rotating electrical machines

Abstract

To provide a rotary electric machine that can shorten a busbar terminal.SOLUTION: A motor as a rotary electric machine includes a busbar holder 61 provided on one side of a stator 21 in the axial direction, and a plurality of busbar terminals 71 electrically connecting the stator 21 and a control unit 50. The stator 21 has a plurality of windings 23 provided all around in the circumferential direction. A lead wire 82 is led out to the busbar terminal 71 side in the axial direction from a lead portion 81 positioned between a plurality of windings 23 adjacent in the circumferential direction and positioned on the busbar terminal 71 side of the winding 23. The busbar terminal 71 includes a winding-side terminal portion 72 including two connection portions 73, and a substrate-side terminal portion 77 connected to the substrate 51. The lead wire 82 is wired so as to extend from one of the plurality of lead portions 81 scattered around the entire circumferential direction to one of the plurality of connection portions 73 gathered in a portion of the circumferential direction.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a rotating electric machine. [Background technology]

[0002] A known example of a conventional bus bar terminal for a rotating electric machine is described in Patent Document 1. The bus bar terminal disclosed in Patent Document 1 includes a motor connection member that is electrically connected to the windings of a motor, and a terminal member that is separate from the motor connection member and is electrically connected to an external terminal. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2020 / 261866 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, the motor connecting member is formed continuously over almost the entire circumference in accordance with the multiple windings arranged in a full circumferential alignment, which poses a problem of long busbar terminals and the need for a large amount of material.

[0005] The present invention has been made in view of the above-mentioned points, and an object of the present invention is to provide a rotating electric machine in which the bus bar terminals can be shortened. [Means for solving the problem]

[0006] The rotating electric machine of the present invention includes a stator (21), a rotor (31) rotatable relative to the stator, a control unit (50) connected to the stator, a bus bar holder (61) provided on one side of the stator in the axial direction, and a plurality of bus bar terminals (71) fixed to the bus bar holder. The bus bar terminals electrically connect the stator and the control unit.

[0007] The stator has a plurality of windings (23) arranged all around the circumference. From each of the lead-out portions (81) of all the windings, a lead-out wire (82) is drawn out to the busbar terminal side. The busbar terminal has a winding-side terminal portion (72) including at least one connection portion (73), and a board-side terminal portion (77) connected to the board (51) of the control unit. The plurality of busbar terminals are gathered in a portion of the circumference. The lead-out wire runs from one of the plurality of lead-out portions scattered all around the circumference to one of the plurality of connection portions. Radially inward It is wired to extend.

[0008] This allows the bus bar terminals to be provided only partially in the circumferential direction, which makes the bus bar terminals shorter than in the conventional configuration where the bus bar terminals are provided continuously around the entire circumferential direction, thereby reducing the material cost of the bus bar terminals. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a vertical cross-sectional view of a rotating electric machine according to an embodiment; [Figure 2] 2 is a view of the busbar unit, the stator, and the rotor of FIG. 1 as viewed from the direction of arrow II. [Figure 3] FIG. 3 is a diagram showing the busbar unit of FIG. 2; [Figure 4] 3 is a cross-sectional view of the stator, rotor, and protrusions of the bus bar holder of FIG. 2; [Figure 5] A side view of the busbar terminal in Figure 2, seen from the direction of arrow V. [Figure 6] 6 is a perspective view of the bus bar terminal of FIG. 2 as viewed from the direction of arrow VI. [Figure 7] 3 is a diagram showing the busbar unit of FIG. 2, illustrating a connection portion before crimping. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an embodiment of a rotating electrical machine will be described with reference to the drawings.

[0011] [One embodiment] As shown in Fig. 1, motor 10 as a rotating electric machine is an electromechanical integrated type in which rotating machine section 20 and control section 50 are integrally provided. A bus bar unit 60 is provided between rotating machine section 20 and control section 50 as an electromechanical connection section. Control section 50 controls rotating machine section 20 to generate a desired torque based on information input from the outside and information such as motor current detected inside control section 50. The torque of rotating machine section 20 is output to the outside from the output end of rotating shaft 32.

