JP2011120413A - Motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a motor that exhibits superior welding quality, facilitates connection of a conductor and a bus bar, and is advantageous to miniaturization of a motor. <P>SOLUTION: The motor includes a motor base, a shaft, a rotor, and a stator, wherein the stator includes a core 10 having a plurality of teeth, a plurality of coils 30 which are formed by winding a conductor 31 while interposing an insulator 20 therebetween, a bus bar support 40, and at least one bus bar attached to the bus bar support 40, the bus bar has a plurality of terminals 55, the bus bar support 40 has a plurality of conductor supporting members 45, each terminal 55 has an inside terminal and an outside terminal, each conductor supporting member 45 has a terminal receiving opening and a conductor hook 47 over which the conductor is hooked, and the part of the conductor 31 which is hooked over each terminal receiving opening by the conductor hook 47 is arranged between each outside terminal and each inside terminal and then electrically connected with the terminal 55. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a motor, and more particularly to a bus bar structure to which a conductive wire of a coil is connected.

  Regarding the structure of the bus bar to which the conductive wire of the coil is connected, for example, there is JP-A-2002-153003. In this case, the winding end of the winding portion is sandwiched between the bent portions of the connecting portion, and the bridging wire of the winding portion is hooked on the bent portion of the connecting portion. Are connected to each other.

In general, resistance welding or fusing is used as such a connection method. For example, the terminal is bent and a conductive wire is inserted therebetween. A current is passed by sandwiching the conductive wire between the pair of electrodes from the outside of the terminal. By doing so, the insulating material which covers a conductive wire melts, and the exposed conductive wire and a terminal are welded and connected. For example, Japanese Patent Application Laid-Open No. 2005-229677 discloses fusing.
JP 2002-153003 A Japanese Patent Laid-Open No. 2005-229677

  However, when such a connection method is used, since it is necessary to sandwich the connection part of the terminal with a pair of electrodes, there are various restrictions. For example, when the electrodes are pressed from the direction orthogonal to the motor rotation axis (lateral direction) and the terminal connection part is sandwiched, the conventional bus bar holder is assembled by the height of the terminal connection part after connection. Since a space in the direction of the rotation axis (vertical direction) is required, this is a problem in miniaturizing the motor.

  In addition, when the electrode is pressed from the vertical direction to sandwich the connection part of the terminal, the connection part of the terminal is crimped after the connection, so that the height in the vertical direction can be lowered, but another problem occurs instead. . For example, when performing direct spot welding in which electrodes are sandwiched from both sides of a terminal, it is necessary to form a through-hole into which the electrode can be inserted in the core of the motor in order to secure a space for the electrode. When performing indirect spot welding in which the electrode is sandwiched from one side of the terminal, it is necessary to receive the load of both electrodes with a resin bus bar holder.

  In the former case, the amount of magnetic flux generated by forming a through-hole in the core is reduced, which is an obstacle to achieving high efficiency. In the latter case, a large load is applied to the bus bar holder at the time of welding, and heat generated at the terminal or the like is easily transmitted to the bus bar holder. For this reason, a material and structure excellent in strength and heat resistance is required for the bus bar holder, which causes an increase in cost. For example, when the wire diameter of the conductive wire exceeds 0.8 mm, heat resistance of 600 ° C. or higher is required, so that it is difficult to deal with general-purpose products.

  Further, when the conductive wire is hooked and connected to the bus bar terminal, tension is applied to the terminal by being pulled by the conductive wire, so that the welding quality may be impaired.

  An object of the present invention is to provide a motor that is excellent in welding quality, can be easily connected between a conductive wire and a bus bar, and is advantageous for miniaturization of the motor.

  In order to achieve the above object, in the present invention, the bus bar support for mounting the bus bar and the insulator are provided integrally, and the structure of the bus bar support is devised, and then the electrode is pressed from the lateral direction to connect the conductive wire and the terminal. I was able to do it.

