JP5387604B2 - Terminal module for rotating electric machine and rotating electric machine - Google Patents

Description

  The present invention relates to a rotating electrical machine terminal module and a rotating electrical machine, and more particularly to a rotating electrical machine terminal module having a bus bar and a rotating electrical machine having the terminal module.

  Conventionally, a ring-shaped bus bar is provided on an end surface in the axial direction of a cylindrical stator core. Such bus bars are disclosed in, for example, Japanese Unexamined Patent Application Publication No. 2006-180615 (Patent Document 1), Japanese Unexamined Patent Application Publication No. 2005-65374 (Patent Document 2), Japanese Unexamined Patent Application Publication No. 2003-134724 (Patent Document 3), and International Publication No. 04. 010562 pamphlet (Patent Document 4) and the like.

  Japanese Patent Laying-Open No. 2004-336897 (Patent Document 5) discloses an armature of a rotating electrical machine having positioning means for defining the position of a wiring board with respect to an insulator.

JP 2006-180615 A JP 2005-65374 A JP 2003-134724 A WO04 / 010562 pamphlet JP 2004-336897 A

  In order to reduce the manufacturing cost of a rotating electrical machine or to enable mass production thereof, it is desirable that a terminal module including a bus bar can be automatically assembled.

  In the structures described in Patent Documents 1 to 4, it is difficult to automatically determine the phase of rotation around the bus bar in the axial direction and to position the mold of the mold resin, and it is difficult to automatically assemble the terminal module. There was a problem.

  The present invention has been made in view of the problems as described above, and an object of the present invention is to reduce the manufacturing cost of the rotating electrical machine, and to make it possible to support mass production. And providing a rotating electrical machine having the terminal module.

  The rotating electrical machine terminal module according to the present invention is a rotating electrical machine terminal module mounted on an axial end surface of a stator of the rotating electrical machine.

The terminal module for a rotating electrical machine includes a ring-shaped bus bar container having a groove extending in the circumferential direction, a bus bar fitted into the groove, and a connector part having a terminal for connecting the bus bar and external wiring. Has a guide part for positioning the mold of the mold resin part for molding the bus bar container . The guide portion includes a positioning hole or a guide pin formed in the connector portion so as to extend in the radial direction of the stator.

  According to the above configuration, since the mold frame can be positioned by fitting the guide pin to the guide portion, the mold frame can be automatically assembled. As a result, it is possible to reduce the manufacturing cost of the rotating electrical machine and cope with mass production.

  A rotating electrical machine according to the present invention includes a stator core having a tooth portion, an insulator fitted to the tooth portion, a stator coil wound around the insulator, and the above-described terminal module for the rotating electrical machine. It has an engaging part engaged with the terminal module for electric machines.

  According to the said structure, an insulator and the stator coil wound around this insulator can be fixed because an insulator engages with the terminal module for rotary electric machines.

  ADVANTAGE OF THE INVENTION According to this invention, while reducing the manufacturing cost of a rotary electric machine, it can respond to mass production.

It is a figure which shows schematically the structure of the electric vehicle containing the terminal module for rotary electric machines which concerns on one embodiment of this invention. It is a perspective view which shows the stator containing the terminal module for rotary electric machines which concerns on one embodiment of this invention. It is a figure which shows the state which provided the mold resin part in the stator shown by FIG. FIG. 4 is a cross-sectional view of the stator shown in FIG. 3. It is a figure which shows typically the connection state of each bus bar in the terminal module for rotary electric machines shown by FIG. It is sectional drawing which shows the rail contained in the terminal module for rotary electric machines shown by FIG. It is a figure which shows the process of assembling | attaching the terminal module for rotary electric machines shown in FIG. 2 to a stator. It is the figure which expanded and showed the connector part periphery in the stator shown by FIG. It is a top view which shows the modification of the stator containing the terminal module for rotary electric machines which concerns on one embodiment of this invention. FIG. 10 is a cross-sectional view of the stator shown in FIG. 9. It is a flowchart explaining the manufacturing method of the rotary electric machine which concerns on one embodiment of this invention.

