Connection structure, stator, motor, and terminal

Abstract

The disclosed connection structure is a connection structure for a conductor (9) connected to a terminal (20), and comprises a hole (26) and a connecting portion (25). The hole (26) is formed in a plate-shaped terminal body (30) that makes up the terminal (20). The conductor (9) is inserted through the hole (26). The connecting portion (25) is formed when the terminal body (30) is folded back at a position that crosses the hole (26). The conductor (9) is held in place by the connecting portion (25).

Description

[Technical Field]

[0001] This invention relates to a connection structure for conductors connected to a terminal, a stator, a motor, and a terminal. [Background technology]

[0002] In stators such as motors and resolvers, a connection structure is known in which a hook-shaped gripping portion is formed on the terminal, and the end of the conductor (winding) is gripped inside the gripping portion to connect the terminal and the conductor. The gripping portion is formed, for example, by bending a flat plate arranged parallel to the conductor in the circumferential direction of the conductor. This makes it easy to move the conductor in the direction of its extension inside the gripping portion, and makes it possible to adjust the connection position of the conductor to the terminal (see Patent Document 1). [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2022-108590 [Overview of the project] [Problems that the invention aims to solve]

[0004] The above connection structure carries the risk that if an external force perpendicular to the conductor's extension direction acts on the conductor, the conductor may move outside the gripping portion, causing the grip to break. This risk can be eliminated, for example, by pre-welding the conductor and the gripping portion. However, this may require a fixing jig to prevent misalignment between the conductor and the gripping portion during welding. Furthermore, if multiple gripping portions are provided on a single terminal, welding work is required for each gripping portion, increasing the number of fixing jigs required. Thus, there is room for improvement in terms of ease of work and work efficiency regarding the structure related to the connection between terminals and conductors in the conventional technology. It should be noted that such problems can occur not only with terminals attached to stators but also with various other types of terminals.

[0005] One of the objectives of this invention is to provide a connection structure, stator, motor, and terminal that have been devised in light of the above-mentioned problems, and that offer improved ease of use and work efficiency. Another objective of this invention is to achieve effects and benefits derived from each configuration shown in the "Modes for Carrying Out the Invention" described later, which cannot be obtained with conventional technology. [Means for solving the problem]

[0006] The disclosed connection structure, stator, motor, and terminal can be realized in the following embodiments (examples of application) and solve at least some of the above problems. Embodiments 1 to 3 correspond to the connection structure, embodiment 4 to the stator, embodiment 5 to the motor, and embodiment 6 to the terminal. Embodiments 2 to 3 are embodiments that can be optionally selected in addition to the connection structure relating to embodiment 1. Embodiments 2 to 3 are all optional embodiments. Embodiments 2 to 3 do not disclose any embodiments or configurations that are essential to this case.

[0007] Embodiment 1. The disclosed connection structure is a connection structure for a conductor connected to a terminal, comprising a hole and a connecting portion. The hole is formed in a plate-shaped terminal body that constitutes the terminal, and the conductor is inserted through it. The connecting portion is formed by folding the terminal body back at a position that crosses the hole, and the conductor is clamped between the terminals.

[0008] Embodiment 2. With respect to embodiments including Embodiment 1 described above, it is preferable that the conductor is composed of a plurality of wires, the width of the hole is a dimension corresponding to the sum of the diameters of the number of wires, and the height of the hole is a dimension corresponding to the diameter of one of the wires. Embodiment 3. With respect to embodiments including Embodiment 2 described above, it is preferable that the terminal body is provided with two shoulder strap portions that are adjacent to the hole in the direction of extension of the folded line of the terminal body, and that the two shoulder strap portions have the same conductor cross-sectional area.

[0009] Aspect 4. The stator of the disclosure is a stator to which the connection structure described in any one of the above Aspects 1 to 3 is applied. The stator includes a holding member that holds the terminal connected to the winding of the stator, and a base member on which the holding member is placed. Aspect 5. The motor of the disclosure includes the stator described in the above Aspect 4, and a rotor arranged to face the stator in the radial direction.

[0010] Aspect 6. The terminal of the disclosure includes a plate-shaped terminal body, a hole portion, and a connection portion. The hole portion is formed in the terminal body. A conductor is inserted into the hole portion. The connection portion is formed by folding back the terminal body at a position crossing the hole portion. The conductor is sandwiched by the connection portion.

Advantages of the Invention

[0011] According to the connection structure, stator, motor, and terminal of the disclosure, it is possible to make the conductor difficult to come off from the connection portion, and improve the workability and work efficiency related to the connection between the conductor and the terminal.

