KR20220031060A - Stator assembly and electric motor having same - Google Patents

Abstract

The present invention relates to a stator assembly and an electric motor having the same, the stator assembly comprising: a stator core having a plurality of slots; a stator coil formed by connecting a plurality of conductor segments accommodated in the first to N-th layers provided in each of the plurality of slots; a connection ring having a terminal lead, a lead busbar and a neutral busbar; and a support structure connecting the lead wire bus bar and the neutral wire bus bar to the stator coil and supporting the connection ring, wherein the support structure includes a plurality of bus bars connected to the lead wire bus bar and the neutral wire bus bar, respectively. connection; and a plurality of winding connection bus bars connected to each of the plurality of bus bar connection units and connecting a plurality of conductor segments accommodated in different layers.

Description

Stator assembly and electric motor having same

The present invention relates to a stator assembly having improved vibration resistance and an electric motor having a support structure having the same.

In general, an electric motor includes a stator and a rotor, and by rotating the rotor with respect to the stator by the interaction between the rotor and the stator, electrical energy is a device that generates mechanical energy such as rotational power.

The stator includes a stator core having a plurality of slots and a stator coil comprising a plurality of conductor segments inserted into each of the plurality of slots.

The plurality of conductor segments have a rectangular cross-sectional shape and are formed in an approximately "U" shape, also called a hairpin (HAIR PIN).

As a winding method of a stator coil using a conventional hairpin, a wave winding or a middle winding method was used.

The wave winding is a shape in which current is switched to another slot through the weld, and the middle winding is a shape in which the current flows back into the same slot.

In the stator manufactured by adopting the wave winding or middle winding method, various lead wires or jump wires were used to switch from one layer to another.

Finally, a parallel circuit is constructed in the form of connecting the power line to the connection ring.

However, the conventional electric motor has the following problems.

First, the conventional connection ring shakes due to vibration transmitted to the motor housing when the rotor rotates, and there is a problem in that it is damaged due to collision with other surrounding structures and parts. That is, there is a problem in that the conventional connection ring is vulnerable to vibration.

Second, as the number of parallel circuits for each phase of 3-phase AC power increases (for example, 4 or more in parallel), the structure becomes complicated due to the increase in the number of bus bars or jump wires when switching from one layer to another. There is a problem.

Third, in the prior art, in order to connect a three-phase power wire (lead wire) to the connection ring, one side of the copper round copper wire is connected to a terminal lead (Terminal lead), and the other end of the copper round copper wire is connected to the connection ring.

At this time, between the copper round copper wire and the terminal lead, and between the driving round copper wire and the connection ring are coupled to each other by brazing welding.

For this reason, a brazing welding process is added, resulting in an increase in the number of processes and an increase in manufacturing cost.

In addition, due to the flow of the copper round copper wire, there is a problem that the flow of the terminal lead occurs, and it is difficult to control the shape of the copper round copper wire.

To solve this problem, it is possible to align the position of the terminal lead when assembling the terminal lead and the copper round copper wire to the connection ring by putting in a separate person. cause of

The present invention was created to solve the problems of the prior art, and it is a first object to provide a stator assembly capable of improving the vibration resistance performance of a connection ring with respect to vibration caused by rotation of a rotor, and an electric motor having the same.

A second object of the present invention is to provide a stator assembly capable of simplifying the structure without being affected by an increase in the number of parallel circuits for each phase when the windings of two different layers of a stator are connected, and an electric motor having the same.

A third object of the present invention is to provide a stator assembly capable of eliminating the brazing welding process between a terminal lead and a connection ring and completely automating the terminal assembly on a connection ring without the need to correct the position of the terminal lead, and an electric motor having the same There is this.

In order to achieve the first object described above, a stator assembly according to the present invention includes a stator core having a plurality of slots; a stator coil formed by connecting a plurality of conductor segments accommodated in the first to N-th layers provided in each of the plurality of slots; a connection ring having a terminal lead, a lead busbar and a neutral busbar; and a support structure connecting the lead wire bus bar and the neutral wire bus bar to the stator coil and supporting the connection ring, wherein the support structure includes a plurality of bus bars connected to the lead wire bus bar and the neutral wire bus bar, respectively. connection; and a plurality of winding connection bus bars connected to each of the plurality of bus bar connection units and connecting a plurality of conductor segments accommodated in different layers.

In order to achieve the third object described above, according to an example related to the present invention, the connection ring accommodates a portion of each of the terminal lead, the lead wire bus bar and the neutral wire bus bar therein, and is formed by insert injection. can

According to an example related to the present invention, the support structure may accommodate a portion of each of the bus bar connection part and the winding connection bus bar therein, and may be formed by insert injection.

According to an example related to the present invention, the support structure may be provided one for each phase of each of the three phases, and may be disposed to be spaced apart from each other in the circumferential direction at one end of the stator core.

According to an example related to the present invention, the plurality of bus bars for connecting the windings include a bus bar for connecting a first winding and a bus bar for connecting a second winding, and the bus bars for connecting the first and second windings include the stator Among the plurality of conductor segments protruding from one end of the core, two conductor segments spaced apart in a circumferential direction and two conductor segments spaced apart in a radial direction may be respectively coupled to each other to be fixed at four points.

According to this, the connection ring is fixed at four points to the stator by the support structure, and the vibration resistance performance is improved.

In order to achieve the second object described above, according to an example related to the present invention, the bus bars for connecting the first and second windings are accommodated in the support structure in a structure that crosses each other.

According to this, since the bus bars for connecting the first and second windings intersect in an “X” shape, even if the number of parallel circuits for each phase increases, that is, the bus bars for connecting the first and second windings intersect each other. Even if the distance between the winding of the outer layer and the winding of the innermost layer increases, the structure of the bus bar for connecting the first and second windings crossing in an “X” shape may be maintained.

According to an example related to the present invention, each of the bus bars for connecting the first and second windings may include: an outer connecting portion extending in a circumferential direction of the stator core; an inner connecting portion disposed to be spaced apart from the outer connecting portion in a radial direction; and a cross portion connecting the outer connecting portion and the inner connecting portion, wherein one of the first and second winding connecting bus bars crosses the cross bar of the winding connecting bus bar of the other winding connecting bus bar. It can be formed in a structure that is bent a plurality of times in the direction to bypass.

