Bus bar module and current sensor
Patent Information
- Application Number
- PCT/JP2026/007630
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-03-25
- Filing Date
- 2026-02-27
- Publication Date
- 2026-10-01
Smart Images

Figure JP2026007630_01102026_PF_FP_ABST
Abstract
Description
Busbar module, current sensor
[0001] This invention relates to a busbar module and a current sensor using the same.
[0002] Traditionally, electric vehicles that can run by using electricity stored in a battery to drive a motor have been known as HEVs (Hybrid Electric Vehicles), PHEVs (Plug-in HEVs), and BEVs (Battery Electric Vehicles). In recent years, a system called an e-axle has been proposed for these electric vehicles, which combines major components such as the inverter, motor, and transmission into a single part, with the aim of extending the driving range, expanding the interior space, and reducing costs by decreasing assembly man-hours and the number of parts.
[0003] Inverters and motors commonly found in electric vehicles are equipped with current sensors to detect the current value used for controlling the inverter. To miniaturize the e-axle mentioned above, miniaturization of the current sensors is also required.
[0004] Regarding the miniaturization of current sensors installed in electric vehicles, for example, Patent Document 1 is known. Patent Document 1 describes a current sensor in which three output busbars through which UVW three-phase current for driving a motor flows, and a fourth busbar are arranged in parallel, and a magnetic sensor is placed in the gap of a C-shaped magnetic material surrounding each busbar in at least two of the three output busbars and the fourth busbar. In this current sensor, the gap length of the current sensor on the fourth busbar that is further away from the current sensor on the output busbars is made larger than the gap length of the current sensor that is closer, thereby reducing the influence of leakage magnetic flux from the current sensors on the output busbars on the current sensor on the fourth busbar. As a result, even if the distance between adjacent busbars is reduced, a decrease in the measurement accuracy of the current sensor is prevented, and the current sensor is made more compact.
[0005] Japanese Patent Publication No. 2014-6116
[0006] In Patent Document 1, multiple busbars with a wide vertical shape are arranged horizontally on the inverter connection side. However, depending on the arrangement and structure of the output terminals on the inverter side, it may be necessary to match the width direction and the arrangement direction of each busbar. On the other hand, the current detection portion of each busbar requires space to accommodate magnetic material around each busbar. The busbar structure described in Patent Document 1 cannot satisfy both of these requirements, so there is room for improvement in terms of miniaturization.
[0007] The present invention has been made in view of the above problems, and its main objective is to achieve miniaturization of a current sensor in a busbar module for a current sensor consisting of multiple busbars, while ensuring that the width direction and arrangement direction of each busbar are aligned.
[0008] The busbar module according to the present invention comprises a plurality of busbars having a plate-like shape, the plurality of busbars arranged along a first direction, each of the plurality of busbars having a busbar weld portion extending in a second direction perpendicular to the first direction and having a plate width direction that coincides with the first direction, a busbar core penetration portion extending in the second direction and having a plate width direction that coincides with a third direction perpendicular to the first and second directions respectively, and a busbar intermediate portion provided between the busbar weld portion and the busbar core penetration portion, the busbar intermediate portion including at least a portion having a predetermined inclination angle greater than 0° with respect to the first direction, and is formed along a plane parallel to the third direction. The current sensor according to the present invention comprises a busbar module, a plurality of magnetic collecting cores arranged around the busbar core penetration portion of each busbar of the busbar module, a plurality of current detection elements arranged in the gaps of the magnetic collecting cores, and a case portion that houses the magnetic collecting cores and the current detection elements, with the busbar weld portion of each busbar of the busbar module being brought out to the outside.
[0009] According to the present invention, in a busbar module for a current sensor consisting of multiple busbars, it is possible to achieve miniaturization of the current sensor while aligning the width direction and arrangement direction of each busbar.
[0010] This is an external view of a current sensor according to one embodiment of the present invention. This is a diagram showing an example of the busbar structure. This is a top-down perspective view of a current sensor according to one embodiment of the present invention when viewed in the -Z direction. This is a top-down perspective view of a current sensor according to a comparative example when viewed in the -Z direction. This is a partially enlarged view of the busbar module in a current sensor according to one embodiment of the present invention. This is a diagram showing the relationship between the tilt angle A and the pitches Px and Py. This is a top-down perspective view of a current sensor according to a modified example of the present invention when viewed in the -Z direction.