  Embodiments of the present invention will be described below. Note that the same or corresponding portions are denoted by the same reference numerals, and the description thereof may not be repeated.

  Note that in the embodiments described below, when referring to the number, amount, and the like, the scope of the present invention is not necessarily limited to the number, amount, and the like unless otherwise specified. In the following embodiments, each component is not necessarily essential for the present invention unless otherwise specified. In addition, when there are a plurality of embodiments below, it is planned from the beginning to appropriately combine the features of each embodiment unless otherwise specified.

  FIG. 1 is a diagram showing a hybrid vehicle (HV) including a terminal module for rotating electrical machines according to an embodiment of the present invention. In the present specification, the “electric vehicle” is not limited to the hybrid vehicle, and for example, a fuel cell vehicle and an electric vehicle are also included in the “electric vehicle”.

  Referring to FIG. 1, the hybrid vehicle includes a stator 10, a rotor 20, a shaft 30, a speed reduction mechanism 40, a differential mechanism 50, a drive shaft receiving portion 60, and a PCU (Power Control Unit) 70. And a battery 80 that is a rechargeable secondary battery.

  The stator 10 and the rotor 20 constitute a rotating electric machine (motor generator) having a function as an electric motor or a generator. The rotor 20 is assembled to the shaft 30. The shaft 30 is rotatably supported by the housing of the drive unit via a bearing.

  The stator 10 has a ring-shaped stator core. The stator core is configured by laminating plate-like magnetic bodies such as iron or iron alloy. A plurality of stator teeth and a slot portion as a recess formed between the stator teeth portions are formed on the inner peripheral surface of the stator core. The slot portion is provided so as to open to the inner peripheral side of the stator core.

  A stator coil including three winding phases, a U phase, a V phase, and a W phase, is wound around the teeth portion so as to fit into the slot portion. The U phase, the V phase, and the W phase are wound so as to deviate from each other on the circumference. The stator coil is connected to the PCU 70 via a power supply cable. The PCU 70 is electrically connected to the battery 80 via a power supply cable. Thereby, the battery 80 and the stator coil are electrically connected.

  The power output from the motor generator including the stator 10 and the rotor 20 is transmitted from the speed reduction mechanism 40 to the drive shaft receiving portion 60 via the differential mechanism 50. The driving force transmitted to the drive shaft receiving portion 60 is transmitted as a rotational force to the wheels (not shown) via the drive shaft (not shown), thereby causing the vehicle to travel.

  On the other hand, during regenerative braking of the hybrid vehicle, the wheels are rotated by the inertial force of the vehicle body. The motor generator is driven through the drive shaft receiving portion 60, the differential mechanism 50, and the speed reduction mechanism 40 by the rotational force from the wheels. At this time, the motor generator operates as a generator. The electric power generated by the motor generator is stored in the battery 80 via an inverter in the PCU 70.

  2 and 3 are perspective views showing the stator 10 (FIG. 2: before molding resin formation, FIG. 3: after molding resin formation), and FIG. 4 is a cross-sectional view of the stator 10. 2 to 4, the stator 10 includes a stator core 110, a stator coil, a bus bar to which the stator coil is connected, a terminal module 1 to which the bus bar is attached, a mold resin portion 120, and a connector portion 130. And the insulator 140.

  As shown in FIG. 2, the stator coil includes first to fourth U-phase coils 11U to 14U, first to fourth V-phase coils 11V to 14V, and first to fourth W-phase coils 11W to 14W.

  The first U-phase coil 11U is configured by winding a conducting wire 511U around a tooth, one end of the conducting wire 511U is connected to a first U-phase coil terminal 4111U, and the other end of the conducting wire 511U is a first U-phase coil terminal. Connected to 1111U.

