, 20V2A power supply unit, 20W1A power supply unit, 21 stator core, 230 Busbar unit, 240 Busbar, 240a Outer projection, 240b inner protrusion, 240c outer protrusion, 240d inner protrusion, 241 Sensor installation part, 250 Fixed parts, 250a Outer joint part, 250b inner joint, 250c outer joint, 250d inner joint, 250e curved section, 3 output side bracket, 350 fixing part, 350a corner section, 350b corner section, 4 bearings, 40p bent section, 40U1 protruding section, 40U2 protrusion, 40V1 protrusion, 40V2 protrusion, 40W1 protrusion, 40W2 protrusion, 40V1 protrusion, 40V2 protrusion, 430 busbar unit, 460 Temperature sensor, 460a Outer protrusion, 460b Inner protrusion, 461 Main body, 5 shafts, 530 busbar units, 550 mounting parts, 551 mounting parts, 550a outer joint, 550b inner joint, 551c outer joint, 551d Inner joint, 6 Rotor, 630 Busbar unit, 650 Fixing parts, 650e Locking part, 650f Locking part, 7 Stator, 71 Power supply side coil end, 72 Output coil end, 73 Stator core, 73a Yoke section, 73b Teeth section, 73c Slot, 8 Permanent magnets, O Axis, X Radial direction, X1 Outer, X2 Inner, Y Axis, Z Circumferential, cw Clockwise CCW: Counterclockwise.

Claims

1. A stator core having a cylindrical yoke portion and a plurality of teeth portions that protrude radially inward from the inner circumferential surface of the yoke portion at circumferential intervals, It has a coil installed in a slot formed between adjacent teeth in the circumferential direction, The coil has a coil body portion arranged in the slot and a coil terminal protrusion portion connected to the coil body portion and protruding from the stator core. A busbar connecting multiple coil terminal protrusions, A temperature sensor for measuring the temperature of the coil, A stator for a rotating electric machine, comprising a metal fixing component that sandwiches and fixes the temperature sensor between the busbar and the busbar in the radial direction, on the radially outer side of the busbar.

2. The temperature sensor has a rectangular cross-section perpendicular to the circumferential direction of the main body, and the two corners of the rectangle on the side away from the busbar are chamfered. The stator of the rotating electric machine according to claim 1, wherein there is an air gap between the corner portion of the temperature sensor and the fixing part.

3. The temperature sensor has a main body formed in the shape of a rectangular parallelepiped. The axial end faces and radial outer surface of the main body of the temperature sensor are in contact with the fixing part. The radial inner surface of the main body of the temperature sensor is in contact with the busbar, A stator of a rotating electric machine according to claim 1 or claim 2, wherein the position of the temperature sensor is restricted.

4. The busbar has a sensor mounting section for installing the temperature sensor, The sensor mounting portion has an outer projection that protrudes outward in the axial direction and an inner projection that protrudes inward in the axial direction. The fixing component has an outer joint that connects to the outer protrusion of the busbar and an inner joint that connects to the inner protrusion of the busbar. The axial position of the end of the outer projection of the busbar is the same as or axially outward the axial position of the end of the outer joint of the fixing part. The stator of a rotating electric machine according to claim 1 or claim 2, wherein the axial position of the end of the inner projection of the busbar is the same as or axially inward of the end of the inner joint of the fixing part.

5. The outer joint portion and the inner joint portion of the aforementioned fixing component are each formed in two locations. The stator of a rotating electric machine according to claim 4, wherein the fixing component is joined and fixed at two locations on the outer protrusion of the busbar and at two locations on the inner protrusion of the busbar.

6. The aforementioned fixing component includes an elastic curved portion that presses the radial outer surface from the radial outside to the inside, The stator of a rotating electric machine according to claim 1 or 2, wherein the curved portion presses the temperature sensor from the radial outside to the inside and holds the temperature sensor by clamping it with the busbar.

7. The temperature sensor has a rectangular cross-section perpendicular to the circumferential direction of the main body, and the corners of the fixing component corresponding to the two corners of the rectangle away from the busbar are formed with a bulge on the outer and inner sides in the axial direction, respectively. The axial distance of the fixing component that clamps both axial ends of the temperature sensor is The stator of a rotating electric machine according to claim 1 or claim 2, wherein the distance between the bulging corners of the fixed part is smaller than the axial distance between the axial distances of the fixed part.

8. The stator of a rotating electric machine according to claim 1 or claim 2, wherein the fixing component is provided with locking portions that engage with both circumferential sides of the temperature sensor.

9. The stator of a rotating electric machine according to claim 1 or claim 2, wherein the busbar is connected to the three-phase coil terminal protrusions and serves as a neutral point.

10. The stator of a rotating electric machine according to claim 1 or claim 2, wherein the fixing component is formed of the same material and thickness as the busbar.

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