  Specifically, the motor of the present invention includes a motor base, a shaft rotatably supported by the motor base, a rotor fixed coaxially with the shaft, and the motor facing the rotor via a gap. A stator having a plurality of teeth disposed radially around the shaft, an insulating insulator attached to the core, and each of the plurality of teeth. A plurality of coils formed by winding a conductive wire through the insulator, a bus bar support, and at least one bus bar attached to the bus bar support, the bus bar connected to the conductive wire The bus bar support has a plurality of conductive wires provided for each of the plurality of terminals. Each of the terminals is formed in a substantially U-shape and extends in substantially the same direction as the shaft; and an outer side positioned on the outer side in the radial direction of the shaft with respect to the inner terminal portion Each of the conductive wire support portions is open at least in a radial direction of the shaft, and receives a terminal receiving opening portion for receiving the outer terminal portion, and the conductive wire is the terminal in the axial direction of the shaft. A portion of the conductive wire that spans the terminal receiving opening by the conductive wire latching portion, and a conductive wire latching portion that spans the conductive wire so as to pass through an intermediate portion of the receiving opening. However, it is arrange | positioned between each said outer side terminal part and each said inner side terminal part, and is electrically connected with the said terminal.

  Since the conductive wire is arranged between the inner terminal portion extending in the same direction as the shaft and the outer terminal portion positioned outside the shaft, when connecting the terminal and the conductive wire, a pair of electrodes are connected. Can be pressed directly to the terminal from the side. Therefore, it is possible to avoid a problem that occurs when connecting from the vertical direction, and it is possible to easily electrically connect the conductive wire and the terminal.

  Since the portion of the conductive wire to be connected is latched by the conductive wire latching portion, the terminal is not pulled by the conductive wire. Therefore, welding can be performed while reducing the load on the terminals, and the welding quality can be improved.

  As described above, according to the present invention, it is possible to provide a motor that is excellent in welding quality and that can easily connect a conductive wire and a bus bar terminal.

FIG. 1 is a schematic cross-sectional view of the motor of this embodiment. FIG. 2 is a schematic perspective view of the stator. FIG. 3 is an exploded perspective view of the core and the bus bar support. FIG. 4 is an exploded perspective view of the stator. FIG. 5 is a top view of the stator. FIG. 6 is a schematic perspective view showing a main part of the stator. FIG. 7 is a schematic perspective view showing a main part of the stator. FIGS. 8A and 8B are schematic diagrams for explaining connection of terminals. FIG. 9 is a schematic perspective view showing a modified example of the motor.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the following description is merely illustrative in nature and does not limit the present invention, its application, or its use.

  FIG. 1 shows a motor of this embodiment. This motor is a brushless motor, and includes a motor base 1, a shaft 3 that is rotatably supported by the motor base 1 via bearings 2 and 2, and a thin bottomed cylindrical rotor that is fixed coaxially with the shaft 3. 4. It is configured by a thin columnar stator 5 or the like that is positioned on the inner side of the rotor 4 and disposed on the motor base 1 so as to face the rotor 4 with a slight gap therebetween.

  An electric component 6 such as an ECU is mounted on the motor base 1 so as to face the stator 5. A plurality of magnets 7, 7,... For rotating the rotor 4 around the rotation axis A are fixed to the inner peripheral surface of the rotor 4 facing the outer peripheral surface of the stator 5 in cooperation with the stator 5. The rotation axis A coincides with the center line of the shaft 3, and the axial direction, the circumferential direction, the radial direction, and the like described below are the shaft 3 and the rotation axis A in a state where each member is assembled unless otherwise specified. Against. Similarly, in the vertical direction, the motor base 1 side is the upper side and the rotor 4 side is the lower side.

  As shown in FIG. 2, the stator 5 includes a core 10, an insulator 20, a coil 30, a bus bar support 40, a bus bar 50, and the like.