[0011] Figure 1 is an external view of a current sensor according to one embodiment of the present invention. The current sensor 100 shown in Figure 1 is installed, for example, between an inverter and a motor mounted in an electric vehicle, and is used to detect the alternating current input and output between the inverter and the motor. In the following description, it is assumed that the orientations of the X, Y, and Z coordinate axes of the current sensor 100 are defined as shown in the coordinate axis 200.
[0012] The current sensor 100 comprises a sensor body 1 and a busbar module 2 composed of a combination of multiple busbars 20 having a plate-like shape. In this embodiment, the current sensor 100 is illustrated in which the busbar module 2 has nine busbars 20 in order to detect three sets of three-phase AC currents, i.e., a total of nine phases of AC current, that are input and output between the inverter and the motor. In Figure 1, in order to distinguish each busbar 20, reference numerals 20a to 20i are assigned to each busbar 20 according to the order of their arrangement positions in the direction along the X-axis from the left side of the figure. However, the number of busbars 20 that constitute the busbar module 2 is not limited to the example in Figure 1. The current sensor 100 can use a busbar module 2 composed of any number of busbars 20.
[0013] The sensor body 1 comprises a case 10 and a connector 11. The case 10 holds each busbar 20 in a predetermined positional relationship and houses the magnetic collecting core 12 and current detection element 13 (see Figure 2), which are provided for each busbar 20, respectively. The connector 11 is formed by making a part of the case 10 protrude and has a plurality of signal pins electrically connected to each current detection element 13. The output signals from each current detection element 13 are taken out of the sensor body 1 via the connector 11 and transmitted to a control device (not shown) that controls the operation of the inverter. The case 10 and the connector 11 are formed of, for example, resin.
[0014] Figure 2 shows an example of the structure of a busbar 20. In Figure 2, the structure of any one of the multiple busbars 20 that make up the busbar module 2, for example, busbar 20a, is shown as a representative example. Although there are some differences in size, the basic structure of each busbar 20 other than busbar 20a is the same as in Figure 2. Therefore, the structure of all busbars 20 will be explained below using the example in Figure 2.
[0015] The busbar 20 has a busbar welded portion 21, a first bent portion 22, a busbar intermediate portion 23, a second bent portion 24, a busbar core penetration portion 25, a third bent portion 26, and a busbar fastening portion 27. The busbar 20 is made of a conductive material. For example, a busbar 20 with the shape shown in Figure 2 can be created by bending a metal piece cut from a metal plate such as copper into a predetermined shape, and forming the first bent portion 22, the second bent portion 24, and the third bent portion 26 at predetermined positions on the metal piece.
[0016] The busbar weld 21 extends in the Y-axis direction, which is perpendicular to the X-axis direction (see Figure 1), which is the arrangement direction of each busbar 20 in the busbar module 2. The plate width direction of the busbar weld 21 coincides with the X-axis direction.
[0017] The busbar core penetration portion 25 extends in the Y-axis direction, similar to the busbar weld portion 21. Unlike the busbar weld portion 21, the plate width direction of the busbar core penetration portion 25 coincides with the Z-axis direction. A magnetizing core 12 is arranged around the busbar core penetration portion 25 to collect the magnetic force generated when current flows through the busbar core penetration portion 25. The magnetizing core 12 has a U-shape with a portion of its entire circumference surrounding the busbar core penetration portion 25 missing, and a current detection element 13 is arranged in this U-shaped missing portion (gap).
[0018] The current detection element 13 detects the magnitude of the magnetic force collected by the magnetizing core 12 and outputs an output signal corresponding to the detection result to the outside of the sensor body 1 via the connector 11. The signal output from the current detection element 13 in this way represents the magnitude of the current flowing through the busbar core penetration portion 25 and can therefore be used as the current detection signal for the busbar 20. In the current sensor 100 of this embodiment, current detection for each phase is performed by outputting such an output signal from the current detection element 13 for each phase.