Brief Description of the Drawings

[0012] [Figure 1] It is an exploded perspective view of a motor including a connection structure according to an embodiment. [Figure 2] It is an enlarged perspective view of the main part of the terminal and the holding member. [Figure 3] It is a plan view of the terminal and the holding member. [Figure 4] (A) to (D) are enlarged perspective views of the main part of the terminal. (A) shows the terminal (terminal body) before completion, (B) shows the terminal after completion, (C) shows the terminal connected to the lead wire, and (D) shows the terminal as a modification example. [Figure 5] (A) and (B) are cross-sectional views of the holding member holding the terminal. [Figure 6] It is a cross-sectional view for explaining the rail structure (relationship between the concave portion and the convex rib portion). [Figure 7] This is a perspective view illustrating a modified rail structure. [Modes for carrying out the invention]

[0013] The connection structure, stator, motor, and terminals as embodiments will be described with reference to the drawings. The embodiments shown below are merely illustrative, and there is no intention to exclude various modifications or applications of technologies not explicitly shown in the embodiments below. Each component of these embodiments can be modified in various ways without departing from their spirit. Furthermore, each component of these embodiments can be selected or combined as needed.

[0014] [1. Structure] Figure 1 is an exploded perspective view of a motor 1 according to an embodiment. This motor 1 is an inner rotor type brushless DC motor. The motor 1 comprises a rotor 2 and a stator 4. The rotor 2 is a component that rotates integrally with the shaft 3, from which rotational driving force is output. The rotor 2 may have, for example, magnets or balancers. The general shape of the rotor 2 may be, for example, cylindrical or polygonal prism. The columnar surface (side) of the rotor 2 faces the stator 4. The axial shaft 3 is fixed to the bottom surface (top surface) of the rotor 2 in a position coaxial with the rotor 2.

[0015] The stator 4 is a component that generates a magnetic field for rotating the rotor 2. The stator 4 is positioned radially opposite to the rotor 2. In this embodiment, the stator 4 is positioned radially outward from the rotor 2. The general shape of the stator 4 is, for example, cylindrical. Inside the stator 4, the rotor 2 is rotatably mounted at a position coaxial with the stator 4. The orientation of the motor 1 configuration can be defined based on the arrangement of the rotor 2, shaft 3, stator 4, etc.

[0016] R in Figure 1 o R represents the radial outward direction. irepresents the radial-inward direction. R o is, for example, a direction perpendicular to the cylindrical axis of the stator 4 and away from the cylindrical axis of the stator 4. A in FIG. 1 o represents the axial-outward direction, that is, the same direction as the terminal extension direction. A i represents the axial-inward direction, that is, A o represents the direction opposite to A. A o is, for example, a direction perpendicular to the end face of the stator 4 and away from the end face of the stator 4. C in FIG. 1 c represents the circumferential-clockwise direction. C a represents the circumferential-anticlockwise direction. C c , C a is, for example, the rotational direction when looking at the end face of the stator 4 towards the axial-inward direction A i towards.

[0017] The stator 4 has a stator core 5, teeth 6, windings 7, and an insulator 8. The stator core 5 is a cylindrical part formed by laminating a plurality of steel plates in the axial direction of the shaft 3. The teeth 6 are parts formed on the stator core 5. The teeth 6 project radially inward R i from the inner peripheral surface (inner cylindrical surface) of the stator core 5. In the present embodiment, a plurality of teeth 6 are arranged at regular intervals in the circumferential direction. At the radially inner R i ends of each tooth 6, blade parts developed in a curved surface shape are provided to maintain a predetermined gap with respect to the rotor 2.

[0018] Winding 7 is a conductor that forms a coil inside the stator core 5 to generate a magnetic field. Winding 7 is wound around each tooth 6. Both ends of each winding 7 are connected to other windings 7 and lead wires 9. Figure 1 shows 18 windings 7 and 3 sets of lead wires 9 (3 sets of 4 lead wires 9). The number of windings 7 and the number of sets and individual lead wires 9 are not limited to the numbers shown above. Lead wires 9 (conductors) are located axially outward from the windings 7. o It is installed in an upright position facing the direction. A terminal 20 is connected to each lead wire 9. Three terminals 20 are shown in Figure 1.

[0019] The winding 7 and lead wires 9 are, in principle, preferably coated to prevent short circuits. Furthermore, the portion of the lead wire 9 that is clamped by the clamping surface 27 may be a coated wire (e.g., enameled wire), an uncoated wire (e.g., copper wire), or a conductor other than a wire, such as a pin or jumper plate, which is a component intended for electrical conductivity. The same applies to the terminal 20; it may be a component intended for electrical conductivity (wire, conductor), and its shape, number, size, etc., can be selected as appropriate.

[0020] The insulator 8 is a component that electrically insulates the winding 7 wound around the teeth 6 from the stator core 5. The insulator 8 is provided at least on the surface of the teeth 6. In this embodiment, the insulator 8 is provided on the inner circumferential surface of the stator core 5, the surface of the teeth 6, and the radially outer radius of the blade portion. o It is formed in a shape that covers the surface. The insulator 8 is made of, for example, insulating resin, porcelain, glass, etc. The winding 7 is wound around the teeth 6 via the insulator 8. Therefore, the winding 7 is not in contact with the steel plates that make up the stator core 5.

