WO2014057978A1

WO2014057978A1 - Bus ring for motor and manufacturing method therefor

Info

Publication number: WO2014057978A1
Application number: PCT/JP2013/077480
Authority: WO
Inventors: 孝行中田; 森田　司; 田口　直人; 吉留　正朗
Original assignee: 日産自動車株式会社
Priority date: 2012-10-10
Filing date: 2013-10-09
Publication date: 2014-04-17
Also published as: JPWO2014057978A1; JP5954423B2

Abstract

[Problem] To provide a low-cost and compact bus ring for a motor, and a manufacturing method therefor. [Solution] The bus ring includes annular bus bars (50, 52, 54, 56) which electrically connect coils having the same phase in a motor, and an insulating material for integrating the bus bars in an insulated state, the insulating material being constituted by an insulating film (40).

Description

Motor bus ring and manufacturing method thereof

The present invention relates to a motor bus ring and a manufacturing method thereof.

A motor mounted on a vehicle such as a hybrid vehicle or an electric vehicle as a driving source has a bus ring formed by punching a conductive metal plate into a strip shape by pressing (see, for example, Patent Document 1).

JP 2003-134757 A

However, the bus ring is inserted into the resin case and kept insulated. The resin case is expensive, difficult to make compact, and has a problem that the shaft length of the motor becomes long.

The present invention has been made to solve the problems associated with the above-described prior art, and an object thereof is to provide an inexpensive and compact motor bus ring and a method for manufacturing the same.

In order to achieve the above object, a uniform phase of the present invention is for a motor having an annular bus bar that electrically connects coils of the same phase of the motor, and an insulating member for integrating the bus bar in an insulated state. It is a bus ring, and the insulating member is made of an insulating film.

Another aspect of the present invention for achieving the above object is to manufacture a motor bus ring having a step of integrating an annular bus bar electrically connecting coils of the same phase of the motor in an insulated state by an insulating member. In the method, the insulating member is composed of an insulating film.

In the motor bus ring and the manufacturing method thereof according to the present invention, the insulating member of the bus bar is made of an insulating film, so that, for example, compared to the case of using a resin case, the cost of the insulating member is reduced. In addition, the thickness of the bus ring in the motor axial direction can be reduced (the motor shaft length can be reduced). Therefore, an inexpensive and compact motor bus ring and a method for manufacturing the same can be provided.

Further objects, features, and characteristics of the present invention will become apparent by referring to the preferred embodiments illustrated in the following description and the accompanying drawings.

It is a perspective view for demonstrating the motor which concerns on embodiment of this invention. It is a top view for demonstrating the bus ring shown by FIG. It is sectional drawing for demonstrating the insulating film shown by FIG. It is a top view for demonstrating the insulating film shown by FIG. It is a top view for demonstrating the manufacturing method of the insulating film shown by FIG. It is a top view for demonstrating the bus bar for U-phase, V phase, and W phase shown by FIG. It is a top view for demonstrating the wire piece piece shown by FIG. It is a perspective view for demonstrating the leg of the wire piece piece shown by FIG. It is a perspective view for demonstrating joining of the leg front-end | tip part and coil terminal which are shown by FIG. It is a top view for demonstrating the bus bar for neutral phases shown by FIG. It is a block diagram for demonstrating the manufacturing method of the bus ring which concerns on embodiment of this invention. It is sectional drawing for demonstrating joining of the leg base parts of the wire piece which concerns on the laminated body assembly process shown by FIG. It is a perspective view for demonstrating joining of the leg front-end | tip part of a wire piece and a coil terminal which concern on the bus ring assembly process shown by FIG. It is a top view for demonstrating the modification 1 which concerns on embodiment of this invention. It is a top view for demonstrating the modification 2 which concerns on embodiment of this invention. It is sectional drawing for demonstrating the modification 3 which concerns on embodiment of this invention. It is a top view for demonstrating the modification 4 which concerns on embodiment of this invention. It is an exploded view for demonstrating the modification 4 which concerns on embodiment of this invention. It is a top view for demonstrating the manufacturing method of the insulating film piece shown by FIG. 17 and FIG.