  First V-phase coil 11V is formed by winding a conductive wire 511V around a tooth. One end of conducting wire 511V is connected to first V-phase coil terminal 1211V, and the other end of conducting wire 511V is connected to first V-phase coil terminal 2111V.

  First W-phase coil 11W is configured by winding conductive wire 511W around a tooth, one end of conductive wire 511W is connected to first W-phase coil terminal 2211W, and the other end of conductive wire 511W is connected to first W-phase coil terminal 3111W. The

  Second U-phase coil 12U is formed by winding conductive wire 512U around a tooth. Conductive wire 512U has one end connected to second U-phase coil terminal 3212U and the other end connected to second U-phase coil terminal 4112U.

  Second V-phase coil 12V is formed by winding a conductive wire 512V around a tooth. Conductive wire 512V has one end connected to second V-phase coil terminal 3212V and the other end connected to second V-phase coil terminal 1212V.

  Second W-phase coil 12W is formed by winding a conductive wire 512W around a tooth. Conductive wire 512W has one end connected to second W-phase coil terminal 3212W, and the other end connected to second W-phase coil terminal 2212W.

  Third U-phase coil 13U is formed by winding conductive wire 513U around a tooth. Conductive wire 513U has one end connected to third U-phase coil terminal 3313U, and the other end connected to third U-phase coil terminal 1313U.

  Third V-phase coil 13V is formed by winding a conductive wire 513V around a tooth. Conductive wire 513V has one end connected to third V-phase coil terminal 3313V, and the other end connected to third V-phase coil terminal 2313V.

  Third W-phase coil 13W is formed by winding conductive wire 513W around a tooth. Conductive wire 513W has one end connected to third W-phase coil terminal 3313W, and the other end connected to third W-phase coil terminal 3413W.

  Fourth U-phase coil 14U is formed by winding conductive wire 514U around a tooth. Conductive wire 514U has one end connected to fourth U-phase coil terminal 1314U, and the other end connected to fourth U-phase coil terminal 1114U.

  Fourth V-phase coil 14V is configured by winding a conductive wire 514V around a tooth. Conductive wire 514V has one end connected to fourth V-phase coil terminal 2314V, and the other end connected to fourth V-phase coil terminal 2114V.

  Fourth W-phase coil 14W is configured by winding conductive wire 514W around the teeth. Conductive wire 514W has one end connected to fourth W-phase coil terminal 3414W, and the other end connected to fourth W-phase coil terminal 3114W.

  As shown in FIGS. 2 and 4, each coil terminal is provided so as to protrude from the rail 100. The said terminal has a recessed part and a connection with a conducting wire and a terminal is ensured because this recessed part receives each conducting wire. Each coil is wound around the insulator 140 before being assembled to the stator 110 to form a cassette coil.

  Referring to FIGS. 3 and 4, rails and coils provided on stator core 110 are molded by mold resin portion 120 made of resin. Thereby, positioning of each coil is performed reliably and insulation between adjacent coils is ensured. The mold using such a resin is not limited to the formation of a molded body as shown in FIGS. 3 and 4, and an insulating resin such as varnish is applied to the surface of the coil to position each coil. A configuration for ensuring the above may be employed.

  FIG. 5 is a diagram schematically illustrating a connection state of each bus bar in the terminal module 1, and FIG. 6 is a cross-sectional view illustrating the rail 100 included in the terminal module 1.

  With reference to FIGS. 5 and 6, a plurality of grooves 100 </ b> A, 100 </ b> B, 100 </ b> C, and 100 </ b> D are formed in the rail 100 so as to be aligned from the inner peripheral side to the outer peripheral side of the rail 100. Each of the grooves 100A, 100B, 100C, and 100D has a shape that is interrupted in the middle.

  The bus bar includes first bus bars 11 to 13, second bus bars 21 to 23, third bus bars 31 to 34, and a fourth bus bar 41.

