Rotating electric machines and vehicles

Abstract

In the present invention, a rotary electric machine comprises: a rotor; a ring-shaped stator provided with a plurality of stator core blocks arranged around a magnet of the rotor; a plurality of insulating members covering each of the plurality of stator core blocks; a plurality of coils wound on each of the plurality of stator core blocks with each of the plurality of insulating members interposed therebetween; and a bus ring locked to the plurality of insulating members. The bus ring is provided with an inner ring provided with a terminals to which the conductor wires of each of the plurality of coils are connected, an outer ring that is disposed radially outward of the inner ring and that is locked to the plurality of insulating members, and a bridge part that connects the inner ring and the outer ring and that forms a gap in the radial direction between the inner ring and the outer ring.

Description

[Technical Field]

[0001] The present invention relates to a rotating electric machine that collects and distributes power to windings wound around a plurality of stator cores. and vehicles Regarding. [Background technology]

[0002] BACKGROUND ART Conventionally, a bus ring that collects and distributes motor current (collects and distributes current) is known for, for example, a stator winding in a three-phase AC motor (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-124009 Summary of the Invention [Problem to be solved by the invention]

[0004] In the technology disclosed in Patent Document 1, the bus ring is positioned by abutting against an insulating member provided on the stator, and terminals are provided on the circumferential portion of the bus ring. Therefore, when designing an electric motor with a different motor diameter and the distance from the rotor's rotating shaft to the stator changes, the shape of the bus wires to the terminals must also be changed. This has led to an issue of increased design costs when designing a rotating electric machine with a different motor diameter, such as a different distance from the rotor's rotating shaft to the stator core.

[0005] The present invention has been made in view of the above-mentioned problems, and aims to provide a technique that can reduce the design costs of bus rings when designing rotating electric machines with different motor diameters. [Means for solving the problem]

[0006] According to the present invention, a rotating electric machine includes: A rotor, an annular stator including a plurality of stator core blocks arranged to surround the magnets of the rotor; a plurality of insulating members covering the stator core block; a plurality of coils wound around the stator core block via the plurality of insulating members; a bus ring engaged with the plurality of insulating members; A rotating electric machine comprising: The bus ring is an inner ring provided with terminals to which the conductor wires of the coil are connected; an outer ring disposed radially outward of the inner ring and engaged with the insulating members; a bridge portion connecting the inner ring and the outer ring and forming the radial gap between the inner ring and the outer ring; Equipped with 、 The outer ring has projections that engage the insulating members. It is characterized by: [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a technique that can reduce the design cost of a bus ring when designing rotating electric machines with different motor diameters. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a diagram showing the structure of a rotating electric machine according to an embodiment of the present invention; [Figure 2] FIG. [Figure 3] 3A and 3B are diagrams showing the structures of a stator core block and an insulating member. [Figure 4] FIG. 2 is a diagram showing the structure of a bus ring. [Figure 5A] Close-up of the bus ring. [Figure 5B] FIG. [Figure 6A] 4A and 4B are diagrams showing the assembly process of the bus ring and the stator. [Figure 6B] 4A and 4B are diagrams showing the assembly process of the bus ring and the stator. [Figure 6C] 4A and 4B are diagrams showing the assembly process of the bus ring and the stator. [Figure 6D] 4A and 4B are diagrams showing the assembly process of the bus ring and the stator. [Figure 7A] 5A to 5C are diagrams showing a manufacturing process of a bus ring. [Figure 7B] 5A to 5C are diagrams showing a manufacturing process of a bus ring. [Figure 8] FIG. 10 is a diagram showing the structure of a modified example of a rotating electric machine. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0010] Fig. 1 shows a cross-sectional structure of a rotating electric machine according to this embodiment. The rotating electric machine 1 in Fig. 1 includes a stator 10, a bus ring 20, a rotor 30, and a bracket 40. The rotating electric machine 1 is a vehicle generator mounted on a vehicle such as a motorcycle.