[0021] The stator 4 is fitted with a connection structure for connecting the terminal 20 and the lead wire 9. This connection structure includes a hole 26 and a connecting portion 25, which will be described later. Furthermore, the stator 4 of this embodiment is also fitted with a terminal holding structure for holding the terminal 20 connected to the lead wire 9. This terminal holding structure includes a base member 10 and a holding member 11. The holding member 11 may be provided integrally with the base member 10. Alternatively, the holding member 11 may be provided separately from the base member 10 and attached to the base member 10. The holding member 11 may be detachable from the base member 10.

[0022] The base member 10 is a planar member provided on the end face of the stator 4. The base member 10 is formed in an annular shape, for example, by hollowing out the center of a disc. The base member 10 is attached, for example, to the end face of the stator core 5 or to the insulator 8. The base member 10 is located on the axial outer side A of the winding 7 and the insulator 8. o It is arranged along the end of the structure.

[0023] The holding member 11 is located on the axial outer side A of the base member 10. o This is the part that is placed on the device. The holding member 11 holds the terminal 20. The holding member 11 is shaped to allow the terminal 20 to move within a predetermined range relative to the holding member 11. The holding member 11 has the function of limiting (restricting) the range of movement of the terminal 20 within a predetermined range. In other words, the terminal 20 is held by the holding member 11 so that it can move only within a predetermined range relative to the holding member 11. Figure 1 shows a structure in which multiple holding members 11 are integrated. Each holding member 11 can individually move one of the multiple terminals 20 within a predetermined range.

[0024] Figure 2 is an enlarged perspective view of the main parts of the terminal 20 and the retaining member 11. The retaining member 11 in Figure 2 comprises an end retaining portion 12, a base surface 13, a lead wire routing portion 14, a protruding portion 15 (rail structure), and a second end retaining portion 16. The end holding portion 12 is formed in a Π shape and is a portion that movably holds one end of the terminal 20. The end holding portion 12 holds the holding member 11 axially inward A i The shape when viewed from the front is formed in a Π shape. Here, "Π shape" means a recessed shape (a box shape with one side open) that can accommodate one end of the terminal 20. The end holding part 12 holds one end of the leg portion 21 of the terminal 20, which will be described later, so that it can move. In other words, the terminal 20 is held with some play relative to the end holding part 12. The end holding part 12 holds the terminal 20 so that it can move in the radial and circumferential directions.

[0025] The base surface 13 is a flat surface on which the terminal 20 is installed. The base surface 13 makes surface contact with the bottom surface 22 of the terminal 20, which will be described later. This stabilizes the axial position of the terminal 20. The lead wire routing section 14 is a part that penetrates the holding member 11 in the axial direction. The lead wire routing section 14 shown in Figure 2 is located on the radially outer R of the holding member 11. o A shape with a cutout on the surface (radial inner radius) i It has a recessed shape. However, the lead wire routing section 14 may be provided as a through hole. Lead wires 9 connected to the terminal 20 are routed through the lead wire routing section 14. A recess or hole corresponding to the lead wire routing section 14 is also formed in the base member 10. The lead wires 9 are routed on the axial outer side A of the winding 7. o It is inserted inside the lead wire routing section 14 in a position approximately perpendicular to the end face.

[0026] The protruding portion 15 is part of a rail structure formed in a shape that allows the terminal 20 to slide relative to the holding member 11 in a predetermined direction (e.g., radial direction). The protruding portion 15 is formed in a shape that protrudes in a ridge-like manner from the base surface 13 of the holding member 11 facing the terminal 20. The protruding direction of the protruding portion 15 is outward in the axial direction A o This is the direction toward. The extension direction of the convex portion 15 is, for example, along the radial direction.

[0027] However, the extension direction of the protruding portion 15 is not limited to the radial direction. The protruding portion 15 engages with the recess 24 of the terminal 20, which will be described later. This restricts the movement direction of the terminal 20 to the extension direction of the protruding portion 15 (the direction along the radial direction). In addition, the positioning accuracy of the terminal 20 in the circumferential direction is improved. The shape of the protruding portion 15 is not limited to a ridge shape. The protruding portion 15 only needs to have a shape that can engage with the recess 24, and may be, for example, a point or a surface.

[0028] The protruding portion 15 shown in Figure 2 is positioned adjacent to the lead wire routing portion 14. This suppresses misalignment (circumferential misalignment) of the connection position between the lead wire 9 and the terminal 20, making it easier to maintain a good connection between the lead wire 9 and the terminal 20.

[0029] The second end retaining portion 16 has the function of movably holding the terminal 20 together with the end retaining portion 12. The second end retaining portion 16 is formed in a shape that movably holds the other end of the terminal 20 held by the end retaining portion 12. The second end retaining portion 16, for example, similar to the end retaining portion 12, holds the retaining member 11 axially inward A i When viewed from the front, the shape is formed in a Π shape (a Π shape facing the end holding portion 12). The second end holding portion 16 movably holds, for example, the other end of the leg portion 21 of the terminal 20.