  The first bus bars 11, 12, 13 are fitted into the groove 100A. The first bus bar 11 is provided with a first U-phase coil terminal 1111U and a fourth U-phase coil terminal 1114U. Further, the connector terminal 130 </ b> U is attached to the first bus bar 11. Electric power is supplied from the connector terminal 130 </ b> U, and this electric power is transmitted to the first bus bar 11. The first bus bar 12 is provided with a first V-phase coil terminal 1211V and a second V-phase coil terminal 1212V. The first bus bar 13 is provided with a third U-phase coil terminal 1313U and a fourth U-phase coil terminal 1314U.

  The second bus bars 21, 22, 23 are fitted in the grooves 100B. The second bus bar 21 is provided with a first V-phase coil terminal 2111V and a fourth V-phase coil terminal 2114V. A connector terminal 130V is attached to the second bus bar 21. Electric power is supplied from the connector terminal 130 </ b> V, and this electric power is transmitted to the second bus bar 21. The second bus bar 22 is provided with a first W-phase coil terminal 2211W and a second W-phase coil terminal 2212W. The second bus bar 23 is provided with a third V-phase coil terminal 2313V and a fourth V-phase coil terminal 2314V.

The third bus bars 31, 32, 33, 34 are fitted in the grooves 100C. The third bus bar 31 is provided with a fourth W-phase coil terminal 3114W and a first W-phase coil terminal 3111W. A connector terminal 130 </ b> W is attached to the third bus bar 31. Electric power is supplied from the connector terminal 130 </ b> W, and this electric power is transmitted to the third bus bar 31. The third bus bar 32 is provided with a second U-phase coil terminal 3212U, a second V-phase coil terminal 3212V, and a second W-phase coil terminal 3212W. The third bus bar 33 is provided with a third U-phase coil terminal 3313U, a third V-phase coil terminal 3313V, and a third W-phase coil terminal 3313W. Third bus bars 32 and 33 serve as neutral points for connecting the U-phase coil, V-phase coil, and W-phase coil. Third bus bar 34 is provided with third W-phase coil terminal 3413W and fourth W-phase coil terminal 3414W.

  The fourth bus bar 41 is fitted in the groove 100D. The fourth bus bar 41 is provided with a first U-phase coil terminal 4111U and a second U-phase coil terminal 4112U.

  Although FIG. 5 shows a star-connected three-phase AC motor, the present invention is not limited to this. For example, the present invention may be applied to a delta-connected three-phase coil motor.

  Next, the process of assembling the terminal module 1 to the stator 10 will be described with reference to FIG. With reference to FIG. 7, the terminal module 1 includes a positioning pin 101 and a positioning hole 102. A positioning pin insertion hole 111 is formed at a position corresponding to the positioning pin 101 on the axial end surface of the stator core 110.

  When the terminal module 1 is placed on the axial end surface of the stator core 110, the positioning pin 101 is inserted into the positioning pin insertion hole 111. However, since the diameter of the positioning pin insertion hole 111 is slightly larger than the diameter of the positioning pin 101, each terminal of the stator coil and the connector part 130 are only fitted to the positioning pin 101 and the positioning pin insertion hole 111. The accuracy of the position cannot be secured sufficiently.

  In the present embodiment, the terminal module 1 is gripped using a holder and is automatically assembled to the stator core 110 as it is. Here, a phase determining hole 102 is formed in the terminal module 1, and by inserting a guide pin fixed to the holder into the phase determining hole 102, a phase of rotation of the terminal module 1 held by the holder. A decision is made. Thereby, the automatic assembly | attachment of the terminal module 1 is attained.

  7 shows an example in which the terminal module 1 is assembled to the stator core 110 to which the cassette coil is assembled. In a typical example, the stator core 110 is assembled after the terminal module 1 has been assembled to the stator core 110. A cassette coil is assembled to 110.