[0011] The stator 10 is made up of stator core blocks 1001 to 100 n (n is an integer, n=12 in this embodiment), insulating members 1101 to 110 n , coil 1201~120 n Hereinafter, the stator core blocks 1001 to 100 n , insulating members 1101 to 110 n , and coils 1201 to 120 n These may be referred to as the stator core block 100, insulating member 110, and coil 120 without distinction. A set of stator core block 100, insulating member 110, and coil 120 is also called a tooth, and a plurality of teeth are combined to form the annular stator 10. The insulating member 110 covers the stator core block 100 and is made of a material such as resin that electrically insulates the stator core block 100 from the coil 120. The coil 120 is made of a conductor wound around the insulating member 110. Both ends of the conductor of the coil 120 are wired to the bus ring 20 side.

[0012] Bus ring 20 includes insulating ring 200 and buses 2101 to 2104. Hereinafter, buses 2101 to 2104 may be referred to as bus 210 without distinction. Insulating ring 200 is a member for fixing bus 210, which supplies power to coil 120, while electrically insulating it from rotor 30 and stator core block 100. Bus ring 20 is positioned by abutting against stator 10, as will be described later with reference to FIGS. 5A and 5B.

[0013] The rotor 30 includes a shaft 300, a plate 310, and magnets 3201 to 320. m (m is an integer, m=8 in this embodiment). m 2, the rotor 30 is arranged so that the magnets 320 are surrounded by the stator 10. The magnetic field generated by supplying power to the coils 120 interacts with the magnetic field formed by the magnets 320, causing the plate 310 on which the magnets 320 are arranged to rotate.

[0014] Stator 10, bus ring 20, and rotor 30 are housed in bracket 40. Stator 10 is fixed to bracket 40, and the bus ring is fixed to stator 10. This causes rotor 30 to rotate around shaft 300 as the rotation axis.

[0015] As shown in FIG. 1, the stator 10, the bus ring 20, and the rotor 30 have an annular or disc-like shape, and share the axial, circumferential, and radial directions.

[0016] FIG. 2 shows a cross-sectional view of the rotating electrical machine 1 taken along dotted line AA' in FIG. 1, in a plane parallel to the axis of the rotor 30. As shown in FIG.

[0017] Stator 10 is disposed so as to surround magnets 320 installed on rotor 30. Bus ring 20 is disposed axially above plate 310 of rotor 30. Magnets 320 are sandwiched between stator core blocks 100 of stator 10 and rotate shaft 300 via plate 310. Shaft 300 of rotor 30 extends outside bracket 40 and is connected to the drive unit of the vehicle.

[0018] 3 is a diagram showing the structure of one set of stator core blocks 100 and insulating members 110. The stator core block 100 has recessed portions 101 and protruding portions 102 for engaging with another adjacent stator core block 100. The stator core block 100 also has mounting holes 103, and the stator 10 can be fixed to the generator cover by fastening the tip of a bolt passed through the mounting hole 103 to a bolt hole formed on the inner surface of the generator cover.

[0019] The recessed portion 101 and the protruding portion 102 are engagement structures for engaging with the protruding portion 102 and the recessed portion 101 of the adjacent stator core block 100, respectively, as shown in Fig. 1. By fitting the protruding portion 102 of one stator core block 100 into the recessed portion 101 of the other stator core block 100, it is possible to position the multiple stator core blocks 100 relative to each other.

[0020] The insulating member 110 includes a contact portion 111 for positioning with the stator core block 100, a core portion 112 for winding copper wire to form the coil 120, a guide portion 113 for guiding both ends of the coil toward the bus ring 20, and an engagement portion 114 for engaging with the bus ring 20.

[0021] Abutment portion 111 is a structure for positioning insulating member 110 and stator core block 100 by pressing it against T-shaped stator core block 100 until it abuts against it. Core portion 112 has a bobbin structure for preventing the conductor wound around core portion 112 from moving toward stator core block 100 or bus ring 20. Guide portion 113 is a notched (concave) portion provided in core portion 112 and is a structure for guiding both ends of the conductor of coil 120 toward bus ring 20. In one example, guide portion 113 may not be a notched shape, but may be a hole-shaped portion provided on the bus ring 20 side of core portion 112. Engagement portion 114 is a structure for fixing the positions of bus ring 20 and stator 10. The shape of engagement portion 114 will be described later with reference to FIG. 4(B).

