motor
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- TOYOTA JIDOSHA KK
- Filing Date
- 2024-01-18
- Publication Date
- 2026-08-04
Smart Images

Figure 0007899843000001 
Figure 0007899843000002 
Figure 0007899843000003
Abstract
Description
Technical Field
[0001] The technology disclosed in this specification relates to motors.
Background Art
[0002] A stator, which is a component of a motor, includes a cylindrical stator core, a plurality of coils attached to the stator core, and a plurality of busbars. The plurality of coils have, for example, a U-phase coil, a V-phase coil, and a W-phase coil, and are wound around the inner peripheral surface of the stator core by distributed winding. The plurality of busbars include a neutral busbar and three lead-out busbars. The neutral busbar connects the U-phase coil, the V-phase coil, and the W-phase coil to each other to form the neutral point of the plurality of coils. Each of the three lead-out busbars is electrically connected to a corresponding one of the U-phase coil, the V-phase coil, and the W-phase coil.
[0003] Patent Document 1 discloses a motor in which a temperature sensor is attached to a neutral busbar. In this motor, the temperature sensor is press-fitted into a hole formed in the neutral busbar for attachment.
Prior Art Documents
Patent Documents
[0004]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0005] In this type of motor, a technology capable of stably holding a temperature sensor on a busbar is required.
Means for Solving the Problems
[0006] A motor disclosed herein may include a cylindrical stator core, a plurality of coils attached to the stator core, a busbar electrically connected to at least one of the coils, and a temperature sensor attached to the busbar. The busbar may have a plurality of passages. At least a portion of the temperature sensor may pass through each of the plurality of passages to be attached to the busbar.
[0007] At least a portion of the temperature sensor is mounted so as to entangle with the busbar by passing through multiple passages. Thus, in the motor disclosed herein, the temperature sensor is stably held by the busbar.
[0008] Details of the motor disclosed herein and further improvements are described in the following "Modes for Carrying Out the Invention". This will be explained later. [Brief explanation of the drawing]
[0009] [Figure 1] This diagram schematically shows a perspective view of the stator. [Figure 2] This is a cross-sectional view of a stator, schematically showing a cross-sectional view parallel to the axial direction of the stator core. [Figure 3] This is a cross-sectional view including a busbar and a temperature sensor, schematically showing a cross-sectional view perpendicular to the axial direction of the stator core. [Figure 4] This diagram schematically shows a plan view of one modified example of a busbar. [Figure 5] This diagram schematically shows a plan view of one modified example of a busbar. [Figure 6] This diagram schematically shows a plan view of one modified example of a busbar. [Figure 7] This diagram schematically shows a plan view of one modified example of a busbar. [Figure 8] This diagram schematically shows a plan view of one modified example of a busbar. [Figure 9] This diagram schematically shows a plan view of one modified busbar and a side view of the proximal lateral edge of one modified busbar. [Modes for carrying out the invention]
[0010] In one embodiment of the motor disclosed herein, at least one of the multiple passages may be a notch formed in at least one of a pair of side edges extending longitudinally from the busbar. Having a passage that is a notch facilitates the process of passing a temperature sensor through the passage. This improves the ease of attaching the temperature sensor to the busbar.
[0011] In one embodiment, where the passage portion is composed of a notch, the busbar may have a pair of side edges, one being a proximal side edge located on the stator core side and the other a distal side edge located on the opposite side of the proximal side edge. Furthermore, the notch may be formed on the distal side edge of the busbar. When the notch is formed on the distal side edge of the busbar, the worker attaching the temperature sensor to the busbar can easily access the notch formed on the busbar, making it easier to pass the temperature sensor through the passage portion. This improves the workability of attaching the temperature sensor to the busbar.
[0012] In one embodiment, where the through portion is a notch, the busbar may have an adjacent portion adjacent to the notch in the short direction of the busbar. The adjacent portion may include a side edge projection projecting from the side edge of the busbar in the short direction of the busbar, a thickened portion that is thicker than the portion adjacent to the adjacent portion in the longitudinal direction of the busbar, or a combination thereof. If no countermeasures are taken, when a notch is formed in the busbar, the cross-sectional area of the adjacent portion adjacent to the notch (i.e., the cross-sectional area in a section perpendicular to the longitudinal direction of the busbar) decreases, and the electrical resistance of the busbar increases. In the above embodiment, since this adjacent portion is composed of a side edge projection, a thickened portion, or a combination thereof, the increase in the electrical resistance of the adjacent portion is suppressed.