[0030] Figure 3 is a plan view of the terminal 20 and the holding member 11, with the terminal 20 shown by a dashed line. The holding member 11 may include a third end holding portion 17 instead of the second end holding portion 16. The third end holding portion 17, together with the end holding portion 12, has the function of movably holding the terminal 20. Similar to the second end holding portion 16, the third end holding portion 17 has the function of movably holding the other end of the terminal 20 held by the end holding portion 12. The third end holding portion 17 is formed in a flat plate shape that can make surface contact with the plate surface of the leg portion 21 (described later) of the terminal 20.

[0031] The radial movement range of the terminal 20, which is installed on the base surface 13, is limited at least by the end holding portion 12. Furthermore, the circumferential movement of the terminal 20 is limited by the protruding portion 15. The terminal 20 is held by the holding member 11 in a state in which it can move slightly radially along the extending direction of the protruding portion 15. In addition, each of the multiple terminals 20 is held by the holding member 11 in a state in which it can move individually within a predetermined range.

[0032] As shown in Figure 2, the terminal 20 is formed by partially bending a flat conductor cut into a predetermined shape. The terminal 20 includes legs 21, a bottom surface 22, a strip-shaped portion 23, a recess 24 (rail structure), and a connecting portion 25. The leg portion 21 is a flat part that rests on the base surface 13. The bottom surface 22 is the end surface (axially inward A) located at the lower end of the leg portion 21 as shown in Figure 2. i This is the end face. The leg portion 21 is placed on the holding member 11 with its bottom surface 22 in contact with the base surface 13. The orientation of the plate surface of the leg portion 21 is such that its normal vector is aligned with the radial direction. However, it is not necessary for the normal direction of the leg portion 21 to perfectly coincide with the radial direction.

[0033] The strip-shaped portion 23 is a planar part formed in a strip shape that is in the same plane as the leg portion 21. The strip-shaped portion 23 extends axially outward from the leg portion 21 A o It is formed in a shape that extends toward the end. Either the positive or negative side of a DC power supply that drives the motor 1 is electrically connected to the strip-shaped portion 23 at a predetermined period. The recess 24 is the portion that engages with the protruding portion 15 of the retaining member 11. The recess 24 is located axially outward from the bottom surface 22 of the terminal 20. o It is formed in a recessed shape toward the side. The engagement of the recess 24 and the protruding ridge 15 positions the terminal 20 in the circumferential direction. The recess 24 is part of a rail structure formed in a shape that allows the terminal 20 to slide in a predetermined direction (e.g., radially) relative to the holding member 11.

[0034] The connection portion 25 is the part to which the lead wire 9 is connected. As shown in Figure 3, with the end of the terminal 20 held by the end holding portion 12, the connection portion 25 is located directly above the lead wire routing portion 14, in the vicinity of it. The lead wire 9 is connected to the connection portion 25 by, for example, thermocompression (heat crimping, pulse heat method, etc.), spot welding, or soldering (brazing). Also, as shown in Figure 2, the connection portion 25 is located axially outward A from the leg portion 21. o It is positioned as follows: In other words, the position of the connection point between the lead wire 9 and the connection part 25 is axially outward A from the base surface 13. o This results in a position that is separated from the other components. As a result, even when the lead wire 9 and the connector 25 are connected, slight radial movement or tilting of the terminal 20 is more easily tolerated.

[0035] Figures 4(A) to 4(D) are enlarged perspective views of the main part of the terminal 20. As mentioned above, the terminal 20 is formed by bending a flat plate. Figure 4(A) shows the terminal 20 before completion, with the connection portion 25 not bent, and Figure 4(B) shows the terminal 20 after completion, with the connection portion 25 bent. Figure 4(C) shows the terminal 20 connected to the lead wire 9, and Figure 4(D) shows a modified example of the terminal 20. Hereafter, when distinguishing between the terminal 20 before completion (the terminal 20 with the connection portion 25 not bent) and the terminal 20 after completion (the terminal 20 with the connection portion 25 bent), the former will be referred to as the terminal body 30.

[0036] As shown in Figure 4(A), the terminal body 30 is a flat plate, formed, for example, by cutting a flat plate into a predetermined shape. The terminal body 30 is provided with a hole 26. As shown in Figure 4(C), a lead wire 9, which is a conductor, is inserted through the hole 26. The lead wire 9 is electrically connected to the terminal body 30 (terminal 20) while inserted through the hole 26. In other words, the area around the hole 26 becomes the connection part 25, and the connection structure is formed by the hole 26 and the connection part 25. Note that another component may be interposed between the terminal 20 and the lead wire 9. For example, a ring-shaped copper component may be attached between the terminal 20 and the lead wire 9 and welded to connect them.

[0037] The hole 26 shown in Figure 4(A) is a closed hole whose contour does not reach the edge of the plate surface forming the connecting portion 25. The dashed line L in Figures 4(A) and (B) is the folding line corresponding to the center of rotation when bending. The position of the folding line L is set, for example, slightly away from the plate surface of the connecting portion 25. The connecting portion 25 is formed by folding back at a position that crosses the hole 26 in a front view of the hole 26 (a front view of the connecting portion 25 before completion). The direction in which the connecting portion 25 is folded back is the radially outward R when held by the holding member 11, as shown in Figure 2. o That is the case.

