Vehicle motor

Abstract

An objective of an embodiment of the present invention is to provide a motor in which a plate portion, a body portion and a shoulder portion of a power terminal are formed as one piece by a forging process, thus enabling simplification of a manufacturing process, an increase in work efficiency and, at the same time, a reduction in accumulated process risks, and also reducing tolerance in the position of the plate portion by eliminating a process of fusing the plate portion and the body portion.

Description

vehicle motors

[0001] The present invention relates to a motor for a vehicle, and more particularly, to a power terminal for supplying power to the motor.

[0002] In general, a motor is a device that converts electrical energy into rotational energy by utilizing the force that a conductor receives in a magnetic field.

[0003] As motor applications have expanded in recent years, their role has become increasingly important. In particular, with the rapid advancement of vehicle electrification, demand for motors used in steering and braking systems is growing significantly.

[0004] Typically, a motor comprises a rotatably provided shaft, a rotor coupled to the shaft, and a stator fixed inside a housing. The stator is installed with a gap around the rotor. Coils are wound around the stator, which generate a rotating magnetic field, causing electromagnetic interaction with the rotor to induce rotation. As the rotor rotates, the shaft coupled to the rotor rotates, generating driving force.

[0005] Additionally, a bus bar that distributes power to the coil and a power terminal that supplies external power are placed on the upper side of the stator.

[0006] In a power terminal according to the prior art, a member electrically connected to an external connector and a member connected to a bus bar are manufactured separately, and then combined through a fusing process, and a synthetic resin mold is formed at the fusing site through insert injection to reinforce the bonding strength of the two members.

[0007] Conventional power terminals configured in this way are manufactured through multiple processes, so productivity is not as good as expected, and location management is not easy.

[0008] Additionally, although a synthetic resin mold is formed in the fusing area to reinforce strength, there is a risk of deformation, cracking, or damage during the manufacturing process.

[0009] The purpose of the present invention is to provide a vehicle motor that can improve work efficiency and reduce accumulated process risks by simplifying the manufacturing process of a power terminal.

[0010] Another object of the present invention is to provide a vehicle motor capable of reducing the position tolerance of a power terminal.

[0011] In order to achieve the above object, a vehicle motor according to one embodiment of the present invention comprises: a shaft; a rotor coupled to the shaft; a stator arranged around the rotor; a bus bar for distributing power to the stator; and a plurality of power terminals for connecting an external power source to the bus bar, wherein the power terminals include a plate portion electrically connected to the outside, a body portion connected to the bus bar, and a shoulder portion provided between the plate portion and the body portion and protruding from the body portion, and the plate portion, the body portion, and the shoulder portion may be integrally formed of the same material.

[0012] It may further include a guide mold that is coupled to the above bus bar and supports the plurality of power terminals.

[0013] The above plate portion may be processed flat and may have a different shape from the body portion.

[0014] The body portion and the shoulder portion each have a cylindrical shape, and the diameter of the shoulder portion may be larger than the diameter of the body portion.

[0015] The body of the above power terminal may further include a sealing member.

[0016] According to the vehicle motor of the present invention having the configuration described above, the manufacturing process can be simplified by forming the plate portion, body portion, and shoulder portion of the power terminal as one unit.

[0017] Additionally, by simplifying the manufacturing process of power terminals, accumulated manufacturing process risks can be reduced, and cost savings can be achieved, contributing to improved productivity.

[0018] By forming the plate portion and the body portion integrally without the fusing process, the positional tolerance of the plate portion can be reduced, and since cracks or breakage do not occur in the existing fusing formation portion, the occurrence of defects can be prevented at the source.

[0019] Furthermore, according to another embodiment of the present invention, there are additional technical effects not mentioned herein. Those skilled in the art will understand the full scope of the specification and drawings.

[0020] Fig. 1 is a perspective view showing a motor according to an embodiment of the present invention.

[0021] Figure 2 is a cross-sectional view taken along line 'A-A' of Figure 1.

[0022] Figure 3 is a perspective view showing a power terminal according to an embodiment of the present invention.

[0023] Figure 4 is a process diagram showing an assembly process of a power terminal assembly according to an embodiment of the present invention.

[0024] Hereinafter, some embodiments of the present invention will be described in detail with reference to exemplary drawings. When designating components in the drawings, it should be noted that, where possible, identical components will be given identical reference numbers, even if they appear in different drawings. Furthermore, when describing embodiments of the present invention, detailed descriptions of related, known structures or functions will be omitted if they are deemed to hinder understanding of the embodiments of the present invention.

[0025] Additionally, terms such as first, second, A, B, (a), (b), etc. may be used to describe components of embodiments of the present invention. These terms are only intended to distinguish the components from other components, and the nature, order, or sequence of the components are not limited by the terms. When it is described that a component is "connected," "coupled," or "connected" to another component, it should be understood that the component may be directly connected or connected to the other component, but another component may also be "connected," "coupled," or "connected" between each component.

