JP2014193025A - Bus bar device, method of manufacturing the same, stator, and brushless motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a bus bar device that is hardly subjected to high temperature, a stator, and a brushless motor.SOLUTION: In a bus bar device, ends of a plurality of coils are electrically connected together by a plurality of bus bars 50, 60 and 70 adjacent to each other, and insulated layers 80 and 90 made of a nonconductive material are interposed among a plurality of bus bars 50, 60 and 70. The insulated layers 80 and 90 comprise such grooves 82a, 83a, 92a and 93a as to get away from the adjacent bus bars 50, 60 and 70.

Description

  The present invention relates to a bus bar device connected to a plurality of coils included in a motor, a stator including the bus bar device, and a brushless motor including the bus bar device.

  Conventionally, some brushless motors include a plurality of coils arranged in the circumferential direction and a bus bar device having a plurality of bus bars that are electrically connected to an external power supply device. Current is supplied to the plurality of coils from the external power supply device via the bus bar. Usually, an insulating member formed of an insulating material such as resin is interposed between the bus bars. Thereby, the insulation between bus bars is ensured.

  For example, the bus bar device of Patent Document 1 has a configuration in which a plurality of bus bars and insulating materials are alternately stacked in the axial direction of the motor. Thereby, the magnitude | size to the radial direction of a brushless motor is suppressed.

JP 2005-65374 A

  Since the bus bar is a current flow path, heat is generated by supplying current to the coil from an external power supply device. However, since the bus bar device of Patent Document 1 has a configuration in which a plurality of bus bars and an insulating material are stacked, there is little escape space for heat generated in the bus bar. For this reason, a bus-bar apparatus and by extension, a stator and a motor are easy to become high temperature.

  This invention is made | formed in view of such the actual condition, The objective is to provide the bus-bar apparatus which is hard to become high temperature, a stator, and a brushless motor.

  In order to solve the above problem, the ends of the plurality of coils are electrically connected to each other by a plurality of bus bars adjacent to each other, and an insulating layer made of a non-conductive material is interposed between the plurality of bus bars. In the bus bar device according to the aspect of the invention, the insulating layer includes at least one of a groove that is spaced from the adjacent bus bar and a protrusion that protrudes from the adjacent bus bar.

  According to the above configuration, a space is formed between the insulating layer and the bus bar. That is, since the bus bar is in contact with the space, even if heat is generated as a current flows, the heat can move to the space. Thereby, it is suppressed that a bus-bar apparatus becomes high temperature.

The gist of the bus bar is that it is manufactured by forging a conductive material.
Usually, the bus bar is manufactured by punching a conductive material. Since the end face of the bus bar manufactured in this way often has burrs, the yield is poor. In that respect, according to the above configuration, burrs are unlikely to be generated on the end face of the manufactured bus bar, so that the yield is good.

The gist is to include a plurality of coils arranged in the circumferential direction and the bus bar device configured as described above.
According to the said structure, it is suppressed that a stator becomes high temperature.

  The gist of the present invention is to include a stator formed by electrically connecting the ends of a plurality of coils arranged in the circumferential direction in the bus bar device having the above-described configuration, and a rotor disposed inside the stator.

  According to the said structure, it is suppressed that a brushless motor becomes high temperature.

  According to the bus bar device, the stator, and the brushless motor of the present invention, there is an effect that the high temperature hardly occurs.

Sectional drawing of a motor. The perspective view of a copper wire. The exploded perspective view of a bus-bar apparatus. The perspective view of a holder. The perspective view of the 1st bus bar. The perspective view of the 1st and 2nd insulating wall. Sectional drawing of a bus-bar apparatus. The perspective view of a bus-bar apparatus.

Hereinafter, an embodiment of a brushless motor including a bus bar device will be described.
<Overview of brushless motor>
As shown in FIG. 1, the brushless motor 11 (hereinafter, motor 11) includes a bottomed cylindrical case 12 and a lid 13 that closes the opening of the case 12. A cylindrical stator 14 is fixed to the inner peripheral surface of the case 12. The stator 14 includes a cylindrical core 15, two insulators 16 and 17 provided at both ends of the core 15, and a plurality of coils 18 wound around the core 15 via the insulators 16 and 17. ing.