[0038] Of the surrounding edge of the hole 26, two portions adjacent to the hole 26 in the direction perpendicular to the fold line L are called clamping surface portions 27. Also, of the surrounding edge of the hole 26, two portions adjacent to the hole 26 in the direction extending the fold line L are called shoulder strap portions 28. The connection structure of this embodiment includes clamping surface portions 27 and shoulder strap portions 28. As shown in Figure 4(C), the clamping surface portions 27 are portions that clamp the lead wire 9 radially in the connection portion 25 of the completed terminal 20.

[0039] The portion of the lead wire 9 that is clamped by the clamping surface portion 27 is clamped by the clamping surface portion 27 in a state where it is not frayed (in other words, in a state where it is almost in contact with each other or bundled). When the lead wire 9 and the connection portion 25 are heat-compressed, the heat-compression is performed with the welding electrode in surface contact with each of the two clamping surface portions 27. The two clamping surface portions 27 are preferably provided approximately parallel to each other. During heat-compression, the two clamping surface portions 27 are pressed together in a direction that brings them closer to each other, sandwiching the lead wire 9. Therefore, the two clamping surface portions 27 do not need to be formed strictly parallel to each other. In addition, the surface of the clamping surface portion 27 that is in contact with the lead wire 9 may be plated or surface-treated as needed. For example, solder plating to stabilize the joint state or star-stamping to promote coating removal may be applied.

[0040] The shoulder strap portion 28 is the part that connects the two clamping surface portions 27. As shown in Figure 4(C), the shoulder strap portion 28 is located at both ends in the circumferential direction of the clamping surface portion 27. The shape of the shoulder strap portion 28 is an inverted U shape that opens toward the bottom surface 22 when the connecting portion 25 is viewed in the circumferential direction. The two shoulder strap portions 28 function as the initial current flow path when the lead wire 9 and the connecting portion 25 are heat-sealed. If the lead wire 9 is coated, the coating melts due to the resistive heating of the electrodes, after which the lead wire 9 and the connecting portion 25 are joined and heat-sealed.

[0041] The term "joining" here includes not only mechanical joining but also metallurgical joining. Metallurgical joining refers to a joining state in which an alloy layer is formed by the diffusion of metal atoms between contact surfaces. Furthermore, pulse heat joining may be used as a specific example of thermocompression joining. Alternatively, other joining methods may be used instead of thermocompression joining. For example, spot welding or soldering (brazing) may be employed.

[0042] When the lead wire 9 is inserted through the hole 26, the joint portion of the lead wire 9 is surrounded by the clamping surface portion 27 and shoulder strap portion 28 that are located around the hole 26, restricting its movement and making it less likely to unravel. Furthermore, by designing the shape of the hole 26, the joint portions of the lead wire 9 can be aligned in a single line in the circumferential direction. As a result, when joining the lead wire 9 and the connection portion 25, the position of the joint portion of the lead wire 9 is stabilized, preventing multiple wires from overlapping and breaking, or from being joined unevenly. Consequently, the crimping quality, welding quality, and soldering quality at the connection portion 25 are improved.

[0043] The shape of the hole 26 may be an open hole, as shown in Figure 4(D), where its contour reaches the edge of the plate surface forming the connecting portion 25. In this case, the position of the cut connecting the hole 26 and the edge of the plate surface may be set on the clamping surface 27 or on the shoulder strap 28. When the lead wire 9 and the connecting portion 25 are heat-sealed, for example, a cut narrower than the welding electrode may be provided on the clamping surface 27. The hole 26 may also be referred to as a "slit" or "opening."

[0044] Next, the dimensions of the terminal body 30 (terminal 20) will be described in detail. As shown in Figure 4(A), the circumferential (widthwise) dimension of the hole 26 is W0. This dimension W0 is set according to the diameter and number of lead wires 9 connected to the connection part 25. Dimension W0 is set, for example, to correspond to the sum of the diameters of the number of lead wires 9. The "dimension corresponding to the sum of the diameters of the number of lead wires 9" includes a dimension that is large enough to eliminate the need to press-fit the lead wires 9 into the hole 26, or a dimension that is large enough not to reduce the ease of inserting the lead wires 9 into the hole 26.

[0045] For example, when connecting four lead wires 9 with a diameter d side by side to the connection part 25, the dimension W0 is set to approximately 4d to 5d. The dimension W0 may be equal to 4d, or it may be larger than 4d. By setting the dimension W0 to a dimension corresponding to the sum of the diameters of the number of lead wires 9, the lead wires 9 can be more easily bundled inside the hole 26, improving the connection between the lead wires 9 and the connection part 25. In addition, it becomes easier to insert the lead wires 9 into the hole 26, improving work efficiency during manufacturing.