[0012] Hereinafter, a direction parallel to the rotation axis O of the rotating machine section 20 will be referred to as the axial direction. A direction perpendicular to the rotation axis O will be referred to as the radial direction. A direction around the rotation axis O will be referred to as the circumferential direction.

[0013] The rotating machine section 20 is a three-phase brushless motor and includes a stator 21, a rotor 31, and a housing 41 that accommodates them. The stator 21 has a stator core 22 fixed to the housing 41 and a plurality of windings 23 assembled to the stator core 22. The stator core 22 has a plurality of teeth 24 extending radially. An insulating insulator 25 is attached to the teeth 24. The windings 23 are wound around the insulator 25.

[0014] The rotor 31 has a rotating shaft 32 supported by a rear bearing 45 and a front bearing 46, and a rotor core 33 fixed to the rotating shaft 32. The rotor 31 is provided inside the stator 21 and is rotatable relative to the stator 21. A permanent magnet 47 is provided on one end of the rotating shaft 32.

[0015] The housing 41 has a cylindrical case 42, a rear end frame 43 provided at one end of the case 42, and a front end frame 44 provided at the other end of the case 42. The stator core 22 is fixed inside the case 42. The rear end frame 43 and the front end frame 44 are fastened to each other with bolts (not shown). The rear end frame 43 also functions as a heat sink for the control unit 50.

[0016] The control unit 50 has a substrate 51 arranged on the rotation axis O on the opposite side of the rear frame end 43 from the stator 21, various electronic components mounted on the substrate 51, and a cover 55 arranged to cover the substrate 51 and the various electronic components.

[0017] Although not shown in the figures, the various electronic components described above include, for example, a rotation angle sensor that detects the rotation angle of the rotating shaft 32, a motor drive element that switches the current-carrying state of the multiple windings 23 by performing a switching operation, and a control circuit that performs calculations based on information from the outside or the rotation angle sensor, etc., and issues commands to the motor drive element, etc.

[0018] 1 to 6, the busbar unit 60 includes a busbar holder 61 provided on one side of the axial direction relative to the stator 21, between the stator 21 and the rear end frame 43, and a plurality of busbar terminals 71 fixed to the busbar holder 61 and electrically connecting the stator 21 and the control unit 50. In one embodiment, one busbar terminal 71 is provided corresponding to each of the U phase, V phase, and W phase. That is, three busbar terminals 71 are provided.

[0019] The bus bar holder 61 is made of an insulating material, such as resin, and has a partition wall portion 62, a support portion 63, and a plurality of claw portions 64. The partition wall portion 62 is an annular portion formed continuously in the circumferential direction, and is provided between the stator 21 and the rear end frame 43. The support portion 63 protrudes from the partition wall portion 62 in the other axial direction and abuts against the stator 21. The claw portions 64 protrude from the partition wall portion 62 in the other axial direction and engage with the stator 21.

[0020] The partition wall 62 is provided between the stator 21 and the bus bar terminals 71. The bus bar terminals 71 have a winding-side terminal portion 72 including at least one connection portion 73, and a board-side terminal portion 77 connected to the board 51. In one embodiment, each bus bar terminal 71 is provided with two connection portions 73.

[0021] The connection portion 73 is provided at a position where at least a portion thereof overlaps with the rotor 31 when viewed from the axial direction. The board-side terminal portion 77 is provided radially outward from the connection portion 73. The two connection portions 73 provided on each winding-side terminal portion 72 are gathered together in a portion of the circumferential direction and are spaced apart from the connection portions 73 of the other winding-side terminal portions 72 in the circumferential direction.