[0019] A busbar intermediate section 23 is provided between the busbar weld 21 and the busbar core penetration 25. One end of the busbar intermediate section 23 extends in the Z-axis direction and is connected to the busbar weld 21 via a first bend 22, while the other end extends in the X-axis direction and is connected to the busbar core penetration 25 via a second bend 24. The busbar intermediate section 23 includes at least a portion having a predetermined inclination angle greater than 0° with respect to the X-axis direction and is formed along a plane parallel to the Z-axis direction. This point will be described later with reference to Figure 3.
[0020] A busbar fastening portion 27 is provided on the opposite side of the busbar intermediate portion 23 in the busbar core penetration portion 25. The busbar fastening portion 27 is connected to the busbar core penetration portion 25 via a third bend portion 26, and its plate width direction coincides with the X-axis direction. A through hole 28 is formed in the busbar fastening portion 27 for fastening the current sensor 100, which includes the busbar 20, to the motor.
[0021] In the current sensor 100, each busbar 20 of the busbar module 2 is held in the sensor body 1 as described above. At this time, as shown in Figure 1, the busbar weld portion 21 of each busbar 20 is pulled out from the sensor body 1 toward the outside in the +Y direction, and the portion of the busbar fastening portion 27 of each busbar 20 including the through hole 28 is exposed from the sensor body 1. In this way, the busbar weld portion 21 is welded to the terminal portion of the inverter, and the busbar fastening portion 27 is fastened to the terminal portion of the motor using fastening members such as screws, thereby enabling the current sensor 100 to be electrically connected to the inverter and the motor. On the other hand, the busbar intermediate portion 23 and the busbar core through portion 25 are housed in the case portion 10 of the sensor body 1 together with the magnetic collecting core 12 and the current detection element 13.
[0022] Next, the details of the intermediate busbar portion 23 will be described below with reference to Figure 3. Figure 3 is an overhead perspective view of a current sensor 100 according to one embodiment of the present invention, viewed in the -Z direction. In Figure 3, in order to show the shape of each busbar 20, only the magnetic collecting core 12 of the sensor body portion 1 is shown, and the case portion 10, connector portion 11, and current detection element 13 are omitted from the illustration.
[0023] As shown in Figure 3, in the busbar weld 21, the spacing between each busbar 20 is narrowed to match the terminal layout of the inverter to which it is connected. On the other hand, in the busbar core penetration 25, the spacing between each busbar 20 needs to be wider than in the busbar weld 21 in order to allow the magnetic collecting core 12 to be positioned relative to each busbar 20. Therefore, as shown in Figure 3, the length of the intermediate portion 23 of each busbar 20 gradually increases as it moves away from the busbar 20a. However, for busbars 20f to 20i, the intermediate portion 23 bends horizontally (+X direction) midway through, which suppresses the expansion of the intermediate portion 23 in the -Y direction and ensures that the busbar core penetration 25 has a certain length or longer.
[0024] The intermediate portion 23 of each busbar 20 is inclined by a predetermined angle A with respect to the X-axis direction. However, for busbars 20f to 20i, as described above, the intermediate portion 23 of the busbar is bent midway, so in addition to the portion inclined by angle A, the intermediate portion 23 of the busbar also has a portion that extends horizontally. Furthermore, it can be seen that this angle A is common to all busbars 20a to 20i of the busbar module 2. In the current sensor 100 of this embodiment, by doing so, the width direction and arrangement direction of the busbar welded portion 21 of each busbar 20 are aligned with the X-axis direction, while securing the necessary spacing between the busbar core penetration portions 25 to arrange the magnetic collecting core 12, thereby achieving miniaturization of the current sensor 100 as a whole.
[0025] Here, the fact that the current sensor 100 can be miniaturized by tilting the busbar intermediate portion 23 by a predetermined inclination angle A with respect to the X-axis direction, as described above, will be explained below using a comparative example where such a structure is not adopted.
[0026] Figure 4 is an overhead perspective view of the current sensor 100' according to a comparative example, viewed in the -Z direction. Unlike the current sensor 100 shown in Figure 3, the intermediate portion 23 of each busbar 20 in the current sensor 100' is not inclined with respect to the X direction. In this state, in order to increase the spacing between each busbar 20 at the busbar core penetration portion 25, it is necessary to increase the length of the busbar core penetration portion 25 of each busbar 20 as it moves away from the busbar 20a, as shown in Figure 4. As a result, for example, in busbars 20h and 20i, a part of the busbar core penetration portion 25 and the intermediate portion 23 of the busbar protrude from the case portion 10.
