JP5998498B2 - Power distribution component and method for manufacturing power distribution component - Google Patents

Description

  The present invention relates to a power distribution component and a method for manufacturing the power distribution component.

  2. Description of the Related Art A power distribution component of a motor having a plurality of bus rings connected to respective phase coils of a multi-phase motor is known. In such a power distribution component, each bus ring includes an annular lead frame, a lead wire drawn out from the motor coil, and a connection terminal (connection terminal) connected to the lead frame. The lead frame is arranged along the rotation axis direction of the motor, and the lead frame is configured such that the part to which the connection terminal of one lead frame is connected and the part of the other lead frame adjacent to each other have different diameters. In a state where the connection terminals are arranged coaxially in the direction, a structure is known in which the positions of the portions where the connection terminals are arranged are different to correspond to the positions of the laminated lead frames in the rotation axis direction. (Patent Document 1).

JP 2009-17666 A

  However, in the structure of the power distribution component described above, since it is necessary to prepare a different type of connection terminal (connection terminal) for each part where the connection terminal of the lead frame (bus bar) is connected, the distribution component There was a problem that the manufacturing cost was high.

  The problem to be solved by the present invention is to provide a power distribution component that reduces the number of types of connection terminals that connect a bus bar as a lead frame and a coil, and suppresses manufacturing costs.

  The present invention provides a distance from the central axis in a radial direction perpendicular to the central axis of the stator, and an axial direction of the central axis in connection portions to which a plurality of connection terminals of a plurality of bus bars are respectively connected. The above problem is solved by making the positions the same.

  In the present invention, since the distance from the stator central axis and the position in the central axis direction of the connection position connected to the connection terminal are the same, it is necessary to prepare different types of connection terminals according to the height of the connection position. As a result, the number of types of connection terminals can be reduced, and the manufacturing cost of power distribution components can be reduced.

It is a perspective view of a stator provided with power distribution parts concerning an embodiment of the present invention. It is a perspective view of the power distribution component of FIG. FIG. 3 is a perspective view of the bus bar of FIG. 2. It is the perspective view which cut | disconnected a part of torus body. It is sectional drawing which follows the VV line of FIG. It is sectional drawing which follows the VI-VI line of FIG. It is sectional drawing which follows the VII-VII line of FIG. It is a perspective view of the connection terminal of FIG. It is an enlarged view of the bus bar and connection terminal of FIG. It is a fragmentary sectional view of the cross section which follows the XX line of FIG. It is a fragmentary sectional view of a stator provided with power distribution parts concerning a modification of the present invention. It is a fragmentary sectional view of a stator provided with power distribution parts concerning a modification of the present invention. It is a perspective view of the power distribution component which concerns on other embodiment of this invention. It is a perspective view of the mold part of FIG. It is a figure explaining the process of forming an intersection part among the manufacturing methods of the distribution component of FIG. 13, (a) is a perspective view of the distribution component in the state before forming an intersection part, (b) is an intersection. It is a perspective view of the power distribution component in the state after forming the part. (A) is an enlarged view of a portion surrounded by XVIa in FIG. 15 (a), and (b) is an enlarged view of a portion surrounded by XVIb in FIG. 15 (b). 14A and 14B are diagrams illustrating a process of forming a lead line in the method of manufacturing the power distribution component of FIG. 13, wherein FIG. 14A is a perspective view of the lead line before connecting both ends of the bus bar, and FIG. FIG. 3 is a perspective view of a lead line after connecting both ends of 3. It is a perspective view of the holder part of the power distribution component which concerns on the modification of this invention. It is a perspective view of the holder part of the power distribution component which concerns on the modification of this invention. It is a perspective view of the jig | tool used for the manufacturing method of the power distribution component which concerns on other embodiment of this invention. FIG. 21 is a perspective view of a power distribution component with the jig of FIG. 20 attached to a bus bar. It is a perspective view of the power distribution component in the state which formed the mold part in the power distribution component of FIG. FIG. 23 is a perspective view of the power distribution component with a jig removed from the power distribution component of FIG. 22.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

<< First Embodiment >>
FIG. 1 is a perspective view of a stator of a three-phase AC concentrated winding motor provided with power distribution components according to an embodiment of the present invention. The motor of this example is a brushless motor including an annular stator 12 and a power distribution component 40. The rotor is provided on the inner periphery of the annular stator 40.

  The stator 12 is fixed inside the housing 11 by press fitting, shrink fitting or the like. The housing 11 is formed in an annular shape and is disposed on the outer periphery of the motor 1. The housing 11 is a member for holding the stator 12. The stator 12 is configured by arranging a plurality of stator pieces in an annular shape.

  A stator piece constituting the stator 12 includes a stator core 121, a bobbin 122, and a coil 30. The stator core 121 is an iron core configured by stacking a plurality of plate-shaped steel plates. The bobbin 122 is a holding member that holds the coil 30, and is formed of an insulating material in order to insulate between the coil 30 and the stator core 121. The coil 30 is formed by winding a conductive wire around the bobbin 122, and the coil 30 formed by winding the conductive wire is attached to a tooth (not shown) of the stator core 121, thereby forming a stator piece. Yes. A plurality of stator pieces constituted by these are arranged in an annular shape around the central axis so as to follow the outer periphery of the housing 11. Thus, the stator 12 is formed in an outer ring shape, and a plurality of coils 30 are arranged in an annular shape at equal intervals along the inner periphery.