[0022] In one embodiment, three board-side terminal portions 77 corresponding to the U-phase, V-phase, and W-phase are arranged in that order, spaced apart in the circumferential direction. For the V-phase busbar terminal 71, the two connection portions 73 are arranged spaced apart in the circumferential direction in an area relatively close to and radially inward from the board-side terminal portions 77. For the W-phase busbar terminal 71, the two connection portions 73 are arranged spaced apart in the circumferential direction in an area radially inward from the board-side terminal portions 77 and spaced apart in the circumferential direction. For the U-phase busbar terminal 71, the two connection portions 73 are arranged spaced apart in the circumferential direction in an area radially inward from the board-side terminal portions 77 and spaced apart in the circumferential direction.

[0023] With respect to the V-phase busbar terminal 71, the winding-side terminal portion 72 has two connection portions 73, extension portions 74 extending from the board-side terminal portion 77 toward each connection portion 73, and press-fit portions 75 press-fitted into the press-fitted portions 65 of the busbar holder 61. With respect to the U-phase and W-phase busbar terminals 71, the winding-side terminal portion 72 has two connection portions 73, the extension portion 74, the press-fit portion 75, and a bent portion 76 connecting the extension portions 74 and the connection portions 73.

[0024] The multiple windings 23 are arranged around the entire circumferential circumference. Lead-out wires 82 are drawn out from lead-out portions 81 of the windings 23 that are located on the busbar terminal 71 side and between multiple circumferentially adjacent windings 23 toward the busbar terminal 71 in the axial direction. The multiple lead-out portions 81 are scattered around the entire circumferential circumference. Meanwhile, all of the connection portions 73 are gathered in a portion of the circumferential circumference. In one embodiment, all of the connection portions 73 are arranged to fit within approximately half of the circumferential circumference. The lead-out wire 82 is wired so as to extend from one of the multiple lead-out portions 81 scattered around the entire circumferential circumference to one of the multiple connection portions 73 gathered in a portion of the circumferential circumference. The busbar terminals 71 are contained within approximately half of the circumferential circumference, and the overall length is relatively short.

[0025] The partition wall 62 has through holes 66 formed to correspond to each of the connection parts 73. The lead wires 82 extend to the connection parts 73 through the through holes 66 and through a wiring space 67 between the partition wall 62 and the stator 21. Two lead wires 82 are connected to each of the connection parts 73.

[0026] The bus bar holder 61 has at least one protrusion 68 that protrudes in the axial direction in the wiring space 67 toward a radially inner portion of the insulator 25 (hereinafter referred to as the inner portion 26). The gap between the protrusion 68 and the inner portion 26 is smaller than the wire diameter of the lead wire 82. In one embodiment, five protrusions 68 are provided at intervals in the circumferential direction.

[0027] 7, the connection portions 73 are hook-shaped before the lead wires 82 are connected. The hook-shaped connection portions 73 are connected to the lead wires 82 by being crimped with the lead wires 82 hooked thereon. All of the connection portions 73 before being crimped are designed to hook the lead wires 82 from one circumferential direction.

[0028] As shown in Figures 1 to 6, the extending portion 74 is provided a short distance away from the partition wall portion 62 in the axial direction. The connecting portion 73 is provided at the same axial position as at least a portion of the extending portion 74. The press-fitted portion 65 is formed to protrude from the partition wall portion 62. The press-fitted portion 75 is formed to protrude in the axial direction from the extending portion 74 toward the partition wall portion 62 and is press-fitted into the press-fitted portion 65. The bent portion 76 protrudes in the axial direction from the extending portion 74 toward the partition wall portion 62 and is formed to be bent in a U-shape toward the opposite side from the partition wall portion 62, and is connected to the connecting portion 73. The bent portion 76 is provided at the same axial position as at least a portion of the press-fitted portion 75.

[0029] The board-side terminal portion 77 has a wide portion 78 that extends in the axial direction from the winding-side terminal portion 72 toward the board 51, and a narrow portion 79 that protrudes from the wide portion 78 into the connection hole 52 of the board 51. The wide portion 78 has a larger cross-sectional area perpendicular to the axial direction than the narrow portion 79.