[0013] In one embodiment, where the through portion is a notch, the notch may have a first extending portion that extends from the side edge of the busbar along the short direction of the busbar, and a second extending portion that extends from the first extending portion along the longitudinal direction of the busbar at a position away from the side edge of the busbar. That is, at least a part of the notch may have an L-shaped portion. If at least a part of the notch has an L-shaped portion, the temperature sensor is effectively prevented from falling out of the notch, and the temperature sensor is stably held on the busbar.
[0014] In one embodiment of the motor disclosed herein, each of the plurality of coils may have a coil projection that protrudes from the stator core on one axial side of the stator core. In this case, the busbar may be positioned adjacent to the coil projection in the axial direction of the stator core and extend in the circumferential direction of the stator core. Alternatively, the busbar may be positioned around the stator core in the radial direction and extend along the circumferential direction of the stator core.
[0015] In one embodiment, where the busbar extends along the circumferential direction of the stator core, the multiple through-sections may be arranged along the circumferential direction of the stator core. Since the temperature sensor is mounted along the longitudinal direction of the busbar, a long range of the temperature sensor is stably held on the busbar.
[0016] In one embodiment, where the busbar extends circumferentially along the stator core, each of the multiple through-sections may pass through the busbar radially along the stator core. In this embodiment, the temperature sensor may pass through the busbar, for example, from the radially inside to the outside (or from the outside to the inside) of the stator core, and then pass through the busbar from the radially outside to the inside (or from the inside to the outside) of the stator core to be attached to the busbar.
[0017] In one embodiment of the motor disclosed in this specification, the temperature sensor may include a thermistor temperature measurement portion and a cable portion connected to the thermistor temperature measurement portion. In this case, the thermistor temperature measurement portion may pass through at least one of the through portions and be attached to the bus bar. When the thermistor temperature measurement portion passes through the through portion, the thermistor temperature measurement portion is attached close to the bus bar, so that the sensitivity and response speed of the temperature sensor are improved.
[0018] In one embodiment where the thermistor temperature measurement portion passes through the through portion, the bus bar and the thermistor temperature measurement portion may be integrally coated with resin. Since the thermistor temperature measurement portion is attached to the bus bar in close contact by the resin, the sensitivity and response speed of the temperature sensor are improved.
[0019] In one embodiment of the motor disclosed in this specification, the plurality of coils may include a U-phase coil, a V-phase coil, and a W-phase coil. In this case, the bus bar may be a neutral line bus bar that electrically connects the U-phase coil, the V-phase coil, and the W-phase coil to form the neutral point of the plurality of coils. Instead of this embodiment, the bus bar may be any one of the three lead-out bus bars provided corresponding to the U-phase coil, the V-phase coil, and the W-phase coil.
Example
[0020] Hereinafter, with reference to the drawings, the stator, which is a component of the motor, will be described. For the purpose of clear illustration, the shapes of the common components may be changed between different drawings, but the components with the same reference numerals indicate the same components. The motor disclosed in this specification is not particularly limited, but may be mounted on, for example, an electric vehicle. The "electric vehicle" in this specification includes battery electric vehicles (BEVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell electric vehicles (FCEVs), and the like.
[0021] As shown in Figure 1, the stator 1 comprises a stator core 10, a plurality of segment coils 20, a busbar 30, and a temperature sensor 40.
[0022] Here, a cylindrical coordinate system consisting of axial, radial, and circumferential directions is defined with respect to the cylindrical stator core 10. The z-axis shown in the figure is located on the central axis of the stator core 10 and indicates the axial direction of the stator core 10. In this specification, the positive direction of the z-axis is referred to as one side of the axial direction, and the negative direction of the z-axis is referred to as the other side of the axial direction. The r-axis shown in the figure is perpendicular to the z-axis and indicates the radial direction of the stator core 10. In this specification, the positive direction of the r-axis is referred to as the radially outward direction, and the negative direction of the r-axis is referred to as the radially inward direction. The θ-axis shown in the figure is perpendicular to the z-axis and r-axis and indicates the circumferential direction of the stator core 10. In this specification, the positive direction of the θ-axis is referred to as one side of the circumferential direction, and the negative direction of the θ-axis is referred to as the other side of the circumferential direction.