[0027] On the other hand, in the current sensor 100 of this embodiment shown in Figure 3, as described above, the intermediate busbar portion 23 is tilted by a predetermined inclination angle A with respect to the X-axis direction, which prevents the length of the busbar core penetration portion 25 of each busbar 20 from increasing unnecessarily. As a result, the busbar core penetration portion 25 and the intermediate busbar portion 23 of all busbars 20a to 20i can be housed within the case portion 10. Therefore, it is possible to miniaturize the current sensor 100 compared to the comparative example.
[0028] Next, the method for setting the inclination angle A described above will be explained below with reference to Figures 5 and 6.
[0029] Figure 5 is a partially enlarged view of the busbar module 2 in a current sensor 100 according to one embodiment of the present invention. Figure 5 shows an enlarged view of the area around the intermediate portion 23 and the second bent portion 24 of the busbar 20a of the busbar module 2 of the current sensor 100 shown in Figure 3.
[0030] In Figure 5, the inclination angle A of the busbar intermediate portion 23 of the busbar 20a is defined as the angle between the busbar intermediate portion 23 and a virtual straight line 31 drawn horizontally along the X-axis direction (left-right direction in the figure) from the bending center point of the second bend portion 24. The inclination angle A of the busbar intermediate portion 23 is defined similarly for the other busbars.
[0031] The inclination angle A in Figure 5 is determined, for example, to satisfy the following equation (1). In equation (1), Px and Py represent the pitch (distance between centerlines) of the busbar weld 21 and the busbar intermediate portion 23 between adjacent busbars 20 (for example, busbar 20a and busbar 20b) along the arrangement direction. A = tan -1 (Py / Px) ... (1)
[0032] Figure 6 illustrates the relationship between the inclination angle A represented by equation (1) and the pitches Px and Py. In Figure 6, the values of the pitches Px and Py and the inclination angle A are common to each bus bar 20 (bus bars 20a to 20i) of the bus bar module 2.
[0033] According to the first embodiment of the present invention described above, the following effects are achieved.
[0034] (1) The busbar module 2 comprises a plurality of busbars 20 (busbars 20a to 20i) having a plate-like shape. The busbars 20a to 20i are arranged along the X-axis direction. Each of the busbars 20a to 20i has a busbar welded portion 21 that extends in the Y-axis direction perpendicular to the X-axis direction and whose plate width direction coincides with the X-axis direction, a busbar core penetration portion 25 that extends in the Y-axis direction and whose plate width direction coincides with the Z-axis direction which is perpendicular to the X-axis direction and the Y-axis direction, respectively, and a busbar intermediate portion 23 provided between the busbar welded portion 21 and the busbar core penetration portion 25. The busbar intermediate portion 23 includes at least a portion having a predetermined inclination angle A greater than 0° with respect to the X-axis direction and is formed along a plane parallel to the Z-axis direction. In this way, in the busbar module 2 for the current sensor 100 consisting of a plurality of busbars 20, the width direction and arrangement direction of each busbar 20 can be made to coincide at the busbar welded portion 21, while miniaturization of the current sensor 100 can be achieved.
[0035] (2) The inclination angle A is common to all bus bars 20a to 20i. This allows the intermediate busbar portions 23 of bus bars 20a to 20i to be arranged in parallel. As a result, the spread of the intermediate busbar portions 23 of bus bars 20a to 20i when they are arranged side by side can be suppressed, thus enabling miniaturization of the current sensor 100.
[0036] (3) When an order is defined for the bus bars 20a to 20i according to the arrangement position of each bus bar along the X-axis, as shown in Figure 3, the length of the bus bar intermediate portion 23 of the bus bars 20a to 20i gradually increases according to the order. In this way, the length of the bus bar core penetration portion 25 of the bus bars 20a to 20i in the Y-axis direction is prevented from increasing unnecessarily, and the current sensor 100 can be made smaller.
[0037] (4) In the busbar module 2, when the pitches of the busbar weld 21 and the busbar intermediate portion 23 between mutually adjacent busbars 20 among the busbars 20 arranged along the X-axis direction are defined as Px and Py respectively, the value A of the inclination angle can be determined so as to satisfy the above formula (1). With this configuration, it is possible to appropriately set the value of the inclination angle for achieving size reduction of the current sensor 100.