According to an example related to the present invention, one side of the bus bar for connecting the first winding is connected to the conductor segment accommodated in the first layer, the other side is connected to the conductor segment accommodated in the N-th layer, and the second The winding connection bus bar may have one side connected to the conductor segment accommodated in the N-th layer, and the other end connected to the conductor segment accommodated in the first layer.

According to an example related to the present invention, the bus bar connection part may be formed to protrude from the support structure in a vertical direction with respect to the outer connection part or the inner connection part.

According to an example related to the present invention, the support structure may be disposed to overlap one end of the stator core in the axial direction.

According to an example related to the present invention, one terminal lead and one lead wire bus bar are provided for each phase of three phases, and the connection ring is a terminal for mounting a plurality of the terminal leads for connection with an external power source. mounting part; and a plurality of bus bar mounting units respectively provided on both sides of the terminal mounting unit to mount the plurality of lead wire bus bars.

According to an example related to the present invention, the plurality of bus bar mounting units may be disposed to be spaced apart from each other on the same circumference of the stator core, and the terminal mounting units may be disposed outside the bus bar mounting unit.

According to an example related to the present invention, one side of the terminal mounting unit is located on the same plane as one side of the bus bar mounting unit, and the other side extends lower than the other side of the bus bar mounting unit toward one end of the stator core, and the terminal The other side of the mounting part may be in contact with one end of the stator core.

According to an example related to the present invention, a protrusion may be formed to protrude from one side of the support structure to cover the cross portion.

An electric motor according to the present invention includes a stator assembly; and a rotor accommodated in the stator assembly and rotating with respect to the stator assembly about a rotation axis, wherein the stator assembly includes: a stator core having a plurality of slots; a stator coil formed by connecting a plurality of conductor segments accommodated in the first to N-th layers provided in each of the plurality of slots; a connection ring having a terminal lead, a lead busbar and a neutral busbar; and a support structure connecting the lead wire bus bar and the neutral wire bus bar to the stator coil and supporting the connection ring, wherein the support structure includes a plurality of bus bars connected to the lead wire bus bar and the neutral wire bus bar, respectively. connection; and a plurality of winding connection bus bars connected to each of the plurality of bus bar connection units and connecting a plurality of conductor segments accommodated in different layers.

The effects of the stator assembly and the electric motor having the same according to the present invention will be described as follows.

First, the lead wire bus bar and the neutral wire bus bar provided in the connection ring are respectively coupled to the two bus bar connection parts protruding upward from the upper surface of the support structure. Thereby, the connection ring is coupled to the upper portion of the support structure.

Four winding connection bus bars protruding from both sides of the support structure in the circumferential direction of the stator core are coupled to the windings of the innermost and outermost layers of the phase coils for each phase. Thereby, the connection ring is fixed at four points to the stator using the support structure.

Accordingly, it is possible to prevent the connection ring from moving in the axial direction, the radial direction and the circumferential direction with respect to the stator due to the vibration generated when the rotor rotates, and the vibration resistance performance of the connection ring can be improved.

In addition, it is possible to prevent the lead wire bus bar and the neutral wire bus bar provided inside the connection ring from being separated from the bus bar connection part of the support structure due to vibration, and to firmly maintain the coupling state between the winding connection bus bar and the winding of the support structure.

Second, the vibration durability can be strengthened as the insert is injected by crossing the bus bar for winding connection in an X-shape inside the support structure.

Third, the terminal lead, lead wire busbar and neutral wire busbar are molded by insert injection on the connection ring.

Accordingly, the connection ring can securely fix the lead wire bus bar and the neutral wire bus bar to the outside and the inside of the connection ring in the radial direction by insert injection, respectively.

Terminal leads can be fixed to the connection ring without a conventional copper round copper wire.

The number of steps and costs can be reduced by eliminating the brazing process performed when the conventional terminal lead is connected to the connection ring.

Fourth, the flow of the terminal lead is minimized by insert injection of the terminal lead into the connection ring.

In addition, by making a plurality of terminal leads in a rigid plastic shape, there is an advantage in managing the degree of freedom of position of the terminal leads.

Fifth, since the positions of the terminal lead, lead wire busbar, and neutral wire busbar are fixed in the connection ring, complete automation is possible without the need for position correction when assembling the connector.

Sixth, the connection ring is symmetrically disposed along the circumferential direction by insert injection of the first bus bar mounting part and the second bus bar mounting part on both sides of the terminal mounting part.

According to this, the effect of improving durability can be obtained by dispersing the impact by vibration of a plurality of terminal leads.

Seventh, since the terminal lead is positioned lower toward one end of the stator core than the bus bar, the connection ring can optimize the arrangement space of the terminal lead and the bus bar to be compact, and the connection ring can be miniaturized.

1 is a conceptual view showing a stator assembly having a connection ring and a support structure according to the present invention.
FIG. 2 is a plan view of FIG. 1 .
3 is a side view of FIG. 2 ;
FIG. 4 is a conceptual diagram illustrating the connection ring of FIG. 1 .
5 is a plan view illustrating the connection ring of FIG. 2 as viewed from above.
6 is a conceptual view illustrating the stator assembly of FIG. 1 as viewed from another angle.
7 is a conceptual diagram illustrating a connection state between a support structure and a winding after the connection ring is removed in FIG. 6 .
8 is a conceptual diagram illustrating any one of a plurality of support structures in FIG. 7 .
FIG. 9 is a conceptual view illustrating a bus bar for connecting the first and second windings mounted inside the support structure after removing the windings in FIG. 8 .
FIG. 10 is a cross-sectional view taken along XX in FIG. 8 .