[0023] The stator core 10 is constructed by stacking multiple laminated steel plates, for example, made of a magnetic material, in the axial direction. The stator core 10 has a cylindrical yoke portion 12 and multiple teeth 14 extending radially inward from the inner circumferential surface of the yoke portion 12. A rotor (not shown) is inserted into the central hole of the yoke portion 12. Each of the multiple teeth 14 extends axially from one opening edge to the other opening edge of the yoke portion 12 and is spaced apart from adjacent teeth 14 along the circumferential direction. The space between adjacent teeth 14 is called a slot 16.
[0024] Each of the multiple segment coils 20 is inserted into two corresponding slots 16 of the multiple slots 16 of the stator core 10. Each of the multiple segment coils 20 is a flat rectangular wire formed by coating the surface of a conductor (e.g., copper) with an insulator. Each of the multiple segment coils 20 has a first coil projection 22 and a second coil projection 24 that protrude from the slots 16 of the stator core 10 in the axial direction. The first coil projection 22 is the portion of the segment coil 20 that protrudes from the slots 16 of the stator core 10 on one axial side. The second coil projection 24 is the portion of the segment coil 20 that protrudes from the slots 16 of the stator core 10 on the other axial side. Each of the multiple segment coils 20 is formed by shaping it into a substantially U-shape, inserting it into the slots 16 of the stator core 10 along the axial direction, and then bending the first coil projection 22 of the segment coil 20. The tip of the first coil projection 22 of the bent segment coil 20 (corresponding to the delamination portion where the insulator has been peeled off and the conductor is exposed) is welded to the tip of the first coil projection 22 of another bent segment coil 20. Multiple segment coils 20 connected by welding constitute a single coil. As a result, U-phase coils, V-phase coils, and W-phase coils are wound around the inner circumferential surface of the stator core 10 in a distributed winding manner.
[0025] The busbar 30 is positioned adjacent to the first coil projection 22 in the axial direction. More specifically, the busbar 30 is positioned slightly away from the first coil projection 22 in the axial direction, and within the range where the first coil projection 22 exists when viewed from the axial direction. The busbar 30 has a rectangular conductive plate that is curved in the longitudinal direction and extends along the circumferential direction. In this example, the busbar 30 extends only to a portion of the entire circumference of the stator core 10. Alternatively, the busbar 30 may extend around the entire circumference of the stator core 10.
[0026] The busbar 30 has an inner main surface 32 and an outer main surface 34. The inner main surface 32 and the outer main surface 34 extend along the longitudinal direction of the busbar 30, facing each other in the radial direction. The busbar 30 further has a pair of proximal lateral edges 36 and distal lateral edges 38. The pair of proximal lateral edges 36 and distal lateral edges 38 extend along the longitudinal direction of the busbar 30, facing each other in the axial direction. The proximal lateral edge 36 is located closer to the stator core 10 than the distal lateral edge 38.
[0027] As shown in Figures 1 and 2, the busbar 30 has the tip portions 28 of the segment coils 20, which are one end of the U-phase coil, V-phase coil, and W-phase coil, joined to it. More specifically, each tip portion 28 is welded to the outer main surface 34 of the busbar 30. The position where each tip portion 28 is joined to the busbar 30 and the manner of joining are not particularly limited. Thus, the busbar 30 is a neutral wire busbar that electrically connects the U-phase coil, V-phase coil, and W-phase coil to each other and forms the neutral point of these coils. Although not particularly limited, if the motor has a neutral point terminal (not shown), the neutral wire busbar is electrically connected to that neutral point terminal. Such a neutral point terminal can be used for so-called neutral point charging, and is electrically connected to an external DC power supply when charging a battery connected to the motor.
[0028] The leading ends (not shown) of the segment coils 20, which are the other ends of the U-phase, V-phase, and W-phase coils, are electrically connected to the corresponding one of three lead busbars (not shown). These three lead busbars may extend circumferentially, for example, radially outward from the stator core 10. Although not shown, the three lead busbars are also electrically connected to the U-phase, V-phase, and W-phase terminals of the motor, respectively.