[0026] Hereinafter, a motor (10) according to various embodiments of the present invention will be described in detail with reference to the attached drawings.

[0027] FIG. 1 is a perspective view showing a motor (10) according to an embodiment of the present invention, and the motor (10) according to the embodiment may include a housing (100) and a cover (200).

[0028] Next, Fig. 2 is a cross-sectional view taken along line 'A-A' of Fig. 1.

[0029] The X direction illustrated in Fig. 2 may refer to a radial direction, and the Y direction may refer to an axial direction. In addition, the axial direction and the radial direction may be arranged perpendicular to each other.

[0030] Here, the axial direction may be the longitudinal direction of the shaft (500) described later. In addition, the drawing symbol 'C' illustrated in FIG. 2 means the center of rotation, i.e., the axis center, and the direction along a circle having a radius in the radial direction based on the axis center may be referred to as the circumferential direction.

[0031] Referring to FIG. 2, a motor (10) according to an embodiment may include a housing (100), a cover (200), a stator (300), a rotor (400), a shaft (500), a bearing (600), a bus bar (700), and a power terminal assembly (800).

[0032] The housing (100) can accommodate a stator (300), a rotor (400), a shaft (500), a bearing (600), a bus bar (700), etc. inside. The housing (100) can include a cylindrical housing body (110).

[0033] The cover (200) covers the upper portion of the stator (300) and rotor (400) accommodated in the housing body (110) of the housing (100) and is coupled to the housing (100). The cover (200) may be formed in a cylindrical shape, similar to the housing (100).

[0034] The housing (100) and the cover (200) form the outer shape of the motor (10), and the housing (100) and the cover (200) can have a receiving space formed therein. Accordingly, a stator (300), a rotor (400), a shaft (500), a bus bar (700), and a bearing (600) can be placed in the receiving space.

[0035] The housing (100) and cover (200) may be formed of, for example, aluminum, iron, or an alloy containing either of these. However, the present invention is not necessarily limited thereto, and various materials may be adopted and applied. However, it is preferable to form the housing (100) and cover (200) of a metal material, such as aluminum, that has heat resistance and can withstand high temperatures.

[0036] In the motor (10), a stator (300) can be installed inside the housing (100) by a hot pressing method.

[0037] Here, the hot pressing method means a method of fixing the stator (300) by fitting it into the internal receiving space during the dimensional change process through heating and cooling of the housing (100).

[0038] The stator (300) may include a stator core (310), an insulator (320), and a coil (330).

[0039] A coil (330) that forms a rotating magnetic field may be wound around the stator (300). Specifically, the coil (330) may be wound around the insulator (320) of the stator (300). The coil (330) may be wound around the stator (300) and may be supplied with an external power source. When an external power source is supplied to the coil (330), it causes an electromagnetic interaction with the rotor (400).

[0040] The stator core (310) may be formed by stacking multiple thin steel plates, but is not limited thereto, and may be formed as a single part.

[0041] The stator core (310) may include a cylindrical yoke portion (not shown) and a plurality of teeth portions (not shown) protruding from the yoke portion toward the center.

[0042] The insulator (320) insulates the stator core (310) and the coil (330). Therefore, the insulator (320) can be installed between the stator core (310) and the coil (330), and the coil (330) can be wound around the stator core (310) on which the insulator (320) is installed.

[0043] The rotor (400) may be placed inside the stator (300). The rotor (400) may have a shaft (500) coupled to its center. Here, the inner side may refer to a direction positioned toward the rotation center (C) of the motor (10) based on the radial direction, and the outer side may refer to a direction opposite to the inner side.

[0044] The rotor (400) may include a rotor core (410) and a magnet (420). The rotor core (410) may be formed in a shape in which a plurality of plates in the form of circular thin steel plates are laminated. A hole may be formed in the center of the rotor core (410) through which a shaft (500) passes and is coupled.

[0045] The rotor (400) can be formed by combining a plurality of magnets (420) to a rotor core (410). For example, the rotor (400) can have magnets (420) installed on the outer peripheral surface of the rotor core (410).

[0046] The magnet (420) forms a rotating magnetic field with the coil (330) wound around the stator core (310). The magnet (420) may be installed so that the N pole and the S pole are alternately positioned. Therefore, the rotor (400) rotates due to the electromagnetic interaction between the coil (330) and the magnet (420), and the shaft (500) rotates in conjunction with the rotation of the rotor (400), thereby generating driving force for the motor (10).

[0047] Here, the magnet (420) of the rotor (400) is also referred to as a drive magnet. The magnets (420) may be installed along the outer peripheral surface of the rotor core (410) at regular intervals.