  Specifically, as shown in FIG. 3, the core 10 is composed of a laminated body in which metal plates having a predetermined shape are laminated. When the core 10 is assembled to the annular core base 11 and the motor base 1, A plurality of (15 in the present embodiment) teeth 12, 12,... Are located radially. Each tooth 12 has a teeth base portion 12a extending radially outward from the core base 11, and a teeth flange portion 12b projecting in the circumferential direction from both sides of the distal end portion of the teeth base portion 12a. It is formed in a letter shape. Three long holes 13 (fitting portions) penetrating in the axial direction at predetermined intervals in the circumferential direction are formed in the core base 11. An insulator 20 is attached to the core 10 so as to cover the outer surface thereof.

  As shown in FIG. 4, the insulator 20 is an injection-molded product of insulating resin, and is composed of a pair of half-insulator bodies 21 and 21. The semi-insulator bodies 21 are attached to the core 10 so as to face each other from the axial direction. The insulator 20 has a cylindrical insulator base portion 20a formed corresponding to the core base 11, and a plurality of insulator extension portions 20b, 20b formed corresponding to the teeth 12 and extending radially from the outer peripheral surface of the insulator base portion 20a. Are formed so as to cover the outer portion of the core base 11, the teeth base portion 12a, the inner portion of the teeth flange portion 12b, and the like. A plurality of claw portions 22, 22,... Are provided at equal intervals along the circumferential direction at the upper end portion of the insulator base portion 20a. Each nail | claw part 22 protrudes toward the center side from there.

  A plurality of coils 30, 30,... Are formed on each tooth 12 via an insulator 20. The plurality of coils 30, 30,... Of the present embodiment are formed by winding a single conductive wire 31. Therefore, work man-hours can be reduced and productivity is excellent. For example, the coil 30 is formed by winding the conductive wire 31 a predetermined number of times around a predetermined tooth 12 at the start of winding, and then winding the conductive wire 31 a predetermined number of times continuously to the tooth 12 adjacent to the tooth 12. To do. By repeating this operation, the coils 30 are formed on all the teeth 12.

  The winding direction of each coil 30 may be either clockwise or counterclockwise when the teeth 12 are viewed from the circumferential direction, but the crossover portion 31a extending between the coils 30 and 30 does not intersect and is short-circuited. It is preferable to unify them in any one direction from the standpoint that it can be prevented. In addition, although the part of the crossover 31a is supported by the conductive wire support part 45 of the bus bar support 40, this is mentioned later.

  The bus bar support 40 is provided integrally with the insulator 20 in order to support and fix the bus bar 50, and is devised so that the height dimension in the axial direction does not increase. Therefore, it is not necessary to secure an assembly space in the axial direction as in the conventional bus bar holder, which is advantageous for miniaturization of the motor.

  The bus bar support 40 of the present embodiment is formed separately from the insulator 20, and is configured to be integrated by attaching both to the core 10. Thus, the cost reduction and the improvement of productivity can be aimed at by forming the insulator 20 and the bus bar support 40 separately. That is, the insulator 20 only needs to be able to insulate the core 10 and the coil 30 from each other, and thus the insulator 20 may be thin. On the other hand, the bus bar support 40 needs to support the bus bar 50, and therefore needs a certain thickness. Therefore, by forming both separately, it becomes easy to form each with appropriate thickness, material cost can be reduced, molding becomes easy, and it is advantageous for productivity.

  As shown in FIG. 3, the bus bar support 40 is an injection-molded product of resin having an annular shape having insulating properties. On the lower surface of the bus bar support 40, three long protrusions 41 (fitting parts) protrude in three axial directions corresponding to the long holes 13 formed in the core base 11. The bus bar support 40 is assembled to the core 10 from the lower surface side, and is attached to the core 10 with the long protrusions 41 fitted into the long holes 13. By doing so, the bus bar support 40 is positioned in the circumferential direction and the radial direction with respect to the core 10.

  As shown in FIG. 4, the half insulator bodies 21 and 21 are assembled to the core 10 to which the bus bar support 40 is attached. The bus bar support 40 attached to the core 10 fits inside the insulator base 20a, and the bus bar support 40 and the insulator 20 are integrated.