Hereinafter, the embodiments disclosed in the present specification will be described in detail with reference to the accompanying drawings, but the same or similar components are assigned the same reference numbers regardless of reference numerals, and redundant description thereof will be omitted. The suffixes "module" and "part" for components used in the following description are given or mixed in consideration of only the ease of writing the specification, and do not have distinct meanings or roles by themselves. In addition, in describing the embodiments disclosed in the present specification, if it is determined that detailed descriptions of related known technologies may obscure the gist of the embodiments disclosed in this specification, the detailed description thereof will be omitted. In addition, the accompanying drawings are only for easy understanding of the embodiments disclosed in the present specification, and the technical idea disclosed herein is not limited by the accompanying drawings, and all changes included in the spirit and scope of the present invention , should be understood to include equivalents or substitutes.

Terms including an ordinal number such as 1st, 2nd, etc. may be used to describe various elements, but the elements are not limited by the terms. The above terms are used only for the purpose of distinguishing one component from another.

When a component is referred to as being “connected” or “connected” to another component, it may be directly connected or connected to the other component, but it is understood that other components may exist in between. it should be On the other hand, when it is said that a certain element is "directly connected" or "directly connected" to another element, it should be understood that the other element does not exist in the middle.

The singular expression includes the plural expression unless the context clearly dictates otherwise.

In the present application, terms such as “comprises” or “have” are intended to designate that a feature, number, step, operation, component, part, or combination thereof described in the specification exists, but one or more other features It should be understood that this does not preclude the existence or addition of numbers, steps, operations, components, parts, or combinations thereof.

1 is a conceptual view showing a stator assembly 100 having a connection ring 120 and a support structure 130 according to the present invention. FIG. 2 is a plan view of FIG. 1 ; 3 is a side view of FIG. 2 ; 4 is a conceptual diagram illustrating the connection ring 120 of FIG. 1 . 5 is a plan view illustrating the connection ring 120 of FIG. 2 as viewed from above.

The electric motor includes a stator assembly 100 and a rotor.

The motor housing forms the exterior of the electric motor. The motor housing (not shown) includes a main housing formed in a cylindrical shape, and a front cover and a rear cover mounted on both ends of the main housing to cover both ends of the main housing.

An accommodation space is provided inside the main housing. The stator assembly 100 is configured to be accommodated in the receiving space of the main housing. The stator may be fixed by being press-fitted to the inner circumferential surface of the main housing.

The rotor may be accommodated in the stator core 110 . The rotor may be rotatably mounted with respect to the stator assembly 100 .

The rotor may be composed of a rotor core and a permanent magnet. The permanent magnet may be installed embedded in the rotor core (embedded permanent magnet) or mounted on the outer surface of the rotor core (surface-attached permanent magnet).

The permanent magnet is not mounted on the rotor core, and the coil may be wound on the rotor core.

The stator assembly 100 includes a stator core 110 and a stator coil 114 .

The stator core 110 has a cylindrical shape. A rotor receiving hole is provided in the inner center of the stator core 110 . A plurality of slots 111 inside the stator core 110 are formed to be spaced apart along the outer circumference of the rotor receiving hole.

The stator coil 114 may be formed in a hairpin shape. The stator coil 114 may configure a parallel circuit for each three-phase, U-phase, V-phase, and W-phase phase. The stator coil 114 may constitute, for example, four parallel circuits.

The stator coil 114 may include a phase coil for each phase. Each phase coil may be composed of a plurality of parallel circuits. The phase coil may be composed of a phase U coil, a phase V coil and a phase W coil.

The stator coil 114 is wound on the stator core 110 through the plurality of slots 111 .

Each of the plurality of slots 111 may include a plurality of first layers 112 to N-th layers 113 along the radial direction of the stator core 110 . N is a natural number greater than or equal to 2. In this embodiment, the slot 111 shows a state in which the first to eighth layers are formed.

The plurality of first layers 112 to N-th layers 113 may be understood as a concept for dividing a section in which the stator coil 114 (winding) is stacked along the radial direction of the slot 111 for each layer.

The stator coil 114 may be configured by connecting the conductor segments 115 in the form of hairpins.

The conductor segment 115 may be formed in a hairpin shape, that is, a “U” shape, and may have a rectangular cross-sectional shape. The conductor segment 115 is provided at two straight parts 1151 arranged in parallel with each other, a crossing part 1152 connecting one end of each of the two straight parts 1151 , and at the other end of each of the two straight parts 1151 . and a bending part 1153 to be used.

The two straight parts 1151 may be accommodated in different slots 111 . The two straight portions 1151 may be accommodated in different layers of different slots 111 .

Crossover 1152 connects two straight portions 1151 of one conductor segment 115 so that one conductor segment 115 crosses from one slot 111 to another. The cross section 1152 is formed to protrude obliquely at a predetermined angle from one end of the stator core 110 . The crossing 1152 may include a first inclined part and a second inclined part.

Each of the first inclined portion and the second inclined portion may be formed to be inclined with respect to the axial direction with a half length of a pitch SLOT PITCH of one slot 111 crossing from one slot 111 to another slot 111 .

For example, the first inclined portion extends obliquely in a direction coming out of one slot 111 , and one end of the first inclined portion is connected to one end of one straight portion 1151 of one conductor segment 115 .

The second inclined portion is formed to be inclined in a direction entering the other slot 111 , one end of the second inclined portion is connected to the other end of the first inclined portion, and the other end of the second inclined portion is inserted into the other slot 111 . It is connected to one end of the other straight part 1151 of the segment 115 .

The bending part 1153 is formed to protrude at a predetermined angle from the other end of the stator core 110 .

The bending part 1153 is configured to connect the straight part 1151 of each of the two conductor segments 115 respectively inserted into different slots 111 . The bending part 1153 is bent toward different straight parts 1151 .

The bending portion 1153 has a joint portion 1154 for joining the two different conductor segments 115 to each other. The two straight portions 1151 , the crossing portion 1152 and the bending portion 1153 of the conductor segment 115 excluding the joint portion 1154 are insulated by an insulating material. The junction 1154 is configured to remove the insulating material to conduct the two different conductor segments 115 .

The two straight portions 1151 of each of the plurality of conductor segments 115 may be inserted into different layers.

A plurality of terminal leads 124 are provided to supply power to each phase coil of the stator coil 114 . The plurality of terminal leads 124 may be provided in one connection ring 120 .

The terminal lead 124 is a conductive member through which an electric current can flow.