[0038] Note that in the above embodiment, as shown in Fig. 3, an example has been described in which the length of the busbar intermediate portion 23 of each busbar 20 gradually increases from the busbar 20a at one end to the busbar 20i at the other end in the busbar module 2. However, the shape of each busbar 20 in the busbar module 2 is not limited thereto. For example, for the busbar 20 positioned at the most center in the arrangement direction of the busbars 20, the length of the busbar intermediate portion 23 of the busbar 20 can be minimized, and the shape of each busbar 20 in the busbar module 2 can also be set such that the length of the busbar intermediate portion 23 gradually increases as the position is further away from the busbar 20 toward both sides in the arrangement direction. Even with this configuration, similarly to the above embodiment, it is possible to achieve size reduction of the current sensor configured using the busbar module 2 while aligning the width direction and the arrangement direction of each busbar 20 at the busbar weld 21.
[0039] The above modified example will be described below with reference to Fig. 7. Fig. 7 is an overhead perspective view of a current sensor 100A according to a modified example of the present invention when viewed in the -Z direction. Note that the current sensor 100A according to the present modified example also has the same configuration as the above-mentioned current sensor 100, but in Fig. 7, similarly to Fig. 3, only the magnetic collecting core 12 of the sensor main body 1 is illustrated so that the shape of each busbar 20 can be seen, and illustration of the case portion 10, the connector portion 11, and the current detection element 13 is omitted.
[0040] In the current sensor 100A shown in Figure 7, the bus bar 20e, which is the centrally located bus bar among the bus bars 20a to 20i in their arrangement direction, has the shortest length of the intermediate portion 23 of the bus bar, as described above. Furthermore, the intermediate portion 23 of the bus bar 20e and the bus bars 20f to 20i, which are arranged in the +X direction starting from bus bar 20e, are inclined downward to the right. In addition, the length of the intermediate portion 23 of the bus bar gradually increases as it moves away from bus bar 20e. On the other hand, the intermediate portions 23 of the bus bars 20a to 20d, which are arranged in the -X direction from bus bar 20e, are inclined in a different direction from bus bars 20e to 20i, specifically upward to the right. Also, similar to bus bars 20e to 20i, the length of the intermediate portion 23 of the bus bar gradually increases as it moves away from bus bar 20e.
[0041] In the current sensor 100A shown in Figure 7, the intermediate busbar portions 23 of busbars 20a to 20d (first busbar group) are each inclined by a predetermined inclination angle B with respect to the X-axis direction. On the other hand, the intermediate busbar portions 23 of busbars 20e to 20i (second busbar group) are each inclined by a predetermined inclination angle C with respect to the X-axis direction. These inclination angles B and C can be determined, similar to the inclination angle A in the current sensor 100, so as to satisfy the aforementioned equation (1). In this case, the pitches Px and Py in equation (1) are determined by the distance between the centerlines of the busbar welds 21 and the intermediate busbar portions 23 of busbars 20a to 20d for inclination angle B, and by the distance between the centerlines of the busbar welds 21 and the intermediate busbar portions 23 of busbars 20e to 20i for inclination angle C.
[0042] In other words, for the busbars 20a to 20d of the first busbar group located on one side in the X-axis direction in the current sensor 100A, the inclination angle B of the busbar intermediate portion 23 is determined such that, for example, the following equation (1B) is satisfied. Equation (1B) is obtained by setting the pitches Px and Py in equation (1) to the pitch Px of the busbar weld 21 and the busbar intermediate portion 23 in each busbar 20 of the first busbar group. 1 , Py 1 These are the results of substituting them as follows: B = tan -1 (Py 1 / Px 1 ) ... (1B)
[0043] Similarly, for busbars 20e to 20i of the second busbar group located on the other side in the X-axis direction in the current sensor 100A, the inclination angle C of the busbar intermediate portion 23 is determined, for example, so as to satisfy the following formula (1C). In formula (1C), the pitches Px and Py of formula (1) are replaced with the pitch Px between the busbar welded portion 21 and the busbar intermediate portion 23 of each busbar 20 of the second busbar group 2 , Py 2 respectively. C=tan -1 (Py 2 / Px 2 ) ... (1C)
[0044] Note that, in the example of Fig. 7, the inclination angle B and the inclination angle C are different from each other, but these are not necessarily different, and may be the same angle.