  A rotor 19 is inserted through the stator 14. The rotor 19 includes a columnar rotating shaft 20, a cylindrical rotor core 24 fixed to the outer peripheral surface of the rotating shaft 20, and a cylindrical rotor magnet 21 fixed to the outer peripheral surface of the rotor core 24. The rotating shaft 20 is rotatably supported via two bearings 22 and 23 provided on the inner bottom of the case 12 and the inner surface of the lid 13. A bus bar device 30 is attached to the end of the stator 14 on the lid 13 side.

<Bus bar device>
As shown in FIG. 3, the bus bar device 30 includes a holder 40, first, second, and third bus bars 50, 60, and 70, and first and second insulating walls 80 and 90. .

  As shown in FIG. 3, the holder 40 includes a cylindrical holder main body 41 and an annular storage portion 42 that is recessed on the surface of the holder main body 41 on the lid 13 side. The depth of the accommodating portion 42 is slightly longer than the total length of the thicknesses of the first, second, and third bus bars 50, 60, and 70 and the thicknesses of the first and second insulating walls 80 and 90. Have

  Further, as shown in FIG. 4, the holder body 41 has 15 cutouts 43A, 43B, 43C, 43D, 43E, 43F, 43G, 43H, 43I, 43J, 43K, 43L, 43M, and 43N on the outer peripheral surface. , 43O are provided. The first to twelfth notches 43A to 43L are provided at regular intervals, that is, every 30 °. The thirteenth and fourteenth notches 43M and 43N are provided at equal intervals between the eleventh notch 43K and the twelfth notch 43L. When the first notch 43A is at a 0 ° position, the thirteenth notch 43M is at a 310 ° position, and the fourteenth notch 43N is at a 320 ° position. The fifteenth notch 43O is provided between the twelfth notch 43J and the thirteenth notch 43K. The fifteenth notch 43O is at a position of 285 °.

  As shown in FIG. 5, the first bus bar 50 includes a ring-shaped bus bar main body portion 51, a power feeding portion 52 extending radially outward from the bus bar main body portion 51, and four bus bars extending from the bus bar main body portion 51 radially outward. Coil connection portions 53, 54, 55, and 56. The inner diameter of the bus bar main body 51 is set slightly smaller than the inner diameter of the accommodating portion 42, and the outer diameter is set slightly smaller than the outer diameter of the accommodating portion 42. The power feeding section 52 is at a position of 320 °. The coil connection portions 53 to 56 are positioned at 30 °, 120 °, 180 °, and 330 °, respectively.

  The coil connection portion 53 is bent from the base end portion thereof and extends toward the lid 13, and is bent from the distal end portion of the first extension portion 53 a and radially outside the bus bar main body portion 51. And a second extending portion 53b extending in the direction. The first extending portion 53a has a length obtained by adding the thickness of the second and third bus bars 60, 70 and the thickness of the first and second insulating walls 80, 90. The coil connection parts 54 to 56 have the same configuration as the coil connection part 53. That is, the coil connecting portion 54 includes the first and second extending portions 54a and 54b, the coil connecting portion 55 includes the first and second extending portions 55a and 55b, and the coil connecting portion 56 includes the first and second extending portions. Extending portions 56a and 56b. The length of the first extension portions 54a, 55a, 56a is the same as that of the first extension portion 53a, and the thickness of the second and third bus bars 60, 70 and the first and second insulating walls 80, The length is the sum of 90 thicknesses.

  As shown in FIG. 3, the second bus bar 60 includes a bus bar main body portion 61, a power feeding portion 62, and four coil connection portions 63, 64, 65, and 66, similarly to the first bus bar 50. . The power feeding unit 62 is at a position of 310 °. The coil connection parts 63 to 66 are positioned at 0 °, 60 °, 210 °, and 270 °, respectively.