  After the terminal module 1 is assembled to the stator core 110, the mold resin portion 120 is formed using a mold. In the present embodiment, as shown in FIG. 8, a positioning hole 131 is formed in the connector portion 130, and a guide pin fixed to the mold is inserted into the positioning hole 131, so that the molding resin portion 120 The formwork is positioned. Thereby, automatic assembly of a formwork is attained.

  As described above, in the present embodiment, since the terminal module 1 and the formwork can be automatically assembled, it is possible to reduce the manufacturing cost of the stator 10 and cope with mass production.

  A protrusion may be provided instead of the phasing hole 102, and a recess engaging the protrusion may be provided at the tip of the guide pin fixed to the holder. Further, a protrusion may be provided in place of the positioning hole 131, and a concave portion that engages with the protrusion may be provided at the tip of the guide pin fixed to the mold.

  FIG. 9 is a top view showing a modified example of the stator 10, and FIG. 10 is a cross-sectional view of the stator 10 shown in FIG. With reference to FIGS. 9 and 10, in the present modification, a protrusion 141 is provided to protrude radially outward of the stator 10 from the back surface of the insulator 140, and the protrusion 141 and the rail 100 of the terminal module 1 are provided. Are engaged. Thereby, it is possible to fix the insulator 140 and the stator coil wound around the insulator 140.

  When the insulator 140 does not have the protruding portion 141, an engaging portion such as a groove that engages with the insulator 140 needs to be provided in the stator core 110 in order to fix the insulator 140. When such a groove is provided, there is a concern that a crack may occur in the portion, or the core width becomes narrow and the magnetic flux is easily saturated, which affects the output of the rotating electrical machine. On the other hand, by providing the projecting portion 141 as described above, it is not necessary to provide a groove or the like in the stator core 110, and cracking of the core, reduction of the core width, and the like can be suppressed. Moreover, the terminal module 1 can be prevented from being lifted by pressing the terminal module 1 from above with the insulator 140.

  In FIG. 9, two protrusions 141 are provided only on the first V-phase coil 11V and the first W-phase coil 11W, but the cassette coil on which the protrusions 141 are provided is changed as appropriate. Typically, all cassette coils are provided with a protrusion 141. Each cassette coil may be provided with only one protrusion 141 or may be provided with three or more protrusions 141.

  Next, a method for manufacturing the stator 10 according to the present embodiment will be described with reference to FIG. As shown in FIG. 11, the method for manufacturing the stator 10 includes a step of holding the terminal module 1 (bus bar module) with a holder (S10), and a step of assembling the terminal module 1 held by the holder to the stator core 110 (S20). And a step (S30) of forming the molded resin portion 120 by resin-molding the terminal module 1 assembled to the stator core 110.

  In S10, when the terminal module 1 is gripped by the holder, the guide pin of the holder is inserted into the phasing hole 102 formed in the terminal module 1 to determine the phase of rotation of the terminal module 1 around the axial direction. . In this way, by determining the phase of the rotation of the terminal module 1 around the axial direction using the phase determination hole 102, the terminal module 1 can be automatically assembled to the stator core 110.

  In S30, when the terminal module 1 is resin-molded, the mold frame is positioned by inserting guide pins of the mold of the mold resin portion 120 into the positioning holes 131 formed in the terminal module 1. Thus, by positioning the mold for resin molding using the positioning hole 131, it becomes possible to automatically assemble the mold. .

  As described above, according to the terminal module 1 according to the present embodiment, the phase of the rotation of the rail 100 can be determined by inserting the guide pin of the holder into the phase determining hole 102. The stator 110 can be automatically assembled.

  In addition, since the phase determining hole 102 can be formed by effectively using the space of the rail 100 where the first to fourth bus bars 11 to 13, 21 to 23, 31 to 34, 41 are not formed, the terminal module 1 does not hinder downsizing.