[0046] As shown in Figure 4(B), the gap dimension (minimum dimension) between the two clamping surfaces 27 is D0. Dimension D0 may be considered as the height of the hole 26 when the connecting portion 25 is folded back. This dimension D0, like dimension W0, is set according to the diameter and number of lead wires 9 connected to the connecting portion 25. Dimension D0 is set, for example, to correspond to the diameter of one lead wire 9. The "dimension corresponding to the diameter of one lead wire 9" here includes a dimension that is large enough to eliminate the need to press-fit the lead wire 9 when inserting it into the hole 26, or a dimension that is large enough not to reduce the workability when inserting the lead wire 9 into the hole 26.

[0047] For example, when connecting lead wires 9 with diameter d to the connector 25 without overlapping them radially, dimension D0 is set to approximately 1d to 2d. Dimension D0 may be equal to 1d or it may be larger than 1d. By setting dimension D0 to a dimension corresponding to the diameter of one lead wire 9, the lead wires 9 can be more easily bundled inside the hole 26, improving the connection between the lead wires 9 and the connector 25. In addition, it becomes easier to insert the lead wires 9 into the hole 26, improving work efficiency during manufacturing.

[0048] As shown in Figure 4(A), the circumferential (widthwise) dimensions of the two shoulder strap sections 28 are W1 and W2, respectively. These dimensions W1 and W2 can be set according to the method of connecting the lead wire 9 and the connection section 25. These dimensions W1 and W2 may be the same or different. For example, when heat-sealing the lead wire 9 and the connection section 25, these dimensions W1 and W2 may be set to the same dimensions. Alternatively, the two shoulder strap sections 28 may have the same conductor cross-sectional area. The conductor cross-sectional area referred to here corresponds to the product of the dimensions W1 and W2 shown in Figure 4(A) and the plate thickness dimension of the shoulder strap section 28, when the plate thickness is uniform. Note that if the plate thickness dimension of the two shoulder strap sections 28 is constant, having the same conductor cross-sectional area is equivalent to having the same dimensions W1 and W2.

[0049] As shown in Figure 4(A), the circumferential (widthwise) dimension of the leg portion 21 and bottom surface 22 of the terminal 20 is W3. The circumferential (widthwise) dimension of the recess 24 is W4. Furthermore, as shown in Figure 4(B), the radial dimension of the leg portion 21 and bottom surface 22 is D1. These dimensions W3, W4, and D1 are set according to the shape of the retaining member 11.

[0050] Figures 5(A) and 5(B) are cross-sectional views of the holding member 11 in which the terminal 20 is held. Figure 5(A) shows the case where the movable range of the terminal 20 is defined by the end holding portion 12 and the second end holding portion 16. Focusing on the movable range of the terminal 20 formed by the end holding portion 12 and the second end holding portion 16, its circumferential (width direction) dimension is W5 and its radial (thickness direction) dimension is D2. The dimension W3 of the terminal 20 is set to a value smaller than the dimension W5, and the dimension D1 is set to a value smaller than the dimension D2. This ensures a margin (adjustment allowance) for fine-tuning the position of the terminal 20.

[0051] Figure 5(B) shows the case where the range of motion of the terminal 20 is defined by the end retainer 12 and the third end retainer 17. In this case, dimension D1 is set to a value smaller than dimension D2. Also, the distance between the third end retainer 17 and the inner surface of the end retainer 12 that is furthest from the third end retainer 17 is W6. This distance W6 is set to a value smaller than the dimension W3 of the terminal 20. This allows the third end retainer 17 to make surface contact with the plate surface of the leg portion 21.

[0052] Figure 6 is a cross-sectional view illustrating the relationship (rail structure) between the recess 24 of the terminal 20 and the protruding portion 15 of the retaining member 11. The circumferential (width direction) dimension of the protruding portion 15 is W4, which is the same dimension as the circumferential (width direction) dimension W4 of the recess 24. The protruding portion 15 is in a direction perpendicular to the recessing direction in the recess 24 (circumferential clockwise direction C c , and the circumferential counterclockwise side C a The recess 24 is formed in a shape that contacts the end face of the ridge 15. As a result, the recess 24 engages (i.e., fits) with the protrusion 15 without any gap in the circumferential direction, improving the circumferential positioning accuracy of the terminal 20.

[0053] Furthermore, while the axial dimension (height) of the protruding portion 15 is H1, the axial dimension (depth) of the recessed portion 24 is H2. The depth H2 of the recessed portion 24 is set to a value greater than the height H1 of the protruding portion 15. The protruding portion 15 is formed in the recessed portion 24 in the direction of recess formation (axial outward A o The terminal is formed in a shape that does not contact the end face of the terminal. This suppresses physical interference and wobbling caused by manufacturing errors in the convex portion 15 and the concave portion 24, making it easier to stabilize the holding state of the terminal 20.