[0022] 4 is a diagram showing the structure of bus ring 20. Buses 2101 to 2104 include buses 2101 to 2103 connected to grommets 2111 to 2113 corresponding to the three-phase outputs of the generator, and bus 2104 connecting a plurality of coils 120. In FIG. 4, four buses 2104 are provided. In addition, buses 2101 to 2104 have a total of 2n terminals 2121 to 2122. 2n (In this embodiment, 2n=24) are provided. 2n They may be referred to as terminals 212 without distinction. Bolts for connecting external output harnesses are connected to the grommets 2111 to 2113.

[0023] In the example of FIG. 4, the bus 2104 has a terminal 212 2i-1 (i=1 to n) are connected to the bus 2101, and the terminals 2122, 2128, and 212 14 , 212 20 are connected to the bus 2102, and the terminals 2126 and 212 12 , 212 18 , 212 24 are connected to the bus 2103, and the terminals 2124 and 212 10 , 212 16 , 212 22 The conducting wire from coil 120 is fixed by clamping and crimping it with terminal 212 on the bus ring 20 side, as will be described later with reference to FIG. 6D.

[0024] The insulating ring 200 is formed of resin and includes an outer ring 201, an inner ring 202, and bridges 203. The outer ring 201 has an engagement structure, which will be described later with reference to FIG. 5A, and is connected to the inner ring 202 by one or more bridges 203. In the example of FIG. 4, six bridges 203 are arranged at equal intervals in the circumferential direction of the bus ring 20. The outer ring 201 has a shape concentric with the inner ring 202, and the bridges 203 extend in the radial direction of the outer ring 201 and the inner ring 202. This allows a gap 204 to be formed between the outer ring 201 and the inner ring 202. A terminal 212 is arranged to overlap this gap 204 in the axial direction of the rotor 30. In other words, the terminal 212 is arranged to protrude radially outward from the inner ring 202. Furthermore, the gap 204 is arranged to overlap at least a portion of the magnet 320 in the axial direction of the rotor 30. This improves the heat dissipation performance of the magnet 320. Furthermore, terminal 212 is disposed at a position that does not overlap magnet 320 in the axial direction of bus ring 20. For example, terminal 212 is disposed closer to the center of inner ring 202 than magnet 320 in the radial direction of bus ring 20. This prevents terminal 212 from interfering with heat dissipation from magnet 320.

[0025] The positioning of bus ring 20 and stator 10 will be described with reference to FIGS. 5A and 5B.

[0026] 5A is an enlarged view of bus ring 20. As shown in FIG. 5A, protrusions (protrusions) 501 are arranged on outer ring 201. In one example, protrusions 501 are arranged at positions that overlap bridges 203 in the circumferential direction. This allows bridges 203 to support the radial load applied to outer ring 201 via protrusions 501 when positioning bus ring 20 and stator 10, preventing bus ring 20 from being damaged when positioning bus ring 20 and stator 10.

[0027] Furthermore, bridge 203 is positioned so as not to overlap terminal 212 in the axial direction of bus ring 20. This reduces the axial thickness of bus ring 20, enabling bus ring 20 to be made thinner, which contributes to reduced manufacturing costs and a more compact rotating electric machine.

[0028] FIG. 5B is an enlarged view of insulating member 110 of stator 10. First recess 511, guide portion 512, second recess 513, and support portion 514 are provided on insulating member 110 on the bus ring 20 side. First recess 511 is recessed radially more than other portions, and bus ring 20 can be placed on support portion 514 by aligning protrusion 501 of bus ring 20 with first recess 511. That is, the radial distance from the center of stator 10 to first recess 511 is greater than the radial distance from the center of bus ring 20 to the tip of protrusion 501, and the radial distance from the center of stator 10 to support portion 514 is smaller than the radial distance. Thus, by aligning protrusion 501 of bus ring 20 with first recess 511 and fitting it in the axial direction until it abuts against support portion 514, stator 10 allows bus ring 20 to move in the circumferential direction while restricting radial movement relative to stator 10.

[0029] Next, bus ring 20, which has been fitted in the axial direction with protrusions 501 aligned with first recesses 511 of stator 10, is rotated in the circumferential direction of stator 10 so that protrusions 501 move toward second recesses 513. In this way, protrusions 501 are moved via guide portions 512 until they engage with second recesses 513, making it easier to align stator 10 and bus ring 20.