[0045] Furthermore, the present invention is not limited to the above-described embodiments and modified examples, and other forms conceivable within the scope of the technical idea of the present invention are also included within the scope of the present invention as long as the features of the present invention are not impaired. A configuration combining the above-described embodiments, modified examples and other modified examples may also be adopted.
[0046] 1: Sensor main body 2: Busbar module 10: Case portion 11: Connector portion 12: Magnetism collecting core 13: Current detection element 20: Busbar 21: Busbar welded portion 22: First bent portion 23: Busbar intermediate portion 24: Second bent portion 25: Busbar core penetrating portion 26: Third bent portion 27: Busbar fastening portion 28: Through hole 100, 100A, 100': Current sensor
Claims
1. A busbar module comprising a plurality of busbars having a plate-like shape, wherein the plurality of busbars are arranged along a first direction, and each of the plurality of busbars has a busbar weld portion extending in a second direction perpendicular to the first direction and having a plate width direction that coincides with the first direction, a busbar core penetration portion extending in the second direction and having a plate width direction that coincides with a third direction perpendicular to the first and second directions, respectively, and a busbar intermediate portion provided between the busbar weld portion and the busbar core penetration portion, wherein the busbar intermediate portion includes at least a portion having a predetermined inclination angle greater than 0° with respect to the first direction and is formed along a plane parallel to the third direction.
2. A busbar module according to claim 1, wherein the inclination angle is common among the plurality of busbars.
3. A busbar module according to claim 2, wherein when an order is defined for each of the plurality of busbars according to the arrangement position of each busbar along the first direction, the length of the intermediate portion of the plurality of busbars gradually increases according to the order.
4. A busbar module according to claim 2, wherein, if Px and Py are the pitches between adjacent busbars and the intermediate portion of the busbars, respectively, among the busbars arranged along the first direction, the value of the inclination angle A is determined to satisfy the following equation (1): A = tan -1 (Py / Px) ...(1) 5. A busbar module according to claim 1, wherein the plurality of busbars include a first busbar group consisting of one or more busbars located on one side in the first direction, and a second busbar group consisting of one or more busbars located on the other side in the first direction, wherein the inclination angle is common between each busbar in the first busbar group and between each busbar in the second busbar group.
6. A busbar module according to claim 5, wherein when an order is defined for each busbar of the first busbar group and the second busbar group according to the arrangement position of each busbar along the first direction, the length of the intermediate portion of each busbar of the first busbar group and the second busbar group gradually increases according to the order.
7. The bus bar module according to claim 5, wherein pitches between the bus bar welded portions and the bus bar intermediate portions of said mutually adjacent bus bars among said bus bars in said first bus bar group arranged along said first direction are respectively Px 1 , Py 1 and pitches between the bus bar welded portions and the bus bar intermediate portions of said mutually adjacent bus bars among said bus bars in said second bus bar group arranged along said first direction are respectively Px 2 , Py 2 then, the bus bar module, wherein an inclination angle value B for each bus bar in said first bus bar group and an inclination angle value C for each bus bar in said second bus bar group are determined so as to satisfy the following formula (1B) and formula (1C), respectively: B = tan -1 (Py 1 / Px 1 ) ... (1B) C = tan -1 (Py 2 / Px 2 ) ... (1C) 8. A busbar module according to claim 1, wherein the spacing between each busbar in the busbar weld is smaller than the spacing between each busbar in the busbar core penetration.
9. A busbar module according to claim 1, wherein each of the plurality of busbars has a busbar fastening portion connected to the busbar core penetration portion, and the plate width direction coincides with the first direction.
10. A current sensor comprising: a busbar module according to any one of claims 1 to 9; a plurality of magnetic collecting cores arranged around the busbar core penetration portion of each busbar of the busbar module; a plurality of current detection elements arranged in the gaps of the magnetic collecting cores; and a case portion housing the magnetic collecting cores and the current detection elements, from which the busbar weld portions of each busbar of the busbar module are extended to the outside.