  The coil connection parts 63 to 66 have the same configuration as the coil connection part 53. That is, the coil connection parts 63-66 are each provided with the 1st and 2nd extension part. The length of the first extending portion is a length obtained by adding the thickness of the third bus bar 70 and the thickness of the second insulating wall 90 together. That is, in the second bus bar 60, the position where the power feeding portion 62 and the four coil connection portions 63 to 66 are provided and the length of the first extension portion of the coil connection portions 63 to 66 are the first bus bar. Only the 50 corresponding configurations are different.

  Similar to the first and second bus bars 50, 60, the third bus bar 70 includes a bus bar main body 71, a power feeding part 72, and four coil connection parts 73, 74, 75, 76. The power feeding unit 72 is at a position of 285 °. The coil connection portions 73 to 76 are provided at positions of 90 °, 150 °, 240 °, and 300 °, respectively, and extend radially outward from the bus bar main body portion 71. That is, the third bus bar 70 is different from the corresponding configuration of the first bus bar 50 in the positions where the power feeding unit 72 and the four coil connection units 73 to 76 are provided. Further, the four coil connection portions 73 to 76 are omitted from the configuration corresponding to the first extension portions of the four coil connection portions 53 to 56 in the first bus bar 50, and the coil connection portions directly from the bus bar main body portion 71. The structure corresponding to the 2nd extension part of 53-56 is provided.

The first to third bus bars 50 to 70 are formed by forging a copper wire 100 which is a conductive material as shown in FIG.
As shown in FIGS. 6 and 7, the first and second insulating walls 80, 90 are made of a non-conductive resin material, and ring-shaped insulating wall main body portions 81, 91, insulating wall main body portions 81, 91, projecting walls 82, 92 projecting in an annular shape on the surface on the lid 13 side, and projecting walls 83, 93 projecting in an annular shape on the surface on the case 12 side of the insulating wall main bodies 81, 91. ing. The inner and outer diameters of the insulating wall main body 81 are set equal to the inner and outer diameters of the bus bar main body portions 51 to 71. The projecting walls 82, 83, 92, 93 have an inner diameter larger than the inner diameter of the insulating wall main body 81 and an outer diameter smaller than the outer diameter of the insulating wall main body 81. Circular grooves 82 a, 83 a, 92 a, and 93 a are recessed in the surface on the lid 13 side of the protruding walls 82 and 92 and the surface on the case 12 side of the protruding walls 83 and 93. The first and second insulating walls 80 and 90 correspond to the insulating layer, and the protruding walls 82, 83, 92, and 93 correspond to the protruding portions, respectively.

  As shown in FIG. 3, the first bus bar 50, the first insulating wall 80, the second bus bar 60, the second insulating wall 90, and the third bus bar 70 are laminated in this order from the case 12 side. It is accommodated in the accommodating portion 42 of the holder 40. The positions at which the power supply portions and the coil connection portions of the first to third bus bars 50 to 70 are provided correspond to the positions of the notches 43A to 43O. Therefore, as shown in FIG. 8, the power feeding portions and the coil connection portions of the first to third bus bars 50 to 70 protrude from the notches 43 </ b> A to 43 </ b> O to the outside of the holder 40.

  In a state of projecting to the outside of the holder 40, the power feeding part 52 is electrically connected to a power supply terminal (not shown) for supplying a U-phase, the power feeding part 62 is a V-phase, and the power feeding part 73 is a W-phase alternating current. Connected. The coil connection parts 53 to 56 are electrically connected to a U-phase coil among the plurality of coils 18. The coil connection parts 63 to 66 are electrically connected to a V-phase coil among the plurality of coils 18. The coil connection portions 73 to 76 are electrically connected to a W-phase coil among the plurality of coils 18.