[0054] Figure 7 is a perspective view illustrating a modified rail structure. The rail structures shown in Figures 2, 6, etc., have a structure in which the protruding portion 15 of the retaining member 11 engages with the recessed portion 24 of the terminal 20. On the other hand, the rail structure shown in Figure 7 has a structure in which the groove portion 18 of the retaining member 11 engages with the protruding portion 29 of the terminal 20. The groove portion 18 is formed in a groove-like recess from the base surface 13 of the retaining member 11 that faces the terminal 20.

[0055] The direction of depression of the groove 18 is axially inward A i The direction is toward the direction. The extension direction of the groove 18 is along a predetermined direction (for example, the radial direction). The protrusion 29 is the part that engages with the groove 18. The protrusion 29 extends axially inward from the bottom surface 22 of the terminal 20 A i It is formed in a shape that protrudes toward the edge. In such a rail structure, the direction of movement of the terminal 20 is restricted to the direction of extension of the groove 18 (direction along the radial direction), and the positioning accuracy of the terminal 20 in the circumferential direction is improved.

[0056] The rail structure shown in Figures 2 and 7 is a structure in which the uneven shape of the retaining member 11 engages with the uneven shape of the terminal 20. The uneven shape of the retaining member 11 is a ridge-like shape, such as a raised ridge portion 15 and a groove portion 18. However, the uneven shape of the retaining member 11 is not limited to a ridge-like shape, and may be dot-like or planar. That is, one of the retaining member 11 and the terminal 20 may have a protrusion that projects toward the other, and the other may have a recess that engages with the protrusion.

[0057] [2. Effects] (1) The connection structure according to this embodiment is a connection structure for a lead wire 9 (conductor) connected to a terminal 20, and comprises a hole 26 and a connection portion 25. The hole 26 is formed in the plate-shaped terminal body 30 that makes up the terminal 20, and is the portion through which the lead wire 9 is inserted. The connection portion 25 is formed when the terminal body 30 is folded back at a position that crosses the hole 26, and is the portion in which the lead wire 9 is held.

[0058] With this configuration, the lead wire 9 is held inside the hole 26, preventing it from coming loose from the connector 25. Even if an external force perpendicular to the direction of extension of the lead wire 9 is applied to it, the lead wire 9 will not move outside the hole 26 and come loose. This connection can be easily achieved, for example, by simply inserting the tip of the lead wire 9 into the hole 26. Therefore, the ease of operation and work efficiency related to connecting the lead wire 9 to the terminal 20 can be improved.

[0059] (2) In the above connection structure, the lead wire 9 (conductor) may be composed of multiple wires. In the example shown in Figure 4(C), four lead wires 9 are connected to one terminal 20. Here, the width dimension W0 of the hole 26 is set to correspond to 4d, which is the sum of the diameters of the lead wires 9. Also, the height dimension D0 of the hole 26 is set to correspond to 1d, which is the diameter of one lead wire 9. This shape of the hole 26 allows the joint portions of the lead wires 9 to be aligned in a single line in the circumferential direction. As a result, when the lead wires 9 and the connection part 25 are joined, the position of the joint portions of the lead wires 9 is stable, preventing multiple wires from overlapping and breaking, or from being joined unevenly. Therefore, the crimping quality, welding quality, and soldering quality at the connection part 25 can be improved.

[0060] (3) The above connection structure comprises two shoulder strap portions 28, as shown in Figures 4(A) to (C). The shoulder strap portions 28 are formed on the terminal body 30 and are provided adjacent to the hole portion 26 in the direction of extension of the folded line L of the terminal body 30. With this configuration, the lead wire 9 can be sandwiched radially between the two shoulder strap portions 28, thereby improving the stability of the connection between the lead wire 9 and the terminal 20.

[0061] Furthermore, the two shoulder strap portions 28 are provided so as to have the same conductor cross-sectional area. For example, for two shoulder strap portions 28 with the same plate thickness, the circumferential (width direction) dimensions W1 and W2 are formed to be the same. By making the conductor cross-sectional area of ​​the two shoulder strap portions 28 the same in this way, it becomes easy to make the bending shape of the two shoulder strap portions 28 substantially the same when bending the connection portion 25 of the terminal body 30 along the fold line L. This makes it possible to make the two clamping surfaces 27 substantially parallel, and improve the joining quality (crimping quality, welding quality, and soldering quality) at the connection portion 25.

[0062] (4) The above-described connection structure is applied to the stator 4 according to this embodiment. The stator 4 comprises a holding member 11 that holds the terminal 20 connected to the winding 7 of the stator 4, and a base member 10 on which the holding member 11 is placed. With this configuration, the ease and efficiency of work related to connecting the lead wire 9 and the terminal 20 can be improved, and the ease and efficiency of work related to manufacturing the stator 4 can be improved. In addition, since the lead wire 9 does not come out of the hole 26, the energization state to the winding 7 can be stabilized, and consequently, a stator 4 that stabilizes the rotation state of the rotor 2 can be provided.