  Each coil 30 is any one of a U-phase coil 31, a V-phase coil 32, and a W-phase coil 33. The U-phase coil 31, the V-phase coil 32, and the W-phase coil 33 are arranged in an annular shape in the order of the U-phase, the V-phase, and the W-phase. Both ends of the coil 30 are led out from the stator 12 to the inside and the outside of the stator 12, respectively. Then, one end of each of the coils 30 led out to the inner side (rotor side) of the motor 1 is concentrated and connected to the same potential via a neutral terminal (not shown). Each other end of the coil 30 is connected to the power distribution component 40.

The power distribution component 40 is a bus ring that distributes and supplies power from the power source of the motor to the coils 30 of each phase, and is connected between the motor 20 and the power source.
The power distribution component 40 has an annular shape along the end surface in the central axis direction of the stator 12, and is between the coil 30 and the housing 11 arranged in an annular shape, and the outer peripheral portion of each stator piece forming the stator 12. Is provided with a space for holding the power distribution component 40. The space may be formed by the shape of the bobbin 122. And the power distribution component 40 is being fixed to the said space.

  The rotation axis of the motor passes through the center point of the rotor and becomes the center axis of the housing 11. The central axis of the stator 12, the central axis of the plurality of coils 30 arranged in an annular shape, and the central axis of the annular power distribution component 40 are concentric with the rotation axis of the motor of this example.

  Next, the structure of the power distribution component 40 will be described with reference to FIGS. FIG. 2 is a perspective view of the power distribution component 40. FIG. 3 is a perspective view of the bus bar, in which the connection terminal 44, the power supply terminal 45, and the mold portion 46 are excluded from the power distribution component 40 shown in FIG. FIG. 4 is a partial perspective view in which a part of the torus body is cut, and is a view for explaining a toroidal direction and a poloidal direction to be described later.

  As shown in FIG. 2, the power distribution component 40 includes a plurality of bus bars 41 to 43, a connection terminal 44, a power supply terminal 45, and a mold part 46. The bus bars 41 to 43 are formed of a conducting wire (round wire conducting wire) having a circular cross section. The bus bars 41 to 43 correspond to the respective phases of the motor, the bus bar 41 is a wiring for supplying power to the U-phase coil, the bus bar 42 is a wiring for supplying power to the V-phase coil, and the bus bar 43 Is a wiring for supplying power to the W-phase coil.

  As shown in FIG. 3, the bus bars 41 to 43 are bundled while crossing the three conducting wires, and are bent into an annular shape along the end surface in the central axis direction of the stator 12, in other words, bent into a substantially torus shape. Yes. The bus bar 41 has an intersection 411 that intersects with the bus bars 42 and 43 and a non-intersection 412 that does not intersect with the bus bars 42 and 43. The bus bar 41 is bent in an annular shape while repeating the intersecting portion 411 and the non-intersecting portion 412 at predetermined intervals. Crossing portions 411 and non-crossing portions 412 are formed such that the number of non-crossing portions 412 per bus bar 41 is the same as the number of coils 30. In addition, at both ends of the bus bar 41, lead portions 413 for connecting to the power supply terminals 45 are formed. The lead portion 413 is formed by drawing a lead wire outward from a circle formed by the intersecting portion 411 and the non-intersecting portion 412.

  The intersecting portion 411 is formed of a covered conductor in which a conductor is covered with a resin or the like. The non-intersecting portion 412 is formed by the covered conductor portion and a portion where a part of the conductor is exposed. In the non-intersection portion 412, the portion where the conductor is exposed becomes a connection portion with the connection terminal 44 described later.

  The bus bar 42 has the same configuration as that of the bus bar 41, and includes an intersecting portion 411 that intersects with the bus bars 41 and 43, a non-intersecting portion 412 that does not intersect with the bus bars 41 and 43, and a drawer portion 423. The lead part 423 has the same shape as the lead part 413. The bus bar 43 has the same configuration as that of the bus bars 41 and 42, and includes an intersection 411 that intersects with the bus bars 41 and 42, a non-intersection portion 412 that does not intersect with the bus bars 41 and 42, and a drawer portion 433. ing. The lead portion 433 has the same shape as the lead portions 413 and 423.

  In the bus bar 41, intersecting portions 411 and non-intersecting portions 412 are alternately arranged in the toroidal direction (see FIG. 4). The non-intersecting part 412 adjacent via the intersecting part 411 is bent in the radial direction (direction perpendicular to the central axis) from the position of the non-intersecting part 412 and rotated 120 degrees in the poloidal direction. The bus bar 41 is formed so as to have a height different from the height (position in the axial direction) of the original non-intersecting portion 412. The bus bar 42 and the bus bar 43 are also bent at the same portion as the intersection 411 of the bus bar 41 by rotating 120 degrees in the poloidal direction. Therefore, with respect to the non-intersecting part 412 adjacent to the bus bars 41 to 43 via the intersecting part 411, the bus bars 41 to 43 of the adjacent non-intersecting part 412 are in different phases, and the non-intersecting part of the bus bars 41 to 43 The position of the portion corresponding to 412 is the same in a cross section by a plane including the central axis of the bus bars 41 to 43.

  Next, the position of the non-intersecting part 412 will be further described with reference to FIGS. 3 and 5 to 7. 5 is a sectional view taken along line V-V in FIG. 3, FIG. 6 is a sectional view taken along line VI-VI in FIG. 3, and FIG. 7 is a sectional view taken along line VII-VII in FIG. In contrast to the XYZ orthogonal coordinate system shown in FIG. 3, FIGS. 5 to 7 show the RZ coordinate system of the R-θ-Z cylindrical coordinate system. In each coordinate system, the annular center point of the torus-shaped bus bars 41 to 43 corresponds to the origin. 5-7, the dashed-dotted line L is corresponded to the central axis of the bus bars 41-43, and is also equivalent to the rotating shaft of a motor. Note that the cross-sectional portion of the bus bar 41 shown in FIG. 5 is a connection portion with a connection terminal 44 described later, and similarly, the cross-sectional portion of the bus bar 42 shown in FIG. This is a connection portion with the connection terminal 44.