[0048] The shaft (500) can be rotatably supported within the housing (100) by a bearing (600). The shaft (500) can rotate together with the rotation of the rotor (400).

[0049] The bearing (600) may be installed on the upper and lower portions of the shaft (500) depending on the installation location. The bearing (600) may include a first bearing (610) supporting the upper portion of the shaft (500) and a second bearing (620) supporting the lower portion of the shaft (500).

[0050] Additionally, the bearing (600) may include a housing bearing installed in the housing (100) and a cover bearing installed in the cover (200).

[0051] And the bearing (600) may include a ball bearing including an outer ring (601), an inner ring (602), and a ball (603) installed between the outer ring (601) and the inner ring (602). As this bearing (600) supports the outer circumference of the shaft (500), the shaft (500) can rotate within the receiving space of the housing (100).

[0052] The bus bar (700) may be placed on the upper side of the stator (300) and may be supported by the insulator (320). The bus bar (700) may be electrically connected to the coil (330) of the stator (300). A power terminal (820) may be coupled to the bus bar (700) and may be electrically connected to a power transmission device such as an external connector through a through hole perforated in the cover (200).

[0053] Next, FIG. 3 is a perspective view showing a power terminal according to an embodiment of the present invention, and FIG. 4 is a process diagram showing an assembly process of a power terminal assembly according to an embodiment of the present invention.

[0054] Referring to FIG. 4, a bus bar (700) includes a plurality of terminals (712) and a bus bar molding (710) in which the plurality of terminals (712) are injection-molded with synthetic resin, and can be formed into a ring shape having an inner circumferential surface and an outer circumferential surface.

[0055] A plurality of busbar terminals (712) electrically connected to a power terminal (820) may be arranged on the upper side of one side of the busbar molding (710).

[0056] The power terminal assembly (800) may include a guide mold (811).

[0057] The guide mold (811) can be formed of a synthetic resin material through injection molding, similar to the busbar molding (710). The guide mold (811) can be placed on the upper side of the busbar molding (710). For example, the guide mold (811) can support the power terminal (820) so that the power terminal (820) can be maintained in an upright state by penetrating the cover (200) while being fused to the busbar terminal (712) provided in the busbar molding (710).

[0058] The power terminal (820) is formed to protrude above the cover (200) by penetrating the cover (200) from the bus bar molding (710) and can be electrically connected to the power transmission device.

[0059] The power terminal (820) according to an embodiment of the present invention may be a circular rod made of copper, which is an electrical conductor, but the material is not limited to copper.

[0060] Referring to Fig. 3, in order to manufacture a power terminal (820), a single workpiece made of a circular bar having a predetermined length can be prepared.

[0061] A relatively flat plate portion (821) can be formed on the upper side of the workpiece so that it can be electrically connected to an external connector.

[0062] The plate portion (821) can be formed by pressing one side of a workpiece through a forging process using a press mold.

[0063] The forging process involves placing the workpiece in a press mold, i.e., an upper mold and a lower mold, preheating the workpiece to a certain temperature if necessary, and then flattening one side of the workpiece, i.e., the part where the plate portion (821) will be formed, with the press mold. The pressing process of the press mold is such that the forging operation is performed according to the downward movement of the press mold, and the surface of the plate portion (821) is sequentially and repeatedly forged through the pressing process of the press mold.

[0064] The unnecessary peripheral portion of the pressed workpiece can be trimmed to form a plate portion (821).

[0065] A shoulder portion (823) can be formed between the plate portion (821) and the body portion (822) of a workpiece whose trimming has been completed by performing a forging process using a press mold.

[0066] The shoulder portion (823) may be formed into a cylinder shape with a relatively large diameter compared to the diameter of the body portion (822). If necessary, the shoulder portion (823) may be formed into a cylinder shape with an enlarged diameter between the plate portion (821) of the power terminal (820) and the body portion (822) by heating the workpiece and then upsetting forging.

[0067] The shoulder portion (823) may be formed in a cylindrical shape with an enlarged diameter compared to the body portion (822), but is not necessarily limited thereto. That is, the shoulder portion (823) may be formed in various shapes as it functions to support the sealing member (824) described below so that it does not separate from the power terminal (820).

[0068] The body part (822) can be applied as a processed product of a round bar without performing a forging process.

[0069] When the outer shape of the power terminal (820) in which the plate portion (821), the body portion (822), and the shoulder portion (823) are integrally formed by the forging process is formed, short processing can be performed to plastically deform the surface of the power terminal (820) and generate compressive residual stress.

[0070] The short process is a processing technology that can improve the fatigue life, surface strength, corrosion resistance, and wear resistance of the power terminal (820).

[0071] Once the short process is completed, the plating process can be performed. The plating process is a processing technology that coats the outer surface of the power terminal (820) with an anti-oxidation film.