  At this time, the lower portions of the plurality of claws 22, 22,... Formed at the upper end of the insulator base 20a are set so as to contact the upper surface of the bus bar support 40 (see FIG. 6). Thereby, the bus bar support 40 is positioned in the axial direction and is prevented from coming off. Various structures are provided on the upper surface of the bus bar support 40 so as to support the bus bar 50 and easily connect to the conductive wire 31, details of which will be described later.

  As shown in FIGS. 4 and 5, the bus bar 50 according to the present embodiment includes a plurality of bus bars 50 including a first bus bar 50A, a second bus bar 50B, and a third bus bar 50C. That is, in this motor, three-phase currents of U, V, and W are supplied to the stator 5 (three-phase AC motor). Each bus bar 50 is made of a metal press-processed product having excellent electrical conductivity, and has a main arc portion 54 extending in the circumferential direction, and a plurality of (in the present embodiment, five) integrally provided with the main body portion 54. A terminal 55 and a connection piece 56 are provided. Each main body 54 is attached to the bus bar support 40, each connection piece 56 is connected to the electrical component 6, and each terminal 55 is connected to the conductive wire 31 led out from each coil 30.

  Each terminal 55 of each bus bar 50 is provided at a predetermined position in the circumferential direction, and is formed in a substantially U shape. Specifically, each terminal 55 includes an extended terminal portion 55a extending radially outward from the main body portion 54, an inner terminal portion 55b extending substantially axially from the distal end of the extended terminal portion 55a, and a distal end of the inner terminal portion 55b. The outer terminal portion 55c extends outward in the radial direction and bends in a U shape toward the inner terminal portion 55b, and has an outer terminal portion 55c that is inclined and opposed to the inner terminal portion 55b (see FIGS. 7 and 8).

  The main body portion 54 of each bus bar 50 has a different radius of curvature. The main body portion 54a of the first bus bar 50A, the main body portion 54b of the second bus bar 50B, and the main body portion 54c of the third bus bar 50C increase in order. Yes. The main body 54 of each bus bar 50 is arranged on the upper surface of the bus bar support 40 so that the radial direction overlaps inside and outside.

  As shown in FIG. 6, on the upper surface of the bus bar support 40, a portion between two adjacent main body portions 54, 54 is provided with an insulating protruding wall portion 42 (main body support) for positioning the main body portions 54, 54. Are provided at predetermined locations. Each main body 54 is press-fitted between the protruding wall portions 42. Thereby, each main-body part 54 is fixed in the state positioned by the bus bar support 40, and is prevented from contacting each other.

  Further, in the present embodiment, the bus bar support 40 is provided with a snap fit 43 (prevention preventing portion) that allows entry into the protruding wall portion 42 but does not allow escape. Thereby, each main-body part 54 is prevented from coming off and is stably fixed in the axial direction.

  As shown in FIG. 5, in the state where each bus bar 50 is mounted on the bus bar support 40, the distance r between the center of the rotation axis A and the inner peripheral surface of each inner terminal portion 55b in the radial direction is set to be substantially the same. Has been. This facilitates connection as will be described later. Moreover, the extended terminal part 55a of the bus bar 50 becomes longer as it is located on the inner side, and the extended terminal part 55a of the inner bus bar 50 may straddle the main body part 54 of another bus bar 50 located on the outer side.

  Therefore, as shown in FIG. 6, such an extended terminal portion 55 a (elevated extended terminal portion 57) is extended to the lower portion of the extended extended terminal portion 57 in the bus bar support 40. A protrusion 44 (short-circuit prevention portion) that supports the lower surface of the terminal portion 57 is provided. Thereby, the contact of the elevated extension terminal part 57 and the main body part 54 crossing the lower side can be stably prevented.

  A plurality of (15 in this embodiment) conductive wire support portions 45, 45,... Are provided for each terminal 55 of each bus bar 50 on the outer peripheral portion of the upper surface of the bus bar support 40. These conductive wire support portions 45 are respectively located at portions (15 locations) between two adjacent teeth 12 (see FIG. 5).

  As shown in FIG. 7, each conductive wire support portion 45 has a terminal receiving opening 46 that opens in the axial upper end side and the radial direction, and a conductive wire retaining portion 47 that spans the conductive wire 31. ing.