As shown in FIG. 5, the distance from the central axis L to the non-intersection portion 412 of the bus bar 41 in the direction perpendicular to the central axis L and in the radial direction of the bus bars 41 to 43, in other words, the bus bar. The distance from the central axis of the bus bars 41 to 43 to the center point of the cross section of the bus bar 41 in the radial direction of 41 is r ₁ . Further, the height to the bus bar 41 (height to the center point of the cross section of the bus bar 41) with respect to the reference plane A whose main surface is a direction parallel to the axial direction of the central axis of the bus bars 41 to 43 is h _1. And

Similarly, as shown in FIG. 6, the distance from the central axis L to the non-intersection portion 412 of the bus bar 42 in the direction perpendicular to the central axis L and in the radial direction of the bus bars 41 to 43, in other words. When, in the radial direction of the bus bar 42, the distance from the center axis of the bus bar 41 to 43 to the center point of the cross-section of the bus bar 42 and _{r 2.} Further, the height to the bus bar 42 (height to the center point of the cross section of the bus bar 42) is set to h ₂ with respect to the reference plane A whose main surface is a direction parallel to the axial direction of the central axis of the bus bars 41 to 43. And

Similarly, as shown in FIG. 7, the distance from the central axis L to the non-intersection portion 412 of the bus bar 43 in the direction perpendicular to the central axis L and in the radial direction of the bus bars 41 to 43, in other words. The distance from the central axis of the bus bars 41 to 43 to the center point of the cross section of the bus bar 43 in the radial direction of the bus bar 43 is r ₃ . Further, the height to the bus bar 43 (height to the center point of the cross section of the bus bar 42) is defined as h ₃ with respect to the reference plane A whose main surface is a direction parallel to the axial direction of the central axis of the bus bars 41 to 43. And

Then, the non-intersecting portion 412, a distance _r 1 ~r ₃ is the same distance as the height _h 1 to h ₃ at the same height, the bus bars 41 to 43 are arranged. As shown in FIGS. 5 to 7, the non-intersecting portions 412 of the bus bars 41 to 43 are arranged so as to have an equilateral triangle shape in a cross section including the central axis L (corresponding to the paper surface of FIGS. ing.

  As a result, the non-intersecting part 412 of the bus bars 41 to 43 has one side of the triangle parallel to the central axis L in the cross section by the plane including the central axis L, and the apex that is both ends of the one side is the central axis L In the radial direction (corresponding to the R direction in FIG. 5 to FIG. 7) from the top, it is arranged so as to be inside the vertex not included in the one side.

  Further, as shown in FIG. 3, the non-intersecting portion 412 corresponding to FIG. 5 is adjacent to the non-intersecting portion 412 shown in FIG. 6 via the intersecting portion 411, and the non-intersecting portion 412 shown in FIG. It is adjacent to the non-intersecting part 412 shown in FIG. Therefore, among the positions of the non-intersecting portions 412 that are adjacent via the intersecting portion 411, the position of one non-intersecting portion 412 is in a cross section by a plane including the central axis L with respect to the position of the other non-intersecting portion 412. It can be seen that they are arranged to rotate 120 degrees around the center of gravity of the equilateral triangle.

  Therefore, an arbitrary point on the central axis of the bus bars 41 to 43 is an origin (for example, the central axis L and the origin of the reference plane A), and each non-intersecting portion 412 of the bus bars 41 to 43 is indicated by a cylindrical coordinate system. When L is one of the coordinate axes, the position of the non-intersecting portion 412 is represented by the same coordinates except for the angle component.

  Next, the configuration of the connection terminal 44 will be described with reference to FIG. FIG. 8 is a perspective view of the connection terminal 44. The connection terminal 44 includes a holding portion 441, a holding portion 442, and a connecting portion 443, and is formed of a conductive material. The sandwiching portion 441 includes a plate-shaped member and two side walls extending in parallel with the main surface direction of the member from both ends of the member. The space | interval by two side walls respond | corresponds to the diameter of the conductor of the bus bars 41-43. The sandwiching portion 441 is electrically connected to the bus bars 41 to 43 by sandwiching the conductors of the bus bars 41 to 43 from the side walls.

  The sandwiching portion 442 has the same shape as the sandwiching portion 441 and is electrically connected to the coil 30 by sandwiching one end of the coil 30 from the side surface. The connecting portion 443 is a member that connects the holding portion 441 and the holding portion 442, and the direction of the holding portion by the holding portion 441 and the direction of the holding portion by the holding portion 442 are shifted by 90 degrees. As described above, the holding portion 441 and the holding portion 442 are connected. The holding portions 441 and 442 and the connecting portion 443 are integrally formed.

  Next, a configuration of a connection portion between the bus bars 41 to 43 and the connection terminal 44 will be described with reference to FIGS. 9 and 10. FIG. 9 is an enlarged perspective view of the bus bars 41 to 43 and the connection terminals 44. FIG. 10 is a partial cross-sectional view taken along line XX in FIG. The connection terminals 44 are connected to the vicinity of the center of the non-intersecting part 412 of the bus bars 41 to 43, respectively. As shown in FIGS. 1 and 9, three non-intersecting portions 412 are arranged corresponding to each phase of the coil 30, and one non-intersecting portion 412 among the three non-intersecting portions 412. It is connected to the.