The connection ring 120 according to the present invention includes a plurality of terminal leads 124 and a plurality of bus bars.

The plurality of terminal leads 124 may be formed in a plate shape. Each of the plurality of terminal leads 124 has a coupling hole. When the power line is connected to the terminal lead 124 , a fastening member such as a bolt may be fastened to the coupling hole.

The plurality of terminal leads 124 may be composed of three for connecting a three-phase power line. The first terminal lead 1241 may be connected to the U-phase power line, the second terminal lead 1242 may be connected to the V-phase power line, and the third terminal lead 1243 may be connected to the W-phase power line.

The plurality of terminal leads 124 may be embedded in the connection ring 120 . The plurality of terminal leads 124 may be installed inside the connection ring 120 by insert injection (INSERT INJECTION).

Insert injection means that parts other than plastic, for example, a plurality of terminal leads 124 are mounted inside the mold, and then the plastic molten resin is injected and molded.

The plurality of terminal leads 124 are integrally formed inside the connection ring 120 by insert injection. The plurality of terminal leads 124 may be fixed to the inside of the connection ring 120 .

According to this configuration, the plurality of terminal leads 124 can be connected to the connection ring 120 without a connecting member such as a separate copper round copper wire.

The bus bar includes a plurality of lead wire bus bars 125 for connecting a power line and a neutral line bus bar 126 for connecting a neutral line.

The plurality of lead wire bus bars 125 may be formed integrally with the terminal leads 124 , respectively.

The plurality of lead wire bus bars 125 may be embedded in the connection ring 120 together with the terminal leads 124 by insert injection molding.

The plurality of lead wire bus bars 125 may be respectively connected to the phase coils for supplying three-phase power. The plurality of lead wire bus bars 125 may extend in a circumferential direction. The plurality of lead wire bus bars 125 may extend to different circumferential lengths.

The plurality of lead wire bus bars 125 may be disposed to be spaced apart from each other in the circumferential direction of the stator core 110 .

The plurality of lead wire bus bars 125 may include a first lead wire bus bar 1251 to a third lead wire bus bar 1253 .

The first lead line bus bar 1251 may have one end connected to the first terminal lead 1241 for connection with the U-phase power line, and the other end connected to the U-phase coil.

The second lead line bus bar 1252 may have one end connected to the second terminal lead 1242 for connection with the V-phase power line, and the other end connected to the V-phase coil.

The third lead line bus bar 1253 may have one end connected to the third terminal lead 1243 for connection with the W-phase power line, and the other end connected to the W-phase coil.

The plurality of lead wire bus bars 125 may be disposed to overlap one end of the stator core 110 in the axial direction. Each of the plurality of lead wire bus bars 125 may be spaced apart from each other on the same circumference of the stator core 110 .

The plurality of lead wire bus bars 125 may be disposed to overlap the outermost circumference in the radial direction of the stator core 110 in the axial direction.

Each of the plurality of lead wire bus bars 125 may be spaced apart from each other on the same layer in different slots 111 of the stator core 110 .

A bus bar coupling part 1250 is provided at each end of the plurality of lead wire bus bars 125 . The bus bar coupling part 1250 is formed to protrude upward from the end of the lead wire bus bar 125 and may be coupled to the upper coil by welding or the like.

A bus bar coupling part 1250 of each of the plurality of lead wire bus bars 125 may be disposed to be in contact with a lead wire connection part 1391 of a bus bar connection part 139 to be described later.

The bus bar coupling part 1250 and the lead wire connection part 1391 may be disposed to overlap each other in a radial direction, and may be coupled by welding.

Each of the plurality of terminal leads 124 may extend obliquely at a predetermined angle with respect to the radial direction of the stator core 110 . Each of the plurality of terminal leads 124 may be spaced apart from each other in parallel.

One neutral wire bus bar 126 may extend in a circular arc shape along the circumferential direction.

One neutral wire bus bar 126 is disposed to be radially spaced apart from each other inside the plurality of lead wire bus bars 125 .

The neutral bus bar 126 is disposed to overlap one end of the stator core 110 in an axial direction. A plurality of neutral point coupling portions 1261 , 1262 , and 1263 are provided on the circumference of the neutral bus bar 126 . Each of the plurality of neutral point coupling parts 1261 , 1262 , and 1263 is formed to protrude in the axial direction or upward from the neutral wire bus bar 126 , and is connected to the neutral wire connection part 1392 connecting the neutral point, which is an end of each phase coil.

The plurality of neutral point coupling units 1261 , 1262 , and 1263 may include a first neutral point coupling unit 1261 to a third neutral point coupling unit 1263 .

The first neutral point coupling part 1261 may be connected to the neutral point of the U-phase coil.

The second neutral point coupling part 1262 may be connected to the neutral point of the V-phase coil.

The third neutral point coupling part 1263 may be connected to the neutral point of the phase W coil.

Each of the plurality of neutral point coupling portions 1261 , 1262 , 1263 is coupled to the neutral point portion of each phase coil by welding. Each of the plurality of neutral point coupling parts 1261 , 1262 , and 1263 is coupled to a neutral wire connection part 1392 of a bus bar connection part 139 to be described later by welding.

Here, each of the bus bar coupling parts 1250 of the lead wire bus bar 125 and the neutral point coupling parts 1261 , 1262 , and 1263 of the neutral wire bus bar 126 are flat or in surface contact with the neutral point part of each phase coil. It may be formed in a curved shape.

The neutral wire bus bar 126 may be mounted on the inner circumference of the connection ring 120 . The plurality of lead wire bus bars 125 may be embedded in the outer periphery of the connection ring 120 and disposed to be radially spaced apart from the neutral wire bus bars 126 .

The connection ring 120 may be configured in a plate shape having a predetermined vertical height and area. The connection ring 120 may be formed to extend along the circumferential direction from one end of the stator core 110 .

The connection ring 120 is formed to surround an arc section of about 120 degrees out of a 360 degree section along the circumferential direction of the stator core 110 .

The connection ring 120 may be made of a material different from the bus bar. The connection ring 120 may be formed of a plastic material. The connection ring 120 may be manufactured by injection molding.

The connection ring 120 includes a terminal mounting unit 121 and bus bar mounting units 122 and 123 .