[0072] The plating process can use a method of coating the outer surface of the power terminal (820) with an anti-oxidation paint using an air spray method.

[0073] Referring to FIG. 4, such a shoulder portion (823) can prevent a separate sealing member (824) for improving the sealing performance of the external connector from being separated from the power terminal (820).

[0074] A support tube (825) can be inserted into the body (822) on the lower side of the sealing member (824) to support the sealing member (824).

[0075] Although the shoulder portion (823) is limited to being formed in a cylindrical shape in the drawing, it is not necessarily limited to this, and any structure may be adopted as long as it is a structure that prevents the sealing member (824) from being separated from the power terminal (820).

[0076] Continuing with reference to FIG. 4, the power terminal (820) according to an embodiment of the present invention may be formed integrally with a plate portion (821), a body portion (822), and a shoulder portion (823) made of the same material. In addition, a sealing member (824) and a support tube (825) may be sequentially inserted into the lower side of the shoulder portion (823) of the power terminal (820).

[0077] In this way, in a state where a sealing member (824) and a support tube (825) are inserted into a power terminal (820) made of a single conductive material in which a plate portion (821), a body portion (822), and a shoulder portion (823) are integrally formed by a forging process, the power terminal (820) can be assembled into a through-hole of a guide mold (811) installed in a busbar molding (710).

[0078] At this time, the power terminal (820) can be connected to the busbar terminal (712) of the busbar (700) through a fusing operation. That is, the body part (822) of the power terminal (820) can be connected to the busbar terminal (712) through a fusing operation, and the power terminal (820) can be maintained in an upright state from the busbar molding (710) by the guide mold (811).

[0079] Meanwhile, the trimming process of the power terminal (820) is a process for adjusting the size of the plate portion (821) to a desired size during the process of forming the plate portion (821). After completing the plate portion (821), body portion (822), and shoulder portion (823) of the power terminal (820), an unnecessary portion of the workpiece may be trimmed as a subsequent process.

[0080] According to the motor (10) according to the present invention, the number of manufacturing processes for the power terminal (820) can be reduced by forming the plate portion (821), the body portion (822), and the shoulder portion (823) integrally with a conductive material. In addition, by reducing the number of these three parts to a single unit, cost reduction and productivity improvement can be achieved.

[0081] In addition, by simplifying the manufacturing process of the power terminal (820), the accumulated manufacturing process risk can be reduced, and by forming the plate portion (821) and the body portion (822) integrally without the fusing process, the position tolerance of the plate portion (821) can be reduced, and since cracks or breakage do not occur in the existing fusing formation portion, the occurrence of defects can be fundamentally prevented.

[0082] The above description of the present invention is for illustrative purposes only, and those skilled in the art will readily appreciate that the present invention can be readily modified into other specific forms without altering the technical spirit or essential characteristics of the present invention. Therefore, the embodiments described above should be understood as illustrative in all respects and not restrictive. The scope of the present invention is defined by the following claims, and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be construed as being included within the scope of the present invention.

[0083] According to the present invention, a motor for a vehicle can be provided.

Claims

1. Shaft; A rotor coupled to the above shaft; A stator arranged around the rotor; A busbar distributing power to the stator; and It includes multiple power terminals for connecting external power to the above bus bar, The power terminal includes a plate portion electrically connected to the outside, a body portion connected to the bus bar, and a shoulder portion provided between the plate portion and the body portion and protruding from the body portion. A motor for a vehicle, wherein the plate portion, body portion, and shoulder portion are formed integrally from the same material.

2. In paragraph 1, A vehicle motor further comprising a guide mold coupled to the bus bar and supporting the plurality of power terminals.

3. In paragraph 1, A vehicle motor in which the above plate portion is processed flat and has a different shape from the above body portion.

4. In paragraph 1, The above body portion and the above shoulder portion each include a cylindrical shape, A motor for a vehicle, wherein the diameter of the shoulder portion is larger than the diameter of the body portion.

5. In paragraph 1, A vehicle motor further comprising a sealing member provided on the body of the above power terminal.

6. In paragraph 1, A vehicle motor in which the plate portion, body portion, and shoulder portion are integrally formed by a forging process.

7. In paragraph 1, A vehicle motor in which the plate portion, body portion, and shoulder portion are manufactured using a single workpiece formed in a circular bar shape with a predetermined length.

8. In paragraph 7, A vehicle motor in which the plate portion is formed using a press mold on the other side of a single workpiece made of a circular bar having a predetermined length, one end of which is defined as the body portion.

9. In paragraph 7, The above shoulder portion is a vehicle motor formed by performing a forging process using a press mold between the plate portion and the body portion of the workpiece.

10. In paragraph 7, A vehicle motor in which the shoulder portion is formed into a cylinder shape with an enlarged diameter between the plate portion and the body portion by performing upsetting forging.

Images