[0030] (effect) As described above, in one embodiment, the lead wire 82 is wired so as to extend from one of the plurality of lead portions 81 scattered around the entire circumferential direction to one of the plurality of connection portions 73 gathered in a portion of the circumferential direction. This means that it is sufficient to provide the bus bar terminal 71 only in a portion of the circumferential direction, and therefore the bus bar terminal 71 can be shorter than in the conventional configuration in which the bus bar terminal is provided continuously around almost the entire circumferential direction. This reduces the material cost of the bus bar terminal 71.

[0031] In one embodiment, the connection portion 73 is provided at a position where at least a portion thereof overlaps with the rotor 31 when viewed from the axial direction. Therefore, the connection portion 73 can be disposed by effectively utilizing the space on one side of the rotor 31 in the axial direction.

[0032] In one embodiment, the board-side terminal portion 77 is provided radially outward from the connection portion 73. The multiple connection portions 73 provided on each winding-side terminal portion 72 are gathered in a portion of the circumferential direction and are spaced apart from the connection portions 73 of the other winding-side terminal portions 72 in the circumferential direction. This allows each winding-side terminal portion 72 to be arranged so that it does not intersect with the other winding-side terminal portions 72 when viewed in the axial direction. Therefore, the axial height of the three winding-side terminal portions 72 can be reduced compared to a comparative example in which the multiple winding-side terminal portions are configured to intersect with each other when viewed in the axial direction.

[0033] In one embodiment, the bus bar holder 61 has at least one protrusion 68 that protrudes axially toward a radially inner portion of the insulator 25 in the wiring space 67 in which the lead wires 82 are routed. The gap between the protrusion 68 and the insulator 25 is smaller than the diameter of the lead wires 82. This allows the protrusion 68 to act as a wall to prevent the lead wires 82 from moving toward the rotor 31. This prevents the lead wires 82 from getting tangled in the rotor 31 when the motor 10 is operating.

[0034] In one embodiment, the connection portion 73 is provided at the same axial position as at least a portion of the extension portion 74. The bent portion 76 is provided at the same axial position as at least a portion of the press-fit portion 75. This allows the axial height of the winding-side terminal portion 72 to be reduced compared to when the bent portion 76 is provided at a different axial position from the press-fit portion 75.

[0035] In one embodiment, all of the connection portions 73 before crimping are configured to hook the lead wires 82 from one circumferential direction, thereby improving the ease of assembly when connecting the lead wires 82 to the connection portions 73.

[0036] In one embodiment, the bus bar holder 61 has an insulating partition wall 62 provided between the stator 21 and the bus bar terminal 71. This ensures insulation.

[0037] In one embodiment, two or more lead wires 82 are connected to each connection portion 73. This reduces the number of connections between connection portions 73 and lead wires 82, thereby reducing the number of manufacturing steps.

[0038] Here, a problem with the bus bar terminals 71 that connect the rotating machine unit 20 and the control unit 50 will be described. A larger current flows through the bus bar terminals 71 than through signal lines and the like within the control unit 50, and therefore the amount of heat generated is greater. For this reason, it is common to make the bus bar terminals 71 thicker to reduce electrical resistance. However, when the bus bar terminals 71 are joined to the board 51 of the control unit 50 by soldering, thickening the bus bar terminals 71 increases the area to be soldered, which increases the difficulty of the soldering. Therefore, there is a need to reduce the difficulty of soldering the bus bar terminals 71 while suppressing heat generation.

[0039] In this regard, in one embodiment, the board-side terminal portion 77 has a wide portion 78 that extends in the axial direction from the winding-side terminal portion 72 toward the board 51, and a narrow portion 79 that protrudes from the wide portion 78 into the connection hole 52 of the board 51. The wide portion 78 has a larger cross-sectional area perpendicular to the axial direction than the narrow portion 79. This makes it possible to reduce the difficulty of soldering by soldering the relatively thin narrow portion 79 to the board 51, while also reducing electrical resistance and suppressing self-heating by arranging the wide portion 78, which has a relatively large cross-sectional area, next to the narrow portion 79.