[0029] As shown in Figures 1 and 3, the busbar 30 has a first notch 31 and a second notch 33. Both the first notch 31 and the second notch 33 are formed on the distal side edge 38 of the busbar 30 and penetrate radially between the inner main surface 32 and the outer main surface 34 of the busbar 30. The first notch 31 and the second notch 33 are spaced apart along the circumferential direction. In this example, only two notches 31 and 33 are shown, but the busbar 30 may have three or more notches.
[0030] The temperature sensor 40 includes a thermistor temperature measuring unit 42 and a cable section 44 connected to the thermistor temperature measuring unit 42. The thermistor temperature measuring unit 42 is not particularly limited, but for example, it is an electronic component having a resistance thermometer at its tip. The thermistor temperature measuring unit 42 has a structure in which two lead wires extending from the resistance thermometer are covered with a resin tube, and the majority of it, excluding the resistance thermometer, is a flexible, elongated shape. The cable section 44 also has a structure in which two conductors are covered with a resin tube, and the majority of it is a flexible, elongated shape. The two conductors of the cable section 44 are electrically connected to the corresponding lead wires of the two lead wires that make up the thermistor temperature measuring unit 42. A connector (not shown) is connected to the end of the cable section 44 opposite to the end connected to the thermistor temperature measuring unit 42.
[0031] As shown in Figure 1, the thermistor temperature sensor 42 is attached to the busbar 30 by passing through the first notch 31 and the second notch 33, respectively. Alternatively, the cable portion 44 may be attached to the busbar 30 by passing through at least one of the first notch 31 and the second notch 33. In this example, observing from the cable portion 44 toward the tip of the thermistor temperature sensor 42, the thermistor temperature sensor 42 passes through the first notch 31 from the inner main surface 32 toward the outer main surface 34 of the busbar 30, and then passes through the second notch 33 from the outer main surface 34 toward the inner main surface 32 of the busbar 30 to be attached to the busbar 30. The thermistor temperature sensor 42 is attached so as to wrap around the busbar 30 by reciprocating between the inner main surface 32 and the outer main surface 34 of the busbar 30. As a result, the temperature sensor 40 is stably held on the busbar 30. Furthermore, since the first notch 31 and the second notch 33 are arranged apart from each other along the longitudinal direction of the bus bar 30, a long range of the thermistor temperature measuring section 42 is stably held on the bus bar 30.
[0032] The first notch 31 and the second notch 33 formed on the distal side edge 38 of the busbar 30 are positioned so as to be exposed outward from the stator core 10, and are therefore easily accessible to the worker attaching the temperature sensor 40 to the busbar 30. This makes it easier to pass the temperature sensor 40 through the first notch 31 and the second notch 33, thereby improving the workability of attaching the temperature sensor 40 to the busbar 30.
[0033] In this example, the thermistor temperature measuring unit 42 is attached to the busbar 30 by passing through the first notch 31 and the second notch 33, so the thermistor temperature measuring unit 42 is attached in close proximity to the busbar 30. As a result, the heat generated in the busbar 30 is efficiently transferred to the thermistor temperature measuring unit 42, improving the sensitivity and response speed of the temperature sensor 40.
[0034] As shown in Figure 3, the busbar 30 and the thermistor temperature sensing unit 42 are integrally covered with resin 50. In Figures 1 and 2, the resin 50 is removed for clarity. The resin 50 is not particularly limited, but for example, it may be formed to integrally cover the busbar 30 and thermistor temperature sensing unit 42 by applying powdered resin to the busbar 30 and thermistor temperature sensing unit 42, or it may be formed to integrally cover the busbar 30 and thermistor temperature sensing unit 42 by immersing them in molten resin. The resin 50 may also be formed to integrally cover the welded joint at the tip of the first coil projection 22. Because the thermistor temperature sensing unit 42 is attached in close contact with the busbar 30 by the resin 50, the sensitivity and response speed of the temperature sensor 40 are improved. Furthermore, since the heat generated in the busbar 30 can be transferred to the thermistor temperature measuring unit 42 via the resin 50, the sensitivity and response speed of the temperature sensor 40 are also improved in this respect.