  The connection terminal 44 is a holding portion 441 that opens downward in the axial direction of the central axis of the bus bars 41 to 43, and holds the bus bars 41 to 43 from above the bus bars 41 to 43, so that the non-intersection portion 412. Further, the lead wire drawn out from the coil 30 is pinched by the holding portion 442 opened in the radial direction of the bus bars 41 to 43, and is connected to the coil 30.

  Further, in order to facilitate the connection between the connection terminal 44 and the non-intersection portion 412, the connection portion between the connection terminal 44 and the non-intersection portion 412 is close to the coil 30 in the non-intersection portion 412 and the bus bar 41. To the non-intersecting portion 412 arranged on one end side in the axial direction of the central axis of .about.43. That is, the connection portion between the bus bars 41 to 43 and the connection terminal 44 becomes the non-intersection portion 412 of the bus bar 41 in the case of the arrangement of the non-intersection portion 412 shown in FIG. 5, and the arrangement of the non-intersection portion 412 shown in FIG. In this case, the non-intersecting portion 412 of the bus bar 42 is obtained, and in the case of the arrangement of the non-intersecting portion 412 shown in FIG. Moreover, the connection terminal 44 is connected to the non-intersecting part 412 including one apex at both ends of the side parallel to the central axis L in the equilateral triangle shown in FIGS.

  Next, the insulation distance between the stator core and coil 30 and the bus bars 41 to 43 will be described. As shown in FIG. 10, when the power distribution component 40 of this example is disposed between the housing 11 and the stator 12, the non-intersection portion 412 of the bus bars 42 and 43 disposed on the stator core 121 side among the bus bars 41 to 43. Is covered with an insulating material. In addition, a sufficient insulation distance is secured between the non-intersecting portion 412 of the bus bar 41 connected to the connection terminal 44 and the stator core 121. Therefore, in this example, an insulation distance from the connection portion between the connection terminal 44 and the bus bar 41 to the stator core 121 can be ensured.

  Further, a side wall by the bobbin 122 is interposed between the coil 30 and the non-intersecting portion 412 of the bus bar 41 connected to the connection terminal 44. The side wall is a side wall used for winding the coil 30 around the bobbin 122. That is, in this example, in order to ensure the insulation between the coil 30 and the bus bars 41 to 43, it is not necessary to provide a separate insulating wall on the insulator (bobbin or the like). Therefore, in this example, while securing the insulation distance from the connection portion with the connection terminal 44 to the coil 30, the stator core 121 and the bobbin 122, the connection portion can be brought close to the coil 30, and the connection terminal 44 can be downsized. Can be achieved.

  Thereby, in this example, each connection part of bus bars 41-43 and connection terminal 44 is located on the plane perpendicular to central axis L, but the distance from central axis L is the same on the plane concerned. It is arranged to become. In other words, the connecting portions are arranged so that the radial positions of the bus bars 41 to 43 and the positions in the central axis direction are relatively the same.

  Returning to FIG. 2, the lead-out portions 413 formed at both ends of the bus bar 41, the lead-out portions 423 formed at both ends of the bus bar 42, and the lead-out portions 433 formed at both ends of the bus bar 43 have power supply terminals 45. They are connected by caulking. The power supply terminal 45 is a terminal for connecting a power source such as a battery and a motor via an inverter (not shown).

  The mold part 46 is made of resin and is a member for fixing the bundled bus bars 41 to 43. The mold part 46 covers the intersecting part 411 with resin.

  Next, the manufacturing method of the power distribution component 40 of this example is demonstrated. First, three conductor wires covered with an insulating material are formed so as to correspond to each phase of the motor, and the power supply terminal 45 of each phase is formed. In addition, a connection terminal 44 having the same shape is formed. And the insulating member of the front-end | tip part which is the both ends of the said conducting wire is processed, and the electroconductivity of a front-end | tip part is ensured. Moreover, the insulating member of the connection part connected with the connection terminal 44 is processed, and the electroconductivity of a connection part is ensured. As described above, the connection terminals 44 are connected to correspond to the plurality of coils 30, and the plurality of coils 30 are annularly arranged with regularity. Therefore, the parts processed to connect the connection terminals 44 are formed by the bus bars 41 to 43 at regular intervals while changing the intervals.

  Next, the drawer portions 413, 423, and 433 are secured at both end portions of the processed bus bars 41 to 43, and the remaining portions are annularly gathered so as to have the same axis. Then, by bending the adjacent non-intersecting portions 412 via the intersecting portion 411 so as to rotate 120 degrees in the poloidal direction, the bus bars 41 to 43 intersect with each other at the intersecting portion 411 and are parallel to each other at the non-intersecting portion 412. To. At this time, the crossing portions 411 and the non-crossing portions 412 are periodically arranged while being alternately formed so that the non-crossing portions 412 correspond to a plurality of coils. Moreover, the distance from the central axis to the radial direction perpendicular | vertical with respect to the central axis of the bus bars 41-43 of the part connected to the connection terminal 44 among each non-intersecting part 412, and the axial direction of the said central axis Make the position to the same. Further, the cross section of the non-intersecting part 412 (a cross section of a plane including the central axis L) is arranged in a triangle.

  Next, the connection terminal 44 is connected to each non-intersecting part 412 which is arrange | positioned at the coil 30 side and is arrange | positioned at the one side of the central axis of the bus bars 41-43. At this time, the connection terminal 44 is connected to a conductor portion of the non-intersection portion 412 that is not covered with an insulating material. In addition, the power supply terminal 45 is connected to the lead portions 413, 423, and 433. These connections may be made by fusing, brazing, welding, crimping, or the like.