[0040] [Other embodiments] In other embodiments, the number of bus bar terminals is not limited to three. The number of windings is not limited to one system, but may be two or more systems. The method of connecting the lead wires to the connection parts is not limited to crimping, but may be other methods such as welding.

[0041] In other embodiments, the bus bar holder may be fixed to a location other than the stator. The method of fixing the bus bar holder is not limited to engagement with claws, and may be other methods such as using screws. The partition wall of the bus bar holder is not limited to being annular, and may be formed in part in the circumferential direction.

[0042] In other embodiments, the control unit is not limited to being provided on one side of the axial direction relative to the rotating machine unit, but may be provided on the radially outer side, and correspondingly, the board-side terminal portion may be formed to extend in a direction other than the axial direction.

[0043] The present invention is not limited to the above-described embodiment, and can be implemented in various forms without departing from the spirit of the invention. [Explanation of symbols]

[0044] 10 motor, 21 stator, 23 winding, 31 rotor, 50 control unit, 51 board, 61 bus bar holder, 71 bus bar terminal, 72 winding side terminal portion, 73 connection portion, 77 board side terminal portion, 81 draw-out portion, 82 draw-out wire.

Claims

1. A stator (21); a rotor (31) provided so as to be rotatable relative to the stator; a control unit (50) connected to the stator; a bus bar holder (61) provided on one side of the stator in the axial direction; a plurality of busbar terminals (71) fixed to the busbar holder and electrically connecting the stator and the control unit; Equipped with The stator has a plurality of windings (23) provided around the entire circumferential circumference, A lead wire (82) is led out from each of the lead portions (81) of all the windings to the bus bar terminal side, The bus bar terminal has a winding-side terminal portion (72) including at least one connection portion (73) and a board-side terminal portion (77) connected to a board (51) of the control unit, the plurality of bus bar terminals are gathered in a portion of the circumferential direction, A rotating electric machine in which the lead wire is wired so as to extend radially inward from one of the plurality of lead portions scattered around the entire circumferential direction to one of the plurality of connection portions.

2. the connecting portion is provided at a position where at least a portion thereof overlaps with the rotor when viewed in the axial direction, the board-side terminal portion is provided radially outward from the connection portion, 2. The rotating electric machine according to claim 1, wherein the plurality of connection portions provided on each of the winding side terminal portions are gathered in a circumferential portion and are arranged circumferentially spaced apart from the connection portions of the other winding side terminal portions.

3. the bus bar holder has at least one protrusion (68) that protrudes in the axial direction toward a radially inner portion (26) of the insulator (25) of the stator in a space (67) in which the lead wires are wired, 3. The rotating electric machine according to claim 1, wherein a gap between the protrusion and the insulator is smaller than a diameter of the lead wire.

4. the winding-side terminal portion has the connection portion, an extension portion (74) extending from the board-side terminal portion toward the connection portion, a press-fit portion (75) press-fitted into the bus bar holder, and a bent portion (76) connecting the extension portion and the connection portion, the connecting portion is provided at the same axial position as at least a part of the extending portion, 4. The rotating electric machine according to claim 1, wherein the bent portion is provided at the same axial position as at least a part of the press-fit portion.

5. The connection portion before the lead wire is connected has a hook shape, The hook-shaped connection portion is connected to the lead wire by being crimped in a state in which the lead wire is hooked, 5. The rotating electric machine according to claim 1, wherein all of the connection portions before crimping are configured to hook the lead wires from one circumferential direction.

6. The rotating electric machine according to any one of claims 1 to 5, wherein the bus bar holder has an insulating partition wall portion (62) provided between the stator and the bus bar terminals.

7. 7. The rotating electric machine according to claim 1, wherein two or more of the lead wires are connected to each of the connection portions.

8. The board-side terminal portion has a wide portion (78) extending in the axial direction from the winding-side terminal portion toward the board, and a narrow portion (79) protruding from the wide portion into the connection hole (52) of the board, 8. The rotating electric machine according to claim 1, wherein the wide portion has a larger cross-sectional area perpendicular to the axial direction than the narrow portion.

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