[0035] As described above, in the example where the busbar 30 and the thermistor temperature sensing unit 42 are integrally coated with resin 50, it is necessary to position the thermistor temperature sensing unit 42 relative to the busbar 30 prior to coating with resin 50. Furthermore, it is necessary to hold the thermistor temperature sensing unit 42 in close contact with the busbar 30 during the process of coating with resin 50. By passing the thermistor temperature sensing unit 42 through the first notch 31 and the second notch 33 at specific positions, the thermistor temperature sensing unit 42 is accurately positioned relative to the busbar 30. In addition, the thermistor temperature sensing unit 42 that has passed through the first notch 31 and the second notch 33 is held in close contact with the busbar 30. Thus, the technique of forming the first notch 31 and the second notch 33 in the busbar 30 is particularly useful when the busbar 30 and thermistor temperature sensing unit 42 are integrally coated with resin 50.
[0036] The following lists some variations of the busbar 30. Parts that exhibit the same effects as the busbar 30 are denoted by the same symbols, and their explanations are omitted.
[0037] The busbar 130 shown in Figure 4 is an example with multiple through holes 131 and 133. The temperature sensor 40 is attached to the busbar 130 by passing through each of the multiple through holes 131 and 133. Although the multiple through holes 131 and 133 reduce the ease of passing the temperature sensor 40 through, they prevent the temperature sensor 40 from falling out.
[0038] The busbar 230 shown in Figure 5 is an example in which multiple engaging portions 231, 233 are formed by multiple projections protruding from the side edges of the busbar 230. The multiple projections are spaced apart from each other along the longitudinal direction of the busbar 230. The multiple engaging portions 231, 233 are defined by adjacent projections, and the distance between adjacent projections is adjusted to enable the temperature sensor 40 to be held. The temperature sensor 40 is attached to the busbar 230 by passing through each of the multiple engaging portions 231, 233.
[0039] As shown in the modified examples in Figures 4 and 5, various geometric shapes can be used as a structure for stably holding the temperature sensor 40. These shapes penetrate the busbar in the direction connecting a pair of main surfaces of the busbar and allow the flexible, elongated temperature sensor 40 to pass through. In this specification, the various geometric shapes of the busbar that allow the temperature sensor 40 to pass through are referred to as through sections. Multiple through sections formed in the busbar may be combinations of a single type of through section (for example, a combination of only notches), or combinations of different types of through sections (for example, any combination of notches, through holes, and engaging sections).
[0040] The busbar 330 shown in Figure 6 is an example in which the first notch 31 is formed on one side edge of the busbar 330 and the second notch 33 is formed on the other side edge of the busbar 330. Depending on the position and orientation in which the busbar 330 is arranged, the positions of the multiple notches 31 and 33 within the busbar 330 may be adjusted as appropriate.
[0041] The busbar 430 shown in Figure 7 is an example in which the first notch 31 has a first extended portion 31a that extends from the side edge of the busbar 430 along the short direction of the busbar 430, and a second extended portion 31b that extends from the first extended portion 31a along the longitudinal direction of the busbar 430 at a position away from the side edge of the busbar 430. The second notch 33 is similar. In this way, both the first notch 31 and the second notch 33 are configured in an L shape. When the first notch 31 and the second notch 33 are configured in an L shape, the temperature sensor 40 is effectively prevented from falling out of the first notch 31 and the second notch 33, so that the temperature sensor 40 is stably held on the busbar 430.
[0042] The busbar 530 shown in Figure 8 is an example having a first adjacent portion 35 adjacent to the first notch 31 in the short direction of the busbar 530, and a second adjacent portion 37 adjacent to the second notch 33 in the short direction of the busbar 530. Both the first adjacent portion 35 and the second adjacent portion 37 have a side edge projection 39 that protrudes from the side edge of the busbar 530 in the short direction of the busbar 530. If the first adjacent portion 35 and the second adjacent portion 37 do not have the side edge projection 39, when the first notch 31 and the second notch 33 are formed in the busbar 530, the cross-sectional area of the first adjacent portion 35 and the second adjacent portion 37 (i.e., the area of the cross-section perpendicular to the longitudinal direction of the busbar 530) decreases, and the electrical resistance of the busbar 530 increases. In this example, since each of the first adjacent portion 35 and the second adjacent portion 37 has a side edge projection 39, the increase in electrical resistance of the first adjacent portion 35 and the second adjacent portion 37 is suppressed.