[0030] 5A , terminal 212 has a U-shape that opens in the rotational direction in the circumferential direction of bus ring 20 so that the conductor wire extending through guide portion 113 can be easily sandwiched when stator 10 and bus ring 20 are aligned. This reduces the effort required to sandwich both ends of the conductor wire of coil 120 between terminal 212. Furthermore, first recess 511, guide portion 512, and second recess 513 are positioned so that they do not overlap guide portion 113 and stator 10 in the circumferential direction. This prevents the conductor wire passing through guide portion 113 from hitting protrusion 501 when positioning bus ring 20 and stator 10, improving the convenience of positioning.

[0031] 6A to 6D are diagrams showing the process of assembling stator 10 and bus ring 20. FIG.

[0032] First, twelve stator cores are manufactured by winding a conductor around a set of stator core block 100 and insulating member 110 shown in Fig. 3 to form coils 120. Next, the recessed portions 101 and protruding portions 102 of the twelve stator cores are combined to form stator 10 as shown in Fig. 5A.

[0033] Next, as shown in Fig. 6B, bus ring 20 is placed on stator 10. This is done by aligning protrusions 501 of bus ring 20 with first recesses 511 of stator 10 and fitting them in the axial direction, and bringing them into contact with support portions 514, as described with reference to Figs. 5A and 5B.

[0034] Next, as shown in Fig. 6C, bus ring 20 is rotated relative to stator 10 in the circumferential direction of stator 10. As described with reference to Figs. 5A and 5B, by rotating bus ring 20 relative to stator 10 until protrusions 501 engage with second recesses 513 via guide portions 512, the conductor wires at both ends of coil 120 can be easily guided to positions where they are sandwiched between terminals 212.

[0035] 6D, a load is applied to the terminals 212, and a crimping process is performed to crimp the conductor wire of the coil 120 sandwiched between the U-shaped terminals 212 to the terminals 212. In this embodiment, the crimping process is performed by a simultaneous crimping method so that all the terminals 212 are crimped at the same time.

[0036] The manufacturing process of bus ring 20 will be described with reference to FIGS. 7A and 7B.

[0037] As shown in FIG. 7A, buses 2101 to 2104 of bus ring 20 are manufactured by cutting out a flat metal plate, shaping the cut-out parts into circles, forming bridge sections that connect terminals fixed to inner ring 202 of bus ring 20, and shaping each terminal 212 into a U-shape.

[0038] Next, as shown in FIG. 7B, manufactured buses 2101 to 2104 are fitted into insulating ring 200 made of resin, thereby manufacturing bus ring 20.

[0039] <Modification> FIG. 8 shows the configuration of stator 10 and bus ring 20 applicable to motors with larger diameters. In FIG. 8, when the motor diameter is larger, stator 10 can be designed so that the distance from axis 300 of rotor 30 to stator core block 100 in the radial direction of stator 10 is increased. Even in such a case, as shown in FIG. 8, inner ring 202 can have a configuration similar to that shown in FIG. 1 by increasing the radius of outer ring 201 of bus ring 20 and lengthening bridges 203 in the radial direction of stator 10. Therefore, buses 2101 to 2104 of bus ring 20 can be the same as those shown in FIG. 1, and only insulating ring 200 of bus ring 20 needs to be redesigned, thereby reducing the design cost of bus ring 20.

[0040] As described above, according to this embodiment, bus ring 20, which carries wiring for power collection and distribution, is disposed on the inner periphery of stator 10. Furthermore, according to this embodiment, bus ring 20 includes outer ring 201, inner ring 202, and bridge 203 connecting outer ring 201 and inner ring 202, and inner ring 202 is provided with terminal 212. Furthermore, bridge 203 connects outer ring 201 and inner ring 202 so that gap 204 is formed between outer ring 201 and inner ring 202. This makes it possible to reduce the cost of conductors for wiring bus 210 and the amount of resin used to form the bus ring.

[0041] Furthermore, according to this embodiment, the magnets 320 of the rotor 30 are arranged so that at least a portion of them faces the gap 204. This makes it possible to improve the cooling performance of the magnets 320 of the rotor 30.