  Then, a mold for forming the mold part 46 is set at each intersection 411. And the mold part 46 which covers the cross | intersection part 411 with a resin material is formed by inject | pouring molten resin from the injection port of a shaping | molding die. Thereby, the bus bars 41 to 43 are fixed while the bus bars 41 to 43 maintain the positional relationship shown in FIG. The power distribution component 40 of this example shown in FIG. 2 is completed.

  As described above, in this example, the connecting portions of the plurality of connection terminals 44 and the plurality of bus bars 41 to 43 are distances from the central axis L in the radial direction perpendicular to the central axis L of the bus bars 41 to 43. And the position of the central axis L in the axial direction is the same. Thereby, since it is not necessary to make the connection terminal 44 into a different shape for each phase, the number of types of the connection terminals 44 can be reduced. As a result, since the shape of the connection terminal 44 can be unified, the manufacturing cost of the connection terminal 44 can be reduced.

  Moreover, in this example, the non-intersection part 412 is arrange | positioned at the triangle shape in the cross section by the plane containing the central axis of the bus-bars 41-43. Thereby, since the connection part of the connection terminal 44 and the non-intersection part 412 can be brought close to the coil 30 while ensuring the insulation distance from the connection terminal 44 to the housing 11 and the stator core 121, the connection terminal 44 can be reduced in size. Can be planned.

  Moreover, in this example, the non-crossing part 412 which adjoins via the crossing part 411 among the some non-crossing parts 412 of the bus bars 41-43 of one phase is the above-mentioned cross section (a plane including the central axis of the bus bars 41-43). In the cross section), the bus bars 41 to 43 are arranged at positions rotated by 120 degrees around the center of gravity of the triangle. Thereby, since the position management of the connection part of the non-intersection part 412 and the connection terminal 44 becomes easy, joining of the connection terminal 44 and the bus-bars 41-43 can be made easy. As a result, the positional accuracy of the coupling terminal 44 to the connection portion can be improved, and the processing cost of the coupling terminal 44 can be reduced.

  Further, in this example, the non-intersecting portion 412 is configured so that one of the three sides of the triangle formed by the bus bars 41 to 43 is the central axis of the bus bars 41 to 43 in the cross section (the cross section of the plane including the central axis of the bus bars 41 to 43). The first vertex that is parallel to L and both ends of the one side is arranged in the radial direction from the central axis L so as to be inside the second vertex not included in the one side among the vertices of the triangle, The connection terminal 44 is connected to the non-intersection portion 412 including one vertex of the first vertex. Thereby, in the said radial direction, since the connection part of the connection terminal 44 and the non-intersection part 412 can be brought close to the coil 30, the size reduction of the connection terminal 44 can be achieved. In addition, in this example, an insulation distance can be secured between the connection portion and the coil 30, and it is not necessary to separately provide an insulation wall made of other parts such as an insulator between the connection portion and the coil 30. . As a result, it is possible to reduce the material cost by reducing the size of the connection terminal 44, and it is possible to suppress an increase in cost due to providing other parts such as an insulator.

  Further, in this example, a molded portion is formed at a plurality of intersecting portions 411 by resin molding, and the bus bars 41 to 43 are fixed. Thereby, the intensity | strength of the power distribution component 40 can be raised.

  In this example, the non-intersection portion 412 shown in FIG. 10 may be arranged as shown in FIG. FIG. 11 is a cross-sectional view of a stator including a power distribution component 40 according to a modification of the present invention, and corresponds to a cross-sectional view along the line XX in FIG. As shown in FIG. 11, the non-intersecting portions 412 of the bus bars 41 to 43 are arranged in a triangular shape in a cross section with a plane including the central axis L of the bus bars 41 to 43, and one side of the triangle is the central axis The apex of the triangle that is parallel to the vertical direction (radial direction) with respect to L and is not included in the one side is closer to the lead wire 301 from the coil 30 than the apexes at both ends of the one side in the axial direction of the central axis. It is arranged in the direction. The connection terminal 44 is connected to a non-intersecting portion 412 of the bus bar 41 including a triangular vertex not included in the one side. Thereby, since a space wider than the interval between the bus bar 42 and the bus bar 43 is formed around the non-intersecting portion 412 of the bus bar 41, the connection between the connection terminal 44 and the non-intersecting portion 412 can be facilitated. . As a result, the manufacturing cost in the connection process between the connection terminal 44 and the non-intersection portion 412 can be suppressed.

  In this example, the non-intersecting portion 412 shown in FIG. 10 may be arranged as shown in FIG. 12 is a cross-sectional view of a stator including a power distribution component according to a modification of the present invention, and corresponds to a cross-sectional view along the line XX in FIG. As shown in FIG. 12, the non-intersecting portions 412 of the bus bars 41 to 43 are arranged in a triangular shape in a cross section with a plane including the central axis L of the bus bars 41 to 43, and one side of the triangle is the central axis A vertex that is parallel to L and that is not included in the one side of the triangle is arranged to be inside (on the side closer to the coil 30) in the radial direction from the central axis L than the vertices at both ends of the one side. ing. The connection terminal 44 is connected to a non-intersection portion 412 of the sbar 41 including a vertex that is not included in the one side. As a result, a space wider than the space between the bus bar 42 and the bus bar 43 is formed around the non-intersecting portion 412 of the bus bar 41, so that the connection between the connection terminal 44 and the non-intersecting portion 412 can be facilitated. it can. As a result, the manufacturing cost in the connection process between the connection terminal 44 and the non-intersection portion 412 can be suppressed.