The terminal lead 124 is mounted inside the terminal mounting unit 121 , and the terminal mounting unit 121 is configured to support the terminal lead 124 .

A lead wire bus bar 125 and a neutral wire bus bar 126 are mounted inside the bus bar mounting parts 122 and 123 , and the bus bar mounting parts 122 and 123 are a lead wire bus bar 125 and a neutral wire bus bar 126 . made to support

The terminal mounting portion 121 is disposed at the center portion in the circumferential direction of the connection ring 120 . The terminal mounting unit 121 is disposed radially outward from the plurality of bus bar mounting units 122 and 123 .

The terminal mounting part 121 may be disposed on the outside in the radial direction of the stator core 110 , and the plurality of bus bar mounting parts 122 and 123 may be disposed on the inside in the radial direction of the stator core 110 .

Accordingly, the terminal mounting unit 121 may be arranged to not overlap the stator core 110 in the axial direction, and the plurality of bus bar mounting units 122 and 123 may be arranged to overlap the stator core 110 in the axial direction. .

The plurality of bus bar mounting units 122 and 123 are respectively disposed on both sides of the connection ring 120 with the terminal mounting unit 121 interposed therebetween.

The plurality of bus bar mounting units 122 and 123 may include a first bus bar mounting unit 122 and a second bus bar mounting unit 123 . The first bus bar mounting part 122 and the second bus bar mounting part 123 are disposed to be spaced apart from each other in the circumferential direction.

The terminal mounting unit 121 is configured to connect one side of the first bus bar mounting unit 122 and one side of the second bus bar mounting unit 123 . One edge of the terminal mounting part 121 is connected to one edge of the first bus bar mounting part 122 , and the other edge of the terminal mounting part 121 is connected to one edge of the second bus bar mounting part 123 .

One side of each of the plurality of terminal leads 124 is installed to be accommodated inside the terminal mounting unit 121 , and the other side of each of the plurality of terminal leads 124 is disposed to protrude to the outside of the terminal mounting unit 121 .

Each of the plurality of terminal leads 124 may extend in a direction crossing the circumferential direction of the lead wire bus bar 125 . Each of the plurality of terminal leads 124 may be disposed to be inclined at a preset angle with respect to the radial direction of the stator.

A circular coupling hole is formed in each of the plurality of terminal leads 124 protruding to the outside of the terminal mounting unit 121 , so that an external power line may be coupled to the terminal leads 124 , respectively.

The upper end of the terminal mounting unit 121 is located on the same plane as the upper end of the bus bar mounting units 122 and 123 , and the lower end of the terminal mounting unit 121 is lower than the lower end of the bus bar mounting units 122 and 123 of the stator core 110 . It may extend lower towards one end. The plurality of terminal leads 124 are disposed under the terminal mounting part 121 . The terminal lead 124 may be positioned lower than the lead wire bus bar 125 in a downward direction (based on the axial direction of the stator core 110 ).

According to this, the arrangement space of the plurality of terminal leads 124 and the lead wire bus bar 125 can be compactly optimized by different positions of the terminal lead 124 and the lead wire bus bar 125, and the connection ring ( 120) can be reduced in size.

In order to minimize an increase in material cost and weight due to an increase in the height of the terminal mounting unit 121 , a plurality of recesses 1211 may be formed in the upper portion of the terminal mounting unit 121 .

The lower ends of the bus bar mounting parts 122 and 123 may be disposed to be spaced apart upward from one end of the stator core 110 . According to this, the lead wire bus bar 125 and the neutral wire bus bar 126 mounted on the bus bar mounting units 122 and 123 are easily connected to the end coil of each phase coil protruding in the axial direction from one end of the stator core 110 . can be connected

Each of the first bus bar mounting part 122 and the second bus bar mounting part 123 extends in the circumferential direction and is disposed on the same circumference of the stator core 110 .

One side of the first lead wire bus bar 1251 is connected to the first terminal lead 1241 inside the terminal mounting part 121 , and the other side of the first lead wire bus bar 1251 is of the first bus bar mounting part 122 . It is accommodated therein and extends in the first direction along the circumferential direction.

The other end of the first lead wire bus bar 1251 protrudes from the first bus bar mounting part 122 in the first direction. The bus bar coupling part 1250 of the first lead wire bus bar 1251 is exposed to the outside of the first bus bar mounting part 122 . The bus bar coupling part 1250 protrudes upward from the other end of the first lead wire bus bar 1251 .

One side of the second lead wire bus bar 1252 is connected to the second terminal lead 1242 inside the terminal mounting part 121 , and the other side of the second lead wire bus bar 1252 is directed toward the neutral bus bar 126 . After protruding between the first bus bar mounting part 122 and the second bus bar mounting part 123, it extends in a second direction opposite to the first direction along the circumferential direction. A bus bar coupling part 1250 protrudes upwardly from the other end of the second lead wire bus bar 1252 extending in the second direction.

One side of the third lead line bus bar 1253 is connected to the third terminal lead 1243 inside the terminal mounting part 121 . The other side of the third lead wire bus bar 1253 is installed to be accommodated in the second bus bar mounting part 123 and extends in the second direction. A bus bar coupling part 1250 is formed to protrude upwardly from the other end of the third lead wire bus bar 1253 extending in the second direction.

A first mounting groove 1221 is formed along the inner circumference of the first bus bar mounting part 122 . A second mounting groove 1231 is formed along the inner circumference of the second bus bar mounting part 123 . The first mounting groove 1221 and the second mounting groove 1231 are arranged in the same circumferential shape.

The neutral wire bus bar 126 may be mounted by being inserted into the first mounting groove 1221 and the second mounting groove 1231 .

According to this configuration, the connection ring 120 can securely fix the lead wire bus bar 125 and the neutral wire bus bar 126 to the outside and the inside of the connection ring 120 in the radial direction by insert injection, respectively.

In addition, the terminal lead 124 can be fixed to the connection ring 120 without a conventional copper round copper wire, and the number of steps and costs can be reduced by eliminating the brazing welding process.