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

FIG. 1 is a perspective view for explaining a motor according to an embodiment of the present invention.

The motor according to the embodiment of the present invention is, for example, a three-phase AC motor mounted on a vehicle such as a hybrid vehicle or an electric vehicle as a travel drive source, and has a stator 10 on which an rotor is disposed on the inner peripheral side.

The stator 10 has an annular shape and includes a split core 20 and a bus ring 30. The split core 20 has, for example, a coil wound around an iron core and is arranged at equal intervals in the circumferential direction. The bus ring 30 is an in-motor wiring component for causing a current to flow through the coil of the split core 20.

Next, the bus ring 30 will be described in detail.

2 is a plan view for explaining the bus ring shown in FIG. 1, FIG. 3, FIG. 4 and FIG. 5 are sectional views, a plan view and an insulating film for explaining the insulating film shown in FIG. FIG. 6 is a plan view for explaining the manufacturing method, FIG. 6 is a plan view for explaining the U-phase, V-phase and W-phase bus bars shown in FIG. 2, and FIG. 7 is a diagram of the wire piece shown in FIG. FIG. 8 is a perspective view for explaining the leg of the wire rod piece shown in FIG. 7, and FIG. 9 is for explaining the joining of the leg tip part and the coil terminal shown in FIG. FIG. 10 is a plan view for explaining the neutral phase bus bar shown in FIG.

As shown in FIG. 2, the bus ring 30 includes an insulating film 40,

annular bus bars

50, 52, 54, 56 and an attachment stay 80. The mounting stay 80 is laminated together with the

bus bars

50, 52, 54, and 56 (arranged in the lowermost layer) and has a tab 82 in which a positioning through hole 84 is formed.

The insulating film 40 is an insulating member that integrates the laminated

bus bars

50, 52, 54, and 56 in an insulated state. As shown in FIG. 3, the surface of the bus bar 56, between the bus bar 56 and the bus bar 50, They are arranged between the bus bar 50 and the bus bar 52, between the bus bar 52 and the bus bar 54, and between the bus bar 54 and the mounting stay 80. That is, since the insulating members of the

bus bars

50, 52, 54, and 56 are made of an insulating film, for example, the cost of the insulating member is reduced and the axial direction of the motor is reduced as compared with the case where a resin case is used. It is possible to reduce the thickness of the bus ring (reducing the motor shaft length).

As shown in FIG. 4, the insulating film 40 has an annular shape, corresponds to the shape of the

bus bars

50, 52, 54, 56, and is disposed between the stacked

bus bars

50, 52, 54, 56. . Therefore, the width W ₁ of the insulating film 40 is preferably set larger than the width W _{2 of the} bus bars 50, 52, 54, 56 based on the creepage distance (see FIG. 3), thereby ensuring a good insulating effect. Is possible. As shown in FIG. 5, the insulating film 40 can be manufactured by cutting out from the material sheet 44. Although the method of cutting out from the raw material sheet 44 is not specifically limited, For example, press punching is applied.

The material of the insulating film 40 (the material sheet 44) is, for example, thermoplastic engineering plastic such as PPS (polyphenylene sulfide resin), PET (polyethylene terephthalate), PEN (polyethylene naphthalate resin), but is not particularly limited thereto.

The

bus bars

50, 52, 54, and 56 are used to electrically connect coils of the same phase of the motor, and are formed of a bent wire 60 as shown in FIGS. Compared with the case where 50, 52, 54, and 56 are formed by cutting out plate materials (for example, press punching), the yield can be significantly improved. The material of the wire is copper, nickel, aluminum, or an alloy thereof, but is not particularly limited. For example, a tin-plated copper wire can be applied.

The

bus bars

50, 52, and 54 are for the U phase, the V phase, and the W phase, have the same shape as shown in FIG. 6, and have a connection terminal 70 and a high voltage terminal 72. The connection terminal 70 is used for joining