[0042] Furthermore, according to this embodiment, the transition portions connecting the terminals of buses 2101 to 2104 of bus ring 20 have a three-quarter circle shape cut out in the radial direction and a flat shape in the circumferential direction. This makes it possible to form bus 210 by circularly molding a bus bar cut or stamped out from a flat metal plate, thereby reducing material costs during manufacturing.

[0043] Furthermore, according to this embodiment, the rotating electric machine 1 is disposed on the vehicle so that the shaft 300 of the rotor 30 is parallel to the road surface. In such a case, the terminals 212 of the rotating electric machine 1 are disposed closer to the shaft of the rotor 30, i.e., at positions farther from the road surface. Therefore, even if the vehicle enters a puddle or the like, the possibility of the terminals 212 becoming submerged in water can be further reduced, and the submersion resistance of the rotating electric machine 1 can be further improved.

[0044] <Other embodiments> The invention is not limited to the above-described embodiment, and various modifications and variations are possible within the scope of the gist of the invention.

[0045] For example, although the number of stator core blocks 100 is shown as being 12 in this embodiment, a greater or lesser number of stator core blocks 100 may be used.

[0046] Furthermore, in this embodiment, the terminals 212 are configured to protrude radially outward from the inner ring 202, but may be arranged at positions overlapping the inner ring 202 in the axial direction.

[0047] <Summary of the embodiment> 1. The rotating electric machine of the above embodiment (for example, the rotating electric machine 1) a rotor (e.g., rotor 30); an annular stator (e.g., stator 10) including a plurality of stator core blocks (e.g., stator core blocks 100) arranged to surround the magnets (e.g., magnets 320) of the rotor; a plurality of insulating members (e.g., insulating members 110) covering the plurality of stator core blocks, respectively; a plurality of coils (e.g., coil 120) wound around each of the plurality of stator core blocks via each of the plurality of insulating members; a bus ring (e.g., bus ring 20) that is engaged with the plurality of insulating members; A rotating electric machine comprising: The bus ring is an inner ring (e.g., inner ring 202) provided with terminal portions (e.g., terminals 212) to which the respective conductor wires of the plurality of coils are connected; an outer ring (e.g., outer ring 201) disposed radially outward of the inner ring and engaged with the plurality of insulating members; a bridge portion (e.g., bridge 203) connecting the inner ring and the outer ring and forming a radial gap (e.g., gap 204) between the inner ring and the outer ring; Equipped with.

[0048] This makes it possible to reduce the design cost when designing rotating electrical machines with different motor diameters.

[0049] 2. In the rotating electric machine of the above embodiment, The terminal portion is disposed radially inside the outer ring and protrudes radially outward from the inner ring.

[0050] This allows the thickness of the bus ring to be reduced, making it possible to downsize the rotating electrical machine.

[0051] 3. In the rotating electric machine of the above embodiment, In the axial direction of the rotor, the bridge portion of the bus ring is disposed at a position where it does not overlap with the terminal portion.

[0052] This allows the thickness of the bus ring to be reduced, making it possible to downsize the rotating electrical machine.

[0053] 4. In the rotating electric machine of the above embodiment, the outer ring has protrusions (e.g., protrusions 501) that engage with the insulating members; The protrusion is disposed at a position overlapping the bridge portion in the circumferential direction of the bus ring.

[0054] This makes it possible to support the load applied to protrusions 501 in the radial direction of the bus ring, and to prevent damage to bus ring 20.

[0055] 5. In the rotating electric machine of the above embodiment, The magnet of the rotor is disposed at a position where it at least partially overlaps with the gap in the direction of the rotation axis of the rotor.

[0056] This allows the magnet 320 to efficiently dissipate heat through the gap 204 .

[0057] 6. In the rotating electric machine of the above embodiment, The terminal portion of the bus ring is disposed radially inward of the magnet of the rotor.

[0058] This prevents the terminal 212 from interfering with heat dissipation from the magnet 320 .

[0059] 7. The vehicle of the above embodiment is The rotating electric machine of the above embodiment is disposed so that the rotation axis direction of the rotor is substantially parallel to the road surface.