In addition, by making a plurality of terminal leads 124 in a rigid plastic shape, there is an advantage in managing freedom of position of the terminal leads 124 .

In addition, in the connection ring 120 , the first bus bar mounting part 122 and the second bus bar mounting part 123 are symmetrically disposed along the circumferential direction by insert injection on both sides of the terminal mounting part 121 . According to this, the effect of improving durability can be obtained by dispersing the impact caused by the vibration of the plurality of terminal leads 124 .

In addition, since the terminal lead 124 is positioned lower toward one end of the stator core 110 than the bus bar, the connection ring 120 can optimize the arrangement space of the terminal lead 124 and the bus bar compactly, The connection ring 120 can be miniaturized.

In addition, since the terminal mounting portion 121 of the connection ring 120 is supported in contact with one end of the stator core 110 , it is possible to limit axial vibration transmitted to the terminal lead 124 .

6 is a conceptual view illustrating the stator assembly 100 of FIG. 1 as viewed from another angle. 7 is a conceptual diagram illustrating a connection state between the support structure 130 and the winding after the connection ring 120 is removed in FIG. 6 . FIG. 8 is a conceptual view showing any one of the plurality of support structures 130 in FIG. 7 . FIG. 9 is a conceptual diagram illustrating bus bars 136 and 137 for connecting the first and second windings mounted inside the support structure 130 after removing the windings in FIG. 8 . FIG. 10 is a cross-sectional view taken along line X-X in FIG. 8 .

In the present invention, when the bus bar of the connection ring 120 is connected to the stator coil 114, the support structure 130 is provided to enhance the vibration resistance of the contact point between the bus bar and the stator coil 114 (winding).

The support structure 130 includes a plurality of bus bars for connecting windings therein. The plurality of bus bars may be embedded in the support structure 130 by insert injection.

The plurality of winding connection bus bars 135 are configured to connect two conductor segments 115 inserted in different layers.

For example, each of the plurality of winding connection bus bars 135 includes a conductor segment 115 and an innermost layer (slot) of an outermost layer (a radially outermost layer among the layers of the slot 111 ). It may be configured to connect the conductor segments 115 of the radially innermost layer among the layers of 111 .

The plurality of winding connection bus bars 135 may include a first winding connection bus bar 136 and a second winding connection bus bar 137 .

The bus bar 136 for connecting the first winding and the bus bar 137 for connecting the second winding may extend in a direction crossing each other.

The bus bar 136 for connecting the first winding and the bus bar 137 for connecting the second winding form a pair and may be radially spaced apart from each other.

A pair of the bus bar 136 for connecting the first winding and the bus bar 137 for connecting the second winding may be provided in the phase coil for each phase.

The pair of bus bars 135 for connecting the windings may be connected to each of the three-phase, that is, the U-phase, the V-phase, and the W-phase coil.

Each of the plurality of winding connection bus bars 135 may include inner connecting portions 1361 and 1371 , outer connecting portions 1362 and 1372 , cross portions 1363 and 1373 ; and a bus bar connecting portion 139 . .

Each of the plurality of winding connection bus bars 135 has a rectangular cross-sectional shape.

The inner connections 1361 and 1371 are configured to be coupled to the innermost conductor segment 115 of the stator coil 114 . The inner connection parts 1361 and 1371 extend along the circumferential direction of the stator core 110 . The inner connecting portions 1361 and 1371 are disposed on the radially inner circumference of the stator core 110 . A coil coupling part 138 is formed to protrude upward from one end of the inner connection parts 1361 and 1371 .

One side of the inner connection parts 1361 and 1371 is connected to the upper coil through the coil coupling part 138 , and the other side of the inner connection parts 1361 and 1371 is connected to the cross parts 1363 and 1373 .

The cross portions 1363 and 1373 connect the inner connection portions 1361 and 1371 and the outer connection portions 1362 and 1372 to each other. The cross portions 1363 and 1373 extend obliquely with respect to the radial direction.

The outer connections 1362 and 1372 are configured to be coupled to the outermost conductor segment 115 of the stator coil 114 . The outer connecting portions 1362 and 1372 extend along the circumferential direction of the stator core 110 . The outer connections 1362 , 1372 are disposed on the radially outer perimeter of the stator core 110 . A coil coupling part 138 is formed to protrude upward from the other end of the outer connection parts 1362 and 1372 .

One side of the outer connection portions 1362 and 1372 is connected to the cross portions 1363 and 1373 , and the other side of the outer connection portions 1362 and 1372 is connected to the upper coil through the coil coupling portion 138 .

The bus bar 136 for connecting the first winding and the bus bar 137 for connecting the second winding may be disposed on the same plane.

The inner connection portions 1361 and 1371 of the bus bar 136 for connecting the first winding and the outer connection portions 1362 and 1372 of the bus bar for the second winding are disposed to face each other in a radial direction and are spaced apart from each other.

The outer connection portions 1362 and 1372 of the bus bar for connecting the first winding 136 and the inner connection portions 1361 and 1371 of the bus bar for the second winding are disposed to be spaced apart from each other when facing each other in a radial direction.

The cross portions 1363 and 1373 of each of the bus bar 136 for connecting the first winding and the bus bar 137 for connecting the second winding are formed to cross each other.

The cross portions 1363 and 1373 may include a first cross portion 1363 and a second cross portion 1373 . The first cross section 1363 is provided on the bus bar 136 for connecting the first winding, and the second cross section 1373 is provided on the bus bar 137 for connecting the second winding. One of the first and second cross portions 1363 and 1373 is configured to bypass the other cross portions 1363 and 1373 .

In the present embodiment, a state in which the first cross section 1363 bypasses the second cross section 1373 is shown.

One of the first and second cross portions 1363 and 1373 crosses in a direction crossing each other without meeting the other cross portion in the inner connecting portions 1361 and 1371 or the outer connecting portions 1362 and 1372. It may be bent a plurality of times in a circular or polygonal shape.

The second cross portion 1373 is disposed on the same plane as the outer connection portions 1362 and 1372 and the inner connection portions 1361 and 1371 of the bus bar 137 for connecting the second winding.

The first cross part 1363 may be disposed to cover an upper portion of the second cross part 1373 . The first cross portion 1363 may be formed to be spaced apart from the second cross portion 1373 in the upward direction.