  In addition, in this example, FIG.11 and FIG.12 demonstrated the connection part which connected the connection terminal 44 to the bus-bar 41, However, About the junction part of the bus-bars 42 and 43 and the connection terminal 44, it has the same connection structure as the above. Take.

  In this example, the crossing portion 411 and the non-crossing portion 412 are provided on the bus bars 41 to 43, but the crossing portion 411 may be provided continuously and the non-crossing portion 412 may not be provided.

  As shown in FIG. 10, among the vertices of the dotted triangle, the vertices by the bus bars 41 and 42 correspond to the “first vertex” of the present invention, and the vertices by the bus bar 43 correspond to the “second vertex” of the present invention. . Also, as shown in FIG. 11, among the vertices of the dotted triangle, the vertex by the bus bar 41 corresponds to the “third vertex” of the present invention, and the vertex by the bus bars 42 and 43 becomes the “fourth vertex” of the present invention. Equivalent to. Also, as shown in FIG. 12, among the vertices of the dotted triangle, the vertex by the bus bar 41 corresponds to the “fifth vertex” of the present invention, and the vertex by the bus bars 42 and 43 becomes the “sixth vertex” of the present invention. Equivalent to.

<< Second Embodiment >>
FIG. 13 is a perspective view of a power distribution component 40 according to another embodiment of the invention. FIG. 14 is a perspective view of the holder portion 47 provided in the power distribution component 40. In this example, the point which provides the holder part 47 instead of the mold part 46, and a part of manufacturing method of the power distribution component 40 differ with respect to 1st Embodiment mentioned above. Since the configuration other than this is the same as that of the first embodiment described above, the description thereof is incorporated as appropriate.

  As shown in FIG. 13, the power distribution component 40 of this example includes bus bars 41 to 43, a connection terminal 44, a power supply terminal 45, and a holder portion 47. The holder portion 47 is a member for holding the bus bars 41 to 43 and is provided in the non-intersecting portion 412. On the other hand, unlike the power distribution component 40 according to the first embodiment, the power distribution component 40 of the present example does not include the mold portion 46 at the intersecting portion 411.

  As shown in FIG. 14, the holder portion 47 is formed in an octagonal prism shape and has an insertion hole 471 for allowing the bus bars 41 to 43 to pass therethrough. The insertion hole 471 is formed to penetrate between the opposing side walls of the surface of the prism in a columnar shape. The insertion holes 471 are provided corresponding to the number of bus bars 41 to 43, and are three insertion holes 471a to 471c. The holder portion 47 has a flat surface 472 at a portion corresponding to the bottom surface. Further, a notch 473 is provided between both side surfaces provided with the insertion hole 471. Thereby, when the bus bars 41 to 43 pass through the insertion hole 471, it can be visually confirmed that the bus bars 41 to 43 pass through the insertion hole 471.

  The positions of the insertion holes 471 are arranged so as to form a triangle when connecting the center points of the opening portions of the insertion holes 471. That is, in the cross section including the central axis L of the bus bars 41 to 43, the position of the insertion hole 471 corresponds to the position of the non-intersecting portion 412.

  Next, the manufacturing method of the power distribution component 40 of this example is demonstrated using FIGS. 15A and 15B are diagrams for explaining a process of forming the intersection 411. FIG. 15A is a perspective view showing a state of the power distribution component 40 before the intersection 411 is formed, and FIG. It is a perspective view which shows the state of the power distribution component 40 before forming 411. FIG. 16A is an enlarged view of a portion surrounded by the XVIa line in FIG. 15A, and FIG. 16B is an enlarged view of a portion surrounded by the XVIb line in FIG. 15B. FIG. 17 is a diagram for explaining a process of connecting the lead lines 413, 423, and 433. FIG. 17A is a perspective view of the lead lines 413, 423, and 433 before connecting both ends of the bus bars 41 to 43. FIG. (B) is a perspective view of the lead wires 413, 423, 433 after connecting both ends of the bus bars 41-43.

  Since the three bus bars 41 to 43, the connection terminals 44, and the power supply terminals 45 are formed, and the processes until the bus bars 41 to 43 are processed to connect the connection terminals 44 are the same as those in the first embodiment, the description will be made. Is omitted. After processing the bus bars 41 to 43, the three straight bus bars 41 to 43 are passed through the insertion holes 471 of the holder portion 47. A plurality of holders 47 are passed through the bus bars 41 to 43. When the bus bars 41 to 43 are passed through the insertion holes 471, as shown in FIG. 15A and FIG. It passes through the bus bars 41 to 43 in a state where it is rotated 120 degrees with respect to the holder portion 47 passed in front.

  For example, in a certain holder portion 417, the bus bar 41 is passed through the insertion hole 471a (see FIG. 14) among the insertion holes 471 arranged in a triangular shape, the bus bar 42 is passed through the insertion hole 471b, and the bus bar 43 is inserted. It is assumed that the hole 471c is passed. In the next holder portion 471, the bus bar 41 is passed through the insertion hole 471b, the bus bar 42 is passed through the insertion hole 471c, and the bus bar 43 is passed through the insertion hole 471a. Thereby, the plurality of holder portions 417 are arranged at portions corresponding to the intersecting portions 411 of the bus bars 41 to 43 while maintaining a predetermined interval while rotating the main surface direction of the bottom surface 472 of each holder portion 47 by 120 degrees. Is done.

  Next, as shown in FIGS. 15 and 16, each holder part 47 is rotated so that all the bottom surfaces 472 of each holder part 47 are flush with each other. Since portions of the bus bars 41 to 43 that are not penetrated by the holder portion 47 intersect with each other, an intersecting portion 411 is formed. Further, the formation of the intersecting portion 411 holds the holder portion 47 at the boundary portion between the intersecting portion 411 and the non-intersecting portion 412.