[0043] The busbar 630 shown in Figure 9 is an example in which the first adjacent portion 35 adjacent to the first notch 31 in the short direction of the busbar 630 has a thickened portion 52 that is thicker than the portion adjacent to the first adjacent portion 35 in the longitudinal direction of the busbar 630. The same applies to the second adjacent portion 37 adjacent to the second notch 33. In this example as well, even if the first notch 31 and the second notch 33 are formed, the reduction in the cross-sectional area of the first adjacent portion 35 and the second adjacent portion 37 is suppressed, and the increase in the electrical resistance of the first adjacent portion 35 and the second adjacent portion 37 is suppressed. Note that the first adjacent portion 35 and the second adjacent portion 37 may have both a side edge projection 39 (see Figure 8) and a thickened portion (see Figure 9). [Explanation of symbols]
[0044] 1: Stator, 10: Stator core, 12: Yoke section, 14: Teeth, 16: Slot, 20: Segment coil, 22: First coil protrusion, 24: Second coil protrusion, 28: Tip section, 30: Busbar, 31: First notch, 33: Second notch, 40: Temperature sensor, 42: Thermistor temperature measuring section, 44: Cable section
Claims
1. A cylindrical stator core, Multiple coils attached to the stator core, A busbar electrically connected to at least one of the aforementioned plurality of coils, It includes a temperature sensor attached to the busbar, The busbar has a pair of main surfaces facing each other in the radial direction of the stator core, The busbar has a plurality of through portions that penetrate between the pair of main surfaces, A motor in which at least a portion of the temperature sensor is attached to the busbar by passing through each of the plurality of passing sections while being displaced radially in the stator core.
2. The motor according to claim 1, wherein at least one of the plurality of passing portions is a notch formed in at least one of a pair of side edges extending in the longitudinal direction of the busbar.
3. The pair of side edges of the busbar have a proximal side edge located on the stator core side and a distal side edge located on the opposite side from the proximal side edge. The motor according to claim 2, wherein the notch is formed on the distal side edge of the busbar.
4. The busbar has an adjacent portion adjacent to the notch in the short direction of the busbar, The motor according to claim 2, wherein the adjacent portion includes a side edge projection that protrudes from the side edge of the busbar in the direction of the shorter side of the busbar.
5. The busbar has an adjacent portion adjacent to the notch in the short direction of the busbar, The motor according to claim 2, wherein the adjacent portion includes a thicker portion in the longitudinal direction of the busbar than the portion adjacent to the adjacent portion.
6. The motor according to claim 2, wherein the notch comprises a first extended portion cut out from the side edge of the busbar along the short direction of the busbar, and a second extended portion cut out from the first extended portion along the longitudinal direction of the busbar at a position away from the side edge of the busbar.
7. Each of the plurality of coils has a coil projection that protrudes from the stator core on one side of the stator core in the axial direction, The motor according to claim 1, wherein the busbar is arranged adjacent to the coil protrusion in the axial direction of the stator core and extends in the circumferential direction of the stator core.
8. The motor according to claim 7, wherein the plurality of passing sections are arranged along the circumferential direction of the stator core.
9. The aforementioned temperature sensor is Thermistor temperature measuring unit, It has a cable section connected to the thermistor temperature measuring section, The motor according to claim 1, wherein the thermistor temperature measuring unit passes through at least one of the plurality of passing sections and is attached to the busbar.
10. The motor according to claim 9, wherein the busbar and the thermistor temperature measuring unit are integrally covered with resin.
11. The aforementioned plurality of coils include a U-phase coil, a V-phase coil, and a W-phase coil. The motor according to any one of claims 1 to 10, wherein the busbar is a neutral wire busbar that electrically connects the U-phase coil, the V-phase coil, and the W-phase coil to each other to form a neutral point for the plurality of coils.
12. The motor according to claim 1, wherein at least a portion of the temperature sensor passes through one of the plurality of passing sections from the radially inside to the outside of the stator core, and passes through another of the plurality of passing sections from the radially outside to the inside of the stator core, and is attached to the busbar.