  Further, since the mold frame can be positioned by inserting the guide pin of the mold frame into the positioning hole 131, the mold frame can be automatically assembled.

  Further, according to the stator 10 according to the present embodiment, the insulator 140 is engaged with the terminal module 1, whereby the insulator 140, the first to fourth U-phase coils 11 </ b> U to 14 </ b> U wound around the insulator 140, The first to fourth V-phase coils 11V to 14V and the first to fourth W-phase coils 11W to 14W can be fixed.

  The above contents are summarized as follows. That is, the terminal module 1 for a rotating electrical machine according to the present embodiment is fitted into the rail 100 as a ring-shaped “busbar container” having grooves 100A to 100D extending in the circumferential direction and the grooves 100A to 100D. 1 to 4th bus-bar 11-13, 21-23, 31-34,41, and the connector part 130 which has connector terminal 130U, 130V, 130W which connects this bus-bar and external wiring. The rail 100 has a phasing hole 102 for phasing the rotation around the axial direction of the rail 100, and the connector part 130 has a positioning hole 131 for positioning the mold of the mold resin part 120 for molding the rail 100. Have. The phasing hole 102 and the positioning hole 131 constitute a “guide portion” that fits with the guide pin.

  In the terminal module 1, the first to fourth bus bars 11 to 13, 21 to 23, 31 to 34 and 41 are provided so as to be aligned in the radial direction of the rail 100. The phase determining hole 102 is provided at a position where the first to fourth bus bars 11 to 13, 21 to 23, 31 to 34, 41 are all separated in the circumferential direction of the rail 100.

  In the terminal module 1, the phasing hole 102 is provided between the third bus bars 32 and 33 constituting the neutral point of the rotating electrical machine.

  The stator 10 according to the present embodiment includes a stator core 110 having a tooth portion, an insulator 140 fitted to the tooth portion, and first to fourth U-phase coils 11U as “stator coils” wound around the insulator 140. To 14U, first to fourth V-phase coils 11V to 14V, first to fourth W-phase coils 11W to 14W, and a terminal module 1. The insulator 140 has a protruding portion 141 as an “engaging portion” that engages with the terminal module 1.

  Although the embodiments of the present invention have been described above, the embodiments disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  DESCRIPTION OF SYMBOLS 1 Terminal module, 10 Stator, 11-13 1st bus bar, 21-23 2nd bus bar, 31-34 3rd bus bar, 41 4th bus bar, 11U-14U 1st-4th U phase coil, 11V-14V 1st-1st 4th V phase coil, 11W to 14W 1st to 4th W phase coil, 20 rotor, 30 shaft, 40 speed reduction mechanism, 50 differential mechanism, 60 drive shaft receiving portion, 70 PCU, 80 battery, 100 rail, 100A to 100D groove, DESCRIPTION OF SYMBOLS 101 Positioning pin, 102 Phase determination hole, 110 Stator core, 111 Positioning pin insertion hole, 120 Mold resin part, 130 Connector part, 130U, 130V, 130W Connector terminal, 131 Positioning hole, 140 Insulator, 141 Protrusion part.

Claims (2)

A rotating electrical machine terminal module mounted on an axial end surface of a stator of a rotating electrical machine,
A ring-shaped bus bar container having a groove extending in the circumferential direction;
A bus bar fitted into the groove;
A connector portion having a terminal for connecting the bus bar and external wiring;
The connector part has a guide part for positioning a mold frame of a mold resin part for molding the bus bar container ,
The rotating electrical machine terminal module , wherein the guide portion includes a positioning hole or a guide pin formed in the connector portion so as to extend in a radial direction of the stator . A stator core having a teeth portion;
An insulator fitted into the teeth portion;
A stator coil wound around the insulator;
A rotating electrical machine terminal module according to claim 1;
The insulator is a rotating electrical machine having an engagement portion that engages with the terminal module for the rotating electrical machine.

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