The first cross portion 1363 includes two upper and lower extension portions 13631 extending in the vertical direction from the inner connecting portions 1361 and 1371 or the outer connecting portions 1362 and 1372, and the upper ends of the two upper and lower extension portions 13631, respectively. It includes a horizontal extension 13632 connecting the. The first cross portion 1363 may be formed in a shape in which the letter “U” is turned upside down.

The upper and lower extension portions 13631 of the first cross portion 1363 are spaced apart from each other in a direction crossing the second cross portion 1373 . The horizontally extended portion 13632 of the first cross portion 1363 is vertically spaced apart from the second cross portion 1373 .

A connection portion between the vertical extension 13631 and the horizontal extension 13632 of the first cross portion 1363 is formed in an arc-shaped curved surface. The connecting portion of the outer connecting portions 1362 and 1372 and the upper and lower extension portions 13631 may be formed in an arc-shaped curved surface.

The support structure 130 includes bus bars 136 and 137 for connecting the first and second windings. The support structure 130 is a plastic injection molding.

The bus bars 136 and 137 for connecting the first and second windings are inserted crosswise in an “X” shape into the inside of the support structure 130 by insert injection and may be embedded. The bus bars 136 and 137 for connecting the first and second windings may be molded by the support structure 130 .

The support structure 130 may be formed in a fan shape. The outermost circumferential surface and the innermost circumferential surface of the support structure 130 may have the same center and may be formed as curved surfaces of predetermined curvature to have different diameters.

The outermost circumferential surface and the innermost circumferential surface of the support structure 130 may extend parallel to each other.

Both side surfaces of the support structure 130 may be spaced apart from each other in the circumferential direction and inclined at a preset angle with respect to the radial direction.

A first accommodating part in which the bus bar 136 for connecting the first winding is accommodated is formed in the support structure 130 .

A second accommodating part in which the bus bar 137 for connecting the second winding is accommodated is formed in the support structure 130 .

The outer connection portions 1362 and 1372 of the bus bar 136 for connecting the first winding and the inner connection portions 1361 and 1371 of the bus bar 137 for connecting the second winding, respectively, are in the circumferential direction from one side of the support structure 130 . It extends to protrude in the first direction along the

The outer connection portions 1362 and 1372 of the bus bar 137 for connecting the second winding and the inner connection portions 1361 and 1371 of the bus bar 136 for connecting the first winding, respectively, are in the circumferential direction from the other side of the support structure 130 . It extends to protrude in a second direction opposite to the first direction.

Each of the coil coupling parts 138 of the outer connection parts 1362 and 1372 of the bus bar 136 for connecting the first winding and the coil coupling part 138 of the inner connection parts 1361 and 1371 is a conductor segment disposed on the outermost layer The junction 1154 of the 115 (coil) and the junction 1154 of the conductor segment 115 (coil) disposed in the innermost layer are connected and energized.

Each of the coil coupling parts 138 of the inner connection parts 1361 and 1371 of the second winding connection bus bar 137 and the coil coupling part 138 of the outer connection parts 1362 and 1372 of the bus bar 137 for connecting the second winding is a conductor segment disposed on the innermost layer The junction 1154 of 115 and the junction 1154 of the conductor segment 115 disposed in the outermost layer are connected to conduct electricity.

The bus bar connection part 139 may include a lead wire connection part 1391 and a neutral wire connection part 1392 .

The neutral wire connection portion 1392 may extend upwardly from the inner connection portions 1361 and 1371 of the bus bar 136 for connecting the first winding. The neutral wire connection part 1392 is configured to be coupled to the neutral point coupling parts 1261 , 1262 , and 1263 of the neutral wire bus bar 126 by welding or the like.

The lead wire connecting portion 1391 may extend upwardly from the outer connecting portions 1362 and 1372 of the bus bar 137 for connecting the second winding. The lead wire connecting portion 1391 is configured to be coupled to the lead wire bus bar 125 by welding or the like.

The lead wire connection part 1391 may be disposed to be spaced apart from the neutral wire connection part 1392 radially outward. At least a portion of the lead wire connection part 1391 and the neutral wire connection part 1392 may be disposed to overlap in a radial direction.

The neutral wire bus bar 126 may extend across between the lead wire connection part 1391 and the neutral wire connection part 1392 . The neutral wire bus bar 126 may be configured to connect the plurality of neutral wire connection parts 1392 in a circumferential direction.

Each of the neutral point coupling portions 1261 , 1262 , and 1263 of the neutral wire bus bar 126 may be disposed to overlap the neutral wire connection portion 1392 in a radial direction to be contacted and coupled.

The support structure 130 is configured to fix the bus bar 136 for connecting the first winding and the bus bar 137 for connecting the second winding.

The support structure 130 further includes a protrusion 134 to cover the first cross portion 1363 .

The protrusion 134 is formed to protrude upward from one side of the support structure 130 . The protrusion 134 has a rectangular shape to surround the first cross portion 1363 . The first cross portion 1363 is installed inside the protrusion 134 to be accommodated. The second cross portion 1373 is installed inside the support structure 130 to be accommodated. The support structure 130 and the protrusion 134 are fixed to cross the first cross portion 1363 and the second cross portion 1373 in an X-shape.

The support structure 130 is provided in plurality to correspond to the lead wire bus bar 125 .

The plurality of support structures 130 may be disposed to be spaced apart from each other in the circumferential direction on the same circumference of the stator core 110 . The plurality of support structures 130 may include a first support structure 131 to a third support structure 133 .

The first support structure 131 may be configured to be connected to the U-phase lead wire bus bar 125 .

The second support structure 132 may be formed to be connected to the V-phase lead wire bus bar 125 .

The third support structure 133 may be configured to be connected to the W-phase lead wire bus bar 125 .

The connection ring 120 and the support structure 130 may be compactly disposed at one end of the stator core 110 .