<Operation of bus bar device>
As shown in FIG. 7, the inner diameter of the bus bar main body 51 is set slightly larger than the inner diameter of the accommodating portion 42, and the outer diameter is set slightly smaller than the outer diameter of the accommodating portion 42. The inner and outer diameters of the insulating wall main body 81 are set equal to the inner and outer diameters of the bus bar main body portions 51 to 71. The first and second insulating walls 80 and 90 include projecting walls 82, 83, 92 and 93. The projecting walls 82, 83, 92, 93 have an inner diameter larger than the inner diameter of the insulating wall main body 81 and an outer diameter smaller than the outer diameter of the insulating wall main body 81. Furthermore, grooves 82a, 83a, 92a, 93a are formed in the protruding walls 82, 83, 92, 93. Thus, between the bus bar main body 51 and the insulating wall main body 81, between the insulating wall main body 81 and the bus bar main body 61, between the bus bar main body 61 and the insulating wall main body 91, and the insulating wall main body 91. Three spaces S are provided between the main body 71 and the bus bar main body 71. That is, the first to third bus bars 50 to 70 are in contact with the space S. Therefore, even if the first to third bus bars 50 to 70 generate heat as the alternating current is supplied, the heat can move to the space S.

  Conventionally, bus bars having shapes such as the first to third bus bars 50 to 70 are formed by punching a copper material, and thus, for example, burrs were easily generated on the end face of the bus bar. The third bus bars 50 to 70 are formed by forging a copper wire 100 as shown in FIG. For this reason, it is suppressed that a burr | flash generate | occur | produces in the manufacture stage of the 1st-3rd bus-bar 50-70.

As described above in detail, according to the present embodiment, the following effects can be obtained.
(1) In the bus bar device 30, the first bus bar 50, the first insulating wall 80, the second bus bar 60, the second insulating wall 90, and the third bus bar 70 are stacked in this order from the case 12 side. And is assembled by being accommodated in the accommodating portion 42 of the holder 40. In the bus bar device 30 having this configuration, projecting walls 82, 83, 92, 93 are provided on the first and second insulating walls 80, 90. Further, grooves 82a, 83a, 92a, 93a are provided in the projecting walls 82, 83, 92, 93. Thus, between the bus bar main body 51 and the insulating wall main body 81, between the insulating wall main body 81 and the bus bar main body 61, between the bus bar main body 61 and the insulating wall main body 91, and the insulating wall main body 91. A space S is provided between the main body 71 and the bus bar main body 71. That is, the first to third bus bars 50 to 70 are in contact with the space S. Therefore, even if the first to third bus bars 50 to 70 generate heat, the heat can move to the space S. Thereby, it is suppressed that the bus-bar apparatus 30, and by extension, the stator 14 and the motor 11 become high temperature.

  (2) The projecting walls 82, 83, 92, 93 are set to have an inner diameter larger than the inner diameter of the insulating wall main body 81 and an outer diameter smaller than the outer diameter of the insulating wall main body 81. Accordingly, between the bus bar main body 51 and the insulating wall main body 81, between the insulating wall main body 81 and the bus bar main body 61, between the bus bar main body 61 and the insulating wall main body 91, and the insulating wall main body 91. In addition to the space S associated with the grooves 82a, 83a, 92a, and 93a, spaces S are also formed between the inner side and the outer side of the protruding walls 82, 83, 92, and 93. That is, the area where the first to third bus bars 50 to 70 are in contact with the space S is increased by the space S formed inside and outside the protruding walls 82, 83, 92, and 93. Thereby, it is further suppressed that the bus bar device 30, by extension, the stator 14 and the motor 11 are heated to a higher temperature than when only the grooves are provided in the first to third bus bars 50 to 70.

  (3) The first to third bus bars 50 to 70 are manufactured by forging the copper wire 100. Accordingly, the occurrence of burrs on the end surfaces of the first to third bus bars 50 to 70 during the manufacturing process is suppressed. Thereby, the yield of copper material improves compared with the case where a copper bar is punched and a bus bar is manufactured.

In addition, you may change the said embodiment as follows.
In the above embodiment, the projecting walls 82, 83, 92, 93 may be omitted. In this case, grooves 82a, 83a, 92a, 93a are provided in the bus bar main body portions 61-81. Even if comprised in this way, since space S is formed between each bus-bar 50-70 and the 1st and 2nd insulating walls 80 and 90, it is the same as the effect of (1) of the said embodiment. An effect can be obtained.