[0063] (5) The motor 1 according to this embodiment comprises the stator 4 described above and a rotor 2 arranged radially opposite to the stator 4. This configuration improves the ease and efficiency of work related to connecting the lead wires 9 and the terminals 20, and also improves the ease and efficiency of work related to the manufacture of the motor 1. Furthermore, since the lead wires 9 do not come out of the holes 26, the energization state to the windings 7 can be stabilized. Therefore, the quality of the motor 1 can be improved.

[0064] (6) The terminal 20 according to this embodiment comprises a plate-shaped terminal body 30, a hole 26, and a connecting portion 25. The hole 26 is formed in the terminal body 30. A lead wire 9 (conductor) is inserted through the hole 26. The connecting portion 25 is formed by folding the terminal body 30 back at a position that crosses the hole 26. The lead wire 9 is held in place by the connecting portion 25. With this configuration, a terminal 20 that holds the lead wire 9 inside the hole 26 can be easily realized, and a terminal 20 in which the lead wire 9 does not come off the connecting portion 25 can be easily realized. Therefore, the ease of work and work efficiency related to connecting the lead wire 9 and the terminal 20 can be improved.

[0065] [3. Others] The above connection structure can also be applied to the riser (the part of the commutator segment to which the conductors are connected, the commutator leg) of the rotor of a brushed motor. Furthermore, the above connection structure can be applied not only to the motor 1 but also to generators, resolvers, pumps, sensors, etc. For example, by replacing the rotor 2 shown in Figure 1 with a resolver rotor, a resolver equipped with the above connection structure can be realized. The above connection structure can be applied to parts and devices that have at least a hole 26 and a connection part 25.

[0066] The type of motor 1 to which the above connection structure applies is not limited to an inner rotor type brushless DC motor. The above connection structure is applicable not only to DC motors but also to AC motors. Furthermore, the above connection structure is applicable not only to brushless motors but also to brushed motors. Moreover, the above connection structure is applicable not only to inner rotor type motors but also to outer rotor type motors.

[0067] The shapes of the terminal 20 and the terminal body 30 are not limited to those shown in Figures 4(A) to (D), for example. Also, the legs 21, bottom surface 22, strip portion 23, and recess 24 are optional elements. The connecting portion 25 shown in Figure 4(B) extends radially outward from the terminal body 30 with the fold line L as the center. o Although it has a folded shape, the folding direction of the connecting portion 25 is radially inward R iThat's fine. [Industrial applicability]

[0068] This invention is applicable to the manufacturing industry of components having a conductor connection structure connected to a terminal. This invention is applicable to the manufacturing industry of stators to which the connection structure is applied. This invention is applicable to the manufacturing industry of motors, generators, pumps, resolvers, and sensors, including stators to which the connection structure is applied. This invention is applicable to the manufacturing industry of terminals. [Explanation of symbols]

[0069] 1 motor 2 rotors 3 shafts 4 stata 5 Stator Core 6 teeth 7 windings 8 Insulators 9. Lead wire (conductor) 10. Base components 11 Retaining member 12 End holding part 13 Base surface 14 Lead wire routing section 15. Protruding section (rail structure) 16 Second end holding part 17 Third end holding part 18. Groove section (rail structure) Terminal 20 21 Legs 22 Bottom 23. Band-shaped portion 24 Recessed section (rail structure) 25 Connection part 26 Hole 27 Clamping surface part 28 Shoulder strap section 29. Protruding section (rail structure) 30 Terminal Unit A o Axial outward A i Axial inward R o Radial outer R i Radial inner C c Circumferential clockwise direction C a Circumferential counterclockwise side L-shaped return line

Claims

1. A connection structure for conductors connected to a terminal, A hole formed in the plate-shaped terminal body that constitutes the terminal, through which the conductor is inserted, The terminal body is folded back at a position crossing the hole, and the terminal body comprises a connecting portion in which the conductor is sandwiched, The conductor is composed of multiple wires, The width of the hole has a dimension corresponding to the sum of the diameters of the number of wires. The height of the aforementioned hole corresponds to the diameter of one of the aforementioned wires. A connection structure characterized by the following features.

2. The terminal body is formed and comprises two shoulder strap portions adjacent to the hole in the direction of extension of the fold line of the terminal body, The two shoulder strap portions have the same conductive cross-sectional area. The connection structure according to claim 1, characterized in that

3. A stator to which the connection structure described in claim 1 or 2 is applied, A holding member that holds the terminal connected to the winding of the stator, The system comprises a base member on which the aforementioned holding member is placed. A stator characterized by the following features.

4. The stator according to claim 3, The stator is equipped with a rotor arranged radially opposite to the stator. A motor characterized by the following features.

5. A flat terminal body, The terminal body has a hole through which a conductor is inserted, The terminal body is folded back at a position crossing the hole, and the terminal comprises a connecting portion in which the conductor is clamped. The conductor is composed of multiple wires, The width of the hole has a dimension corresponding to the sum of the diameters of the number of wires. The height of the aforementioned hole corresponds to the diameter of one of the aforementioned wires. A terminal characterized by the following features.

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