  And in the bus bars 41-43 provided with the holder part 47, while securing the drawer | drawing-out parts 413, 423, 433 in each both-ends part, forming the remaining part cyclically | annularly bends the bus bars 41-43 in a torus shape. . Thereafter, the power supply terminal 45 is connected to the lead portions 413, 423, and 433, and the connection terminal 46 is connected to the non-intersection portion 412. Thereby, the power distribution component of this example is completed.

  As described above, the power distribution component 40 of the present example is provided with the holder portion 47 at the intersecting portion 411, and the holder portion 47 includes the insertion hole 471 disposed corresponding to the triangle that is the cross-sectional shape of the non-intersecting portion 412. The bus bars 41 to 43 have a plane perpendicular to the central axis L. Accordingly, the bus bars 41 to 43 are passed through the insertion holes 471 of the holder portion 47, and the intersecting portion 411 can be formed by rotating the holder portion 47 so that the plane of the holder portion 47 is flush. . Further, the holder portion 47 can also be used as a fixing member for the bus bars 41 to 43 while acting as a jig for creating the intersecting portion 411. As a result, the man-hours for manufacturing the power distribution component can be reduced.

  In addition, as shown in FIG.18 and FIG.19, the cross section of the holder part 47 of this example is good also as a triangular shape. 18 and 19 are perspective views of the holder part 47 of the power distribution component according to the modification of the present invention. The insertion holes 471 are arranged so as to correspond to the triangles that are arranged in the cross section of the non-intersecting part 412 and are arranged in a triangular shape. Similarly to the above, the holder portion 47 has a bottom surface 472. In the holder portion 47 of FIG. 18, the insertion hole 471 is arranged between the triangle connecting the center points of the insertion hole 471 and the triangle that is the shape of the outer edge of the holder portion 47 so that the sides are parallel to each other. ing. On the other hand, in the holder portion 47 of FIG. 18, the insertion hole 471 is arranged so that the triangle connecting the center points of the insertion holes 471 rotates 30 degrees with respect to the triangle that is the shape of the outer edge of the holder portion 47.

  In this example, the holder 47 has a triangular cross-sectional shape, and the insertion hole 471 is also triangular in cross section. Thereby, after passing the holder part 47 through the bus bars 41 to 43, before and after the formation of the intersecting part 411, the holder part 47 is in the same phase, and after rotating the holder part 47, without changing the rotation position, The next holder 47 can be rotated. Thereby, since the useless movement of the holder part 47 which is a jig | tool can be reduced, the man-hour for manufacturing an electrical distribution component can be reduced.

  The holder portion 47 corresponds to the “holding portion” of the present invention.

<< Third Embodiment >>
FIG. 20 is a perspective view of a jig for manufacturing a power distribution component 40 according to another embodiment of the invention. In this example, a part of the manufacturing method of the power distribution component 40 is different from the first embodiment described above. Since the configuration other than this is the same as that of the first embodiment described above, the description thereof is incorporated as appropriate.

  As shown in FIG. 20, the jig 50 is a jig used to form the intersecting portion 411 of the power distribution component 40 of this example. The jig 50 includes a pair of jigs 51 and 52 and has a shape obtained by dividing a quadrangular prism into two parts. The cut of the jig 50 is formed so as to divide each insertion hole 501. The insertion hole 501 is formed in a cylindrical shape corresponding to the shape of the bus bars 41 to 43.

  Next, the manufacturing method of the power distribution component 40 of this example using the jig 50 will be described with reference to FIGS. FIG. 21 is a perspective view of the power distribution component 40 before the intersections 411 of the bus bars 41 to 43 are formed using the jig 50 and the jig 50 is removed. FIG. 22 is a perspective view of the power distribution component 40 in a state after the non-intersecting portion 412 is molded by the molding portion 46. FIG. 23 is a perspective view of the power distribution component 40 with the jig 50 removed after the non-intersecting portion 412 is molded.

  Since the three bus bars 41 to 43, the connection terminals 44, and the power supply terminals 45 are formed, and the processes until the bus bars 41 to 43 are processed to connect the connection terminals 44 are the same as those in the first embodiment, the description will be made. Is omitted. First, the jig 50 is arranged at a portion where the non-intersecting part 412 is formed, and the bus bars 41 to 43 in the non-intersecting part 412 are held by the jig 50. The jigs 50 are arranged at equal intervals. Then, each jig 50 is rotated so as to rotate 120 degrees between adjacent jigs 50. The rotation axis at this time is perpendicular to the radial direction (corresponding to the R direction in FIGS. 3 and 5-7) and the axial direction of the central axis perpendicular to the central axis L (see FIG. 3) of the bus bars 41 to 43. The direction is the rotation axis. The distribution parts 40 shown in FIG. 21 are formed by forming lead wires 413, 423, and 433 at both ends of the three straight bus bars 41 to 43 and making the remaining portions annular.

  Next, the mold part 46 is formed in the crossing part 411 by injection molding in a state where the bus bars 41 to 43 are held by the jig 50 (see FIG. 22). Then, as shown in FIG. 23, the jig 50 is removed. Finally, the connection terminal 44 and the power supply terminal 45 are connected to the bus bars 41 to 43 to complete the power distribution component of this example.

  As described above, in this example, the bus bars 41 to 43 are held by the pair of jigs 50, and the jigs 50 are rotated by 120 degrees on the rotation shaft, thereby crossing the bus bars 41 to 43. Thereby, since the crossing part 411 can be processed at once, the number of manufacturing steps of the power distribution component can be reduced and the manufacturing time can be shortened.