[0060] This improves the vehicle's resistance to submersion in water.

[0061] 8. The bus ring of the above embodiment is A rotor, an annular stator including a plurality of stator core blocks arranged to surround the magnets of the rotor; a plurality of insulating members covering the plurality of stator core blocks, respectively; a plurality of coils wound around each of the plurality of stator core blocks via each of the plurality of insulating members; A bus ring for a rotating electric machine comprising: an inner ring provided with terminals to which the conductor wires of the plurality of coils are connected; an outer ring disposed radially outward of the inner ring and engaged with the insulating members; a bridge portion connecting the inner ring and the outer ring and forming the radial gap between the inner ring and the outer ring; Equipped with.

[0062] This reduces the cost of designing bus rings for stators of different diameters.

[0063] The present invention is not limited to the above-described embodiments, and various modifications and variations can be made without departing from the spirit and scope of the present invention. Therefore, to apprise the public of the scope of the present invention, the following claims are appended.

Claims

1. A rotor, an annular stator including a plurality of stator core blocks arranged to surround the magnets of the rotor; a plurality of insulating members covering the plurality of stator core blocks, respectively; a plurality of coils wound around each of the plurality of stator core blocks via each of the plurality of insulating members; a bus ring engaged with the plurality of insulating members; A rotating electric machine comprising: The bus ring is an inner ring provided with terminal portions to which the conductor wires of the plurality of coils are connected; an outer ring disposed radially outward of the inner ring and engaged with the insulating members; a bridge portion connecting the inner ring and the outer ring and forming the radial gap between the inner ring and the outer ring; Equipped with The rotating electric machine according to claim 1, wherein the outer ring has protrusions that engage with the insulating members.

2. The rotating electric machine according to claim 1 , wherein the terminal portion is disposed on the radially inner side of the outer ring so as to protrude radially outward from the inner ring.

3. 2. The rotating electric machine according to claim 1, wherein the bridge portion of the bus ring is disposed at a position that does not overlap with the terminal portion in the axial direction of the rotor.

4. A rotating electric motor as described in claim 1, characterized in that the protrusion is arranged in a position that overlaps with the bridge portion in the circumferential direction of the bus ring.

5. 2. The rotating electric machine according to claim 1, wherein the magnet of the rotor is disposed at a position that at least partially overlaps with the gap in the direction of the rotation axis of the rotor.

6. 2. The rotating electric machine according to claim 1, wherein the terminal portion of the bus ring is disposed radially inward of the magnet of the rotor.

7. 10. A vehicle comprising: a rotating electric machine according to claim 1; and a rotor mounted on said rotating electric machine; said rotor having a rotation axis oriented substantially parallel to a road surface.

8. A rotor, an annular stator including a plurality of stator core blocks arranged to surround the magnets of the rotor; a plurality of insulating members covering the plurality of stator core blocks, respectively; a plurality of coils wound around each of the plurality of stator core blocks via each of the plurality of insulating members; a bus ring engaged with the plurality of insulating members; A rotating electric machine comprising: The bus ring is an inner ring provided with terminal portions to which the conductor wires of the plurality of coils are connected; an outer ring disposed radially outward of the inner ring and engaged with the insulating members; a bridge portion connecting the inner ring and the outer ring and forming the radial gap between the inner ring and the outer ring; Equipped with The rotating electric machine is characterized in that the magnet of the rotor is arranged at a position where at least a part of the magnet overlaps with the gap in the direction of the rotation axis of the rotor.

9. A rotor, an annular stator including a plurality of stator core blocks arranged to surround the magnets of the rotor; a plurality of insulating members covering the plurality of stator core blocks, respectively; a plurality of coils wound around each of the plurality of stator core blocks via each of the plurality of insulating members; a bus ring engaged with the plurality of insulating members; A rotating electric machine comprising: The bus ring is an inner ring provided with terminal portions to which the conductor wires of the plurality of coils are connected; an outer ring disposed radially outward of the inner ring and engaged with the insulating members; a bridge portion connecting the inner ring and the outer ring and forming the radial gap between the inner ring and the outer ring; Equipped with The rotating electric machine according to claim 1, wherein the terminal portion of the bus ring is disposed radially inward of the magnet of the rotor.

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