  The conductive wire latching portion 47 is composed of a pair of columnar protrusions standing on both sides in the circumferential direction of the terminal receiving opening 46. A portion of the connecting wire 31 a that extends between the coils 30 is hung on the conductive wire hooking portion 47. The conductive wire 31 spanned over the conductive wire hooking portion 47 passes through an intermediate portion in the axial direction of the terminal receiving opening 46 and is held in a floating state in the space of the terminal receiving opening 46.

  In a state where each bus bar 50 is mounted on the bus bar support 40, the outer terminal portion 55 c of each terminal 55 enters the terminal receiving opening 46. A groove 48 for receiving each extended terminal portion 55a along the radial direction is formed in the lower inner wall surface 46a that defines the terminal receiving opening 46. Accordingly, each terminal 55 is positioned at a predetermined position of each terminal receiving opening 46. In addition, the bus bars 50 can be stably fixed to the bus bar support 40 by preventing the bus bars 50 from contacting each other by cooperation with the projecting wall portion 42 and the projecting portion 44.

  And the part of the crossover 31a currently hold | maintained in the state which floated in the space of the terminal receiving opening part 46 is arrange | positioned so that it may be pinched | interposed between the inner side terminal part 55b and the outer side terminal part 55c in each terminal 55. Thereby, connection work becomes easy and welding quality can be improved.

  As shown in FIG. 8, at the time of connection, the first electrode 100a and the second electrode 100b can be directly pressed against the respective terminals 55 from inside and outside in the radial direction (lateral direction) to perform fusing. Specifically, each member is mounted to form a core assembly, and the core assembly is attached to a predetermined fusing processing apparatus so as to be rotatable around the rotation axis A.

  As shown to (a) of the figure, the 1st electrode 100a is arrange | positioned adjacent to the internal peripheral surface of the inner side terminal part 55b of one of the terminals 55. FIG. The first electrode 100a may be fixed. The second electrode 100b is disposed on the outer side in the radial direction than the outer terminal portion 55c.

  Then, the second electrode 100b is brought close to the first electrode 100a, the outer terminal portion 55c is pressed against the inner terminal portion 55b, and the outer terminal portion 55c, the inner terminal portion 55b, and the conductive wire 31 are pressure-bonded. In this state, current is passed through both electrodes 100a and 100b to generate heat. The insulating material covering the conductive wire 31 is melted using the heat, and the terminal 55 and the conductive wire 31 are welded as shown in FIG.

  In the present embodiment, since the inner peripheral surface of the inner terminal portion 55b of each terminal 55 is disposed at a substantially constant distance from the center of the rotation axis A, the electrodes 100a and 100b are brought closer to and away from each other while rotating the core assembly. All the terminals 55 can be easily connected in succession simply by touching and separating.

  Since each conductive wire support portion 45 is located at a portion between two adjacent teeth 12, 12, when the electrodes 100a, 100b are operated to be separated from each other, the coil 30 and the second electrode 100b are not connected. Contact can be prevented.

  Furthermore, since the part connected to each terminal 55 of the conductive wire 31 is supported by the conductive wire latching portion 47, each terminal 55 can be welded without being pulled by the conductive wire 31. Therefore, since tension does not act on each terminal 55, the welding quality can be improved, and a motor with excellent durability can be realized.

  The winding start end and winding end end of the conductive wire 31 can also be connected in the same manner as the crossover wire 31a. That is, each end is hooked on the conductive wire retaining portion 47 and then bent toward the terminal receiving opening 46. Then, each end portion is arranged in a state of being sandwiched between the inner terminal portion 55b and the outer terminal portion 55c. Thereafter, if processing is performed in the same manner as the portion of the connecting wire 31a, each end 55 can be connected to each terminal 55 in a bundled state.

  In addition, the motor concerning this invention is not limited to the said embodiment, The other various structure is included.

  For example, the core 10 may be a divided core configured by connecting a plurality of element cores. Even when a plurality of conductive wires 31 are used, the end portions of the conductive wires 31 can be bundled and connected as described above.