  In this example, the mold part 46 may be formed at the intersecting part 411 after the jig 50 is removed before injection molding.

DESCRIPTION OF SYMBOLS 10 ... Stator 11 ... Housing 12 ... Stator 121 ... Stator core 122 ... Bobbin 30 ... Coil 31 ... U phase coil 32 ... V phase coil 33 ... W phase coil 301 ... Lead wire 40 ... Power distribution parts 41-43 ... Bus bar 411 ... Intersection 412: Non-intersecting part 413, 423, 433 ... Drawer part 44 ... Connection terminal 441, 442 ... Nipping part 433 ... Connection part 45 ... Feeding terminal 46 ... Mold part 47 ... Holder part 471, 471a, 471b, 471c ... Insertion hole 50, 51, 52 ... Jig 501 ... Insertion hole

Claims (12)

A plurality of bus bars provided corresponding to respective phases of a multi-phase motor including an annular stator and formed in an annular shape along an end surface in the central axis direction of the annular stator;
A plurality of connection terminals for connecting each phase coil of the stator to a corresponding bus bar among the plurality of bus bars and electrically connecting each phase coil of the motor and the corresponding bus bar, respectively. Have
Each of the plurality of bus bars is
A plurality of bus bars that are bent in a radial direction that is perpendicular to the center axis of the annular stator at predetermined intervals in the circumferential direction of the bus bar and intersect with at least one other bus bar of the plurality of bus bars. An intersection and a plurality of non-intersection formed respectively between the plurality of intersections;
The connection portions where the plurality of bus bars and the plurality of connection terminals are connected are located at the non-intersection, and the distance from the central axis in the radial direction and the position of the central axis in the axial direction are the same. Power distribution parts characterized by that. The multi-phase motor is a three-phase motor,
The plurality of bus bars are formed of three bus bars corresponding to the three phases of the motor,
2. The power distribution component according to claim 1, wherein a line segment connecting the three bus bars is arranged to form a triangular shape on a cross section of a plane including the connection portion and the central axis. The triangle is an equilateral triangle,
Among the plurality of non-intersecting portions, the equilateral triangles on the cross section adjacent to each other in the circumferential direction of the ring of the bus bar are arranged at positions rotated by 120 degrees around the center of gravity of the equilateral triangle. The power distribution component according to claim 2. The power distribution component according to claim 2 or 3, wherein the plurality of bus bars in the non-intersecting part are formed to be parallel to each other. The three bus bars are
On the cross section, one side of the three sides of the triangle connecting the three bus bars is parallel to the central axis, and the first vertex that is both ends of the one side is the radial direction from the central axis. And arranged so as to be inside the second vertex not included in the one side among the vertices of the triangle,
4. The power distribution component according to claim 2, wherein the connection portion is formed in the non-intersecting portion including one vertex of the first vertex. 5. The three bus bars are
On the cross section, one side of the three sides of the triangle connecting the three bus bars is parallel to the radial direction, and a third vertex that is not included in the one side among the vertices of the triangle is the axial direction. Then, it is arranged to be closer to the stator coil than the fourth vertex that is both ends of the one side,
4. The power distribution component according to claim 2, wherein the connection portion is formed at the non-intersection including the third vertex. 5. The three bus bars are
On the cross section, one side of the three sides of the triangle connecting the three bus bars is parallel to the central axis, and a fifth vertex not included in the one side of the triangular vertices is the central axis. Is arranged so as to be inside the sixth vertex that is both ends of the one side in the radial direction from
4. The power distribution component according to claim 2, wherein the connection portion is formed at the non-intersection including the fifth vertex. 5. A plurality of holding portions that collectively hold the three bus bars and hold the non-intersecting portion,
The plurality of holding portions have three insertion holes corresponding to the three bus bars,
The power distribution component according to any one of claims 2 to 7, wherein each of the three bus bars is fixed by being inserted into an insertion hole of the holding portion. The power distribution component according to claim 8, wherein the holding portion has an outer shape of a regular triangular prism formed of three planes parallel to the bus bar at the non-intersecting portion. Corresponding to each phase of the motor of a plurality of phases, forming a plurality of bus bars that are respectively electrically connected to the coils of the motor in an annular shape;
An arrangement step of arranging the plurality of bus bars by intersecting at least one bus bar of the plurality of bus bars with another bus bar at predetermined intervals in the circumferential direction of the ring of the bus bars,
Connecting a connection terminal for electrically connecting each bus bar and the coil to the plurality of bus bars,
The arrangement step includes
The distance from the center axis of the ring in the radial direction perpendicular to the center axis of the ring of the plurality of bus bars, and the connecting portions of the plurality of bus bars to which the plurality of connection terminals are respectively connected, and A method of manufacturing a power distribution component, comprising the step of making the position of the central axis of the ring in the axial direction the same. The arrangement step includes
A sandwiching step of sandwiching the plurality of bus bars with a pair of jigs at predetermined intervals in the circumferential direction;
After the sandwiching step, the pair of jigs are rotated 120 degrees at the predetermined intervals with the direction perpendicular to the radial direction and the axial direction as a rotation axis, so that the one bus bar and the The method of manufacturing a power distribution component according to claim 10, further comprising a step of intersecting with another bus bar. 12. The method according to claim 10, further comprising a step of fixing the plurality of bus bars by fixing a non-intersecting portion where the one bus bar and the other bus bar do not intersect with the resin by injection molding. Manufacturing method for power distribution parts.

Images