Therefore, according to the present invention, the lead wire bus bar 125 and the neutral wire bus bar 126 provided in the connection ring 120 are connected to the two bus bar connection parts 139 protruding upward from the upper surface of the support structure 130 . Each of the connection rings 120 is coupled to the upper portion of the support structure 130 , and four winding connection bus bars 135 protruding from both sides of the support structure 130 in the circumferential direction of the stator core 110 . ) is coupled to the windings of the innermost and outermost layers of the phase coil for each phase, and the connection ring 120 is fixed to the stator by the support structure 130 at four points, thereby causing the connection ring 120 to vibrate when the rotor rotates. Due to this, it is possible to prevent movement in the axial direction, radial direction and circumferential direction with respect to the stator, and it is possible to improve the vibration resistance performance of the connection ring 120 .

Accordingly, the lead wire bus bar 125 and the neutral wire bus bar 126 provided inside the connection ring 120 are prevented from being separated from the bus bar connection part 139 of the support structure 130 due to vibration, and support The coupling state between the winding connection bus bar 135 of the structure 130 and the winding may be firmly maintained.

In addition, the vibration durability can be improved as the bus bar 135 for connecting the windings is crossed in an X-shape inside the support structure 130 and the insert is injected.

In addition, when the terminal lead 124, the lead wire bus bar 125, and the neutral wire bus bar 126 are molded into the connection ring 120 by insert injection molding, when the conventional terminal lead 124 is connected to the connection ring 120 By eliminating the brazing process that was performed, it is possible to reduce the number of processes and reduce costs.

In addition, the flow of the terminal lead 124 is minimized by insert injection of the terminal lead 124 into the connection ring 120 , so that the position in the stator assembly 100 is advantageously controlled.

In addition, since the positions of the terminal lead 124 , the lead wire bus bar 125 , and the neutral wire bus bar 126 are determined in the connection ring 120 , complete automation is possible without the need for position correction when assembling the connector.

Claims (15)

a stator core having a plurality of slots;
a stator coil formed by connecting a plurality of conductor segments accommodated in the first to N-th layers provided in each of the plurality of slots;
a connection ring having a terminal lead, a lead wire busbar and a neutral wire busbar; and
and a support structure connecting the lead wire bus bar and the neutral wire bus bar to the stator coil and supporting the connection ring,
The support structure is
a plurality of bus bar connection units respectively connected to the lead wire bus bar and the neutral wire bus bar; and
and a plurality of winding connection bus bars connected to each of the plurality of bus bar connections and connecting a plurality of conductor segments accommodated in different layers;
stator assembly. According to claim 1,
The connection ring is
A portion of each of the terminal lead, the lead wire bus bar and the neutral wire bus bar is accommodated therein, and is formed by insert injection,
stator assembly. According to claim 1,
The support structure is
A portion of each of the bus bar connection part and the winding connection bus bar is accommodated therein, and is formed by insert injection,
stator assembly. According to claim 1,
The support structure is provided with one for each phase of each of the three phases, and is disposed at one end of the stator core to be spaced apart in the circumferential direction,
stator assembly. According to claim 1,
The plurality of winding connecting bus bars includes a first winding connecting bus bar and a second winding connecting bus bar,
A bus bar for connecting the first and second windings,
Is coupled to two conductor segments spaced apart in a circumferential direction and two conductor segments spaced apart in a radial direction among the plurality of conductor segments protruding from one end of the stator core, and is fixed at four points,
stator assembly. 6. The method of claim 5,
The bus bars for connecting the first and second windings are accommodated in the support structure in a structure that crosses each other,
stator assembly. 6. The method of claim 5,
Each of the bus bars for connecting the first and second windings,
an outer connecting portion extending in the circumferential direction of the stator core;
an inner connecting portion disposed to be spaced apart from the outer connecting portion in a radial direction; and
and a cross part connecting the outer connection part and the inner connection part,
One of the bus bars for connecting the first and second windings is bent a plurality of times in a direction intersecting the crossbar of the bus bar for connecting the other winding,
stator assembly. 6. The method of claim 5,
The bus bar for connecting the first winding has one side connected to the conductor segment accommodated in the first layer, and the other side connected to the conductor segment accommodated in the N-th layer,
The bus bar for connecting the second winding has one side connected to the conductor segment accommodated in the N-th layer and the other side connected to the conductor segment accommodated in the first layer,
stator assembly. 8. The method of claim 7,
The bus bar connection part is formed to protrude from the support structure in a vertical direction with respect to the outer connection part or the inner connection part,
stator assembly. According to claim 1,
The support structure is disposed to overlap one end of the stator core in the axial direction,
stator assembly. According to claim 1,
The terminal lead and the lead wire bus bar are provided one by one for each phase of three phases,
The connection ring is
a terminal mounting unit for mounting a plurality of the terminal leads for connection with an external power source; and
A plurality of bus bar mounting parts provided on both sides of the terminal mounting part, respectively, for mounting a plurality of the lead wire bus bars,
stator assembly. 12. The method of claim 11,
The plurality of bus bar mounting units are spaced apart from each other on the same circumference of the stator core,
The terminal mounting portion is disposed outside the bus bar mounting portion,
stator assembly. 12. The method of claim 11,
One side of the terminal mounting unit is located on the same plane as one side of the bus bar mounting unit, and the other side extends lower than the other side of the bus bar mounting unit toward one end of the stator core,
The other side of the terminal mounting portion is in contact with one end of the stator core,
stator assembly. 8. The method of claim 7,
A protrusion is formed so as to cover the cross portion from one side of the support structure,
stator assembly. stator assembly; and
and a rotor accommodated in the stator assembly and rotating with respect to the stator assembly about a rotation axis,
The stator assembly comprises:
a stator core having a plurality of slots;
a stator coil formed by connecting a plurality of conductor segments accommodated in the first to N-th layers provided in each of the plurality of slots;
a connection ring having a terminal lead, a lead wire busbar and a neutral wire busbar; and
and a support structure connecting the lead wire bus bar and the neutral wire bus bar to the stator coil and supporting the connection ring,
The support structure is
a plurality of bus bar connection units respectively connected to the lead wire bus bar and the neutral wire bus bar; and
and a plurality of winding connection bus bars connected to each of the plurality of bus bar connections and connecting a plurality of conductor segments accommodated in different layers;
electric motor.

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