  In the above embodiment, the grooves 82a, 83a, 92a, 93a may be omitted. Even in such a configuration, the inner diameter of the projecting walls 82, 83, 92, 93 is larger than the inner diameter of the insulating wall main body 81 and the outer diameter is smaller than the outer diameter of the insulating wall main body 81. A space S is formed between 50 to 70 and the first and second insulating walls 80 and 90. That is, even if the first to third bus bars 50 to 70 generate heat, the heat can move to the space S. Thereby, it is suppressed that the bus-bar apparatus 30, and by extension, the stator 14 and the motor 11 become high temperature.

  In the above embodiment, the first to third bus bars 50 to 70 may be manufactured by a manufacturing method other than forging. Even if manufactured by another manufacturing method, the same effects as the effects (1) and (2) of the above embodiment can be obtained.

-In the said embodiment, the 1st-3rd bus-bars 50-70 should just be formed with an electrically-conductive material. That is, you may form with materials other than copper material, for example, aluminum.
-In the said embodiment, although the groove | channel provided in the 1st-3rd bus-bars 50-70 was one each on the surface by the side of the lid | cover 13, and the surface by the side of the case 12, multiple may be sufficient.

  In the above embodiment, the inner diameter of the projecting walls 82, 83, 92, 93 may be set equal to the inner diameter of the insulating wall main body 81. In this case, the outer diameter of the protruding walls 82, 83, 92, 93 is set smaller than the outer diameter of the insulating wall main body 81. Further, the outer diameter of the projecting walls 82, 83, 92, 93 may be set equal to the outer diameter of the insulating wall main body 81. In this case, the inner diameter of the projecting walls 82, 83, 92, 93 is set larger than the inner diameter of the insulating wall main body 81. Even in such a configuration, a space S is formed between each of the bus bars 50 to 70 and the first and second insulating walls 80 and 90. Therefore, the bus bar device 30, and consequently the stator 14, and the motor 11 are suppressed from becoming high temperature.

  In the above embodiment, the space S formed by the groove and / or the protruding wall may be provided on at least one of the surface on the lid 13 side and the surface on the case 12 side of each bus bar 50 to 70.

  In the above embodiment, the bus bars 50 to 70 and the first and second insulating walls 80 and 90 are stacked in the axial direction of the motor 11, but may be stacked in the radial direction of the motor 11.

DESCRIPTION OF SYMBOLS 11 ... Brushless motor, 12 ... Case, 13 ... Cover, 14 ... Stator, 15 ... Core, 16, 17 ... Insulator, 18 ... Coil, 19 ... Rotor, 20 ... Rotating shaft, 21 ... Rotor magnet, 22, 23 ... Bearing 24 ... Rotor core, 30 ... Busbar device, 40 ... Holder, 50, 60, 70 ... Busbar, 80, 90 ... Insulating wall, 81 ... Insulating wall main body, 82, 83, 92, 93 ... Projecting wall, 82a, 83a, 92a, 93a ... groove, 100 ... copper wire.

Claims (4)

In the bus bar device in which the ends of the plurality of coils are electrically connected to each other by a plurality of bus bars adjacent to each other, and an insulating layer made of a non-conductive material is interposed between the plurality of bus bars.
The said insulating layer is a bus-bar apparatus provided with at least one of the groove | channel which spaces apart with respect to an adjacent bus bar, and the protrusion part which protrudes with respect to an adjacent bus bar. In the manufacturing method of the bus-bar apparatus of Claim 1,
The bus bar is a method of manufacturing a bus bar device manufactured by forging a conductive material.   The stator provided with the some coil arranged in a circumferential direction, and the bus-bar apparatus of Claim 1.   The brushless motor provided with the stator which electrically connects the edge part of the some coil located in a line with the circumferential direction in the bus-bar apparatus of Claim 1, and the rotor arrange | positioned inside the said stator.