  As shown in FIG. 9, the bus bar support 40 may be formed integrally with the semi-insulator body 21. In this case, workability is excellent because the number of assembly steps is reduced.

  The motor of the present invention is suitable for use in an in-vehicle motor such as an engine cooling fan motor.

DESCRIPTION OF SYMBOLS 1 Motor base 3 Shaft 4 Rotor 5 Stator 10 Core 12 Teeth 20 Insulator 30 Coil 31 Conductive wire 40 Bus bar support 45 Conductive wire support part 46 Terminal receiving opening part 47 Conductive wire latching part 50 Bus bar 55 Terminal 55b Inner terminal part 55c Outer terminal Part

Claims (11)

A motor base;
A shaft rotatably supported by the motor base;
A rotor fixed coaxially with the shaft;
A stator disposed on the motor base facing the rotor via a gap;
Including
The stator is
A core having a plurality of teeth positioned radially around the shaft;
An insulating insulator attached to the core;
A plurality of coils formed by winding a conductive wire around each of the plurality of teeth via the insulator;
Busbar support,
At least one bus bar attached to the bus bar support;
With
The bus bar has a plurality of terminals connected to the conductive wire,
The bus bar support has a plurality of conductive wire support portions provided for the plurality of terminals,
Each of the terminals is formed in a substantially U shape,
An inner terminal portion extending in substantially the same direction as the shaft;
An outer terminal portion located on the outer side in the radial direction of the shaft with respect to the inner terminal portion;
Have
Each conductive wire support is
A terminal receiving opening that opens at least in the radial direction of the shaft and receives the outer terminal; and
A conductive wire hooking portion that spans the conductive wire so that the conductive wire passes through an intermediate portion of the terminal receiving opening in the axial direction of the shaft;
Have
The portions of the conductive wires that are spanned by the conductive wire hooking portions to the terminal receiving openings are disposed between the outer terminal portions and the inner terminal portions and are electrically connected to the terminals. Motor. The motor according to claim 1,
The motor in which the bus bar support is provided integrally with the insulator. In the motor according to claim 1 or 2,
A motor in which the distance between the center of the shaft and the inner peripheral surface of each inner terminal portion in the radial direction of the shaft is substantially the same. In the motor according to any one of claims 1 to 3,
The plurality of coils are formed by winding one conductive wire,
A motor in which a portion between the two adjacent coils of the conductive wire is stretched over each terminal receiving opening. In the motor according to any one of claims 1 to 4,
The motor in which each of the conductive wire support portions is located between two adjacent teeth. In the motor according to any one of claims 3 to 5,
The bus bar is composed of a plurality of bus bars,
Each of the plurality of bus bars has a body portion that is provided integrally with the plurality of terminals and extends in the circumferential direction of the shaft,
Each main body portion of the plurality of bus bars is arranged to overlap in the radial direction of the shaft,
A motor in which an insulative main body supporting portion for positioning them is provided at a portion between two adjacent main body portions. The motor according to claim 6, wherein
Each of the plurality of terminals has an extended terminal portion that extends in the radial direction of the shaft, connected to the main body portion and the inner terminal portion.
The extension terminal part includes an elevated extension terminal part straddling the main body part,
A motor in which an insulating short-circuit prevention portion for supporting a lower portion of the elevated extension terminal portion is provided below the elevated extension terminal portion. The motor according to claim 7, wherein
A motor in which a groove for receiving each extended terminal portion along a radial direction of the shaft is formed on an inner wall surface defining each terminal receiving opening. In the motor according to any one of claims 1 to 8,
A motor in which the insulator and the bus bar support are formed separately and are provided integrally by combining the two. The motor according to claim 9, wherein
The core has at least one fitting portion;
The motor which has the to-be-fitted part which the said bus bar support fits with the said fitting part in the axial direction of the said shaft. The motor according to claim 10, wherein
The insulator has a plurality of claw portions protruding from the outer side in the radial direction of the shaft toward the center side;
A motor in which lower portions of the plurality of claw portions are in contact with the bus bar support combined with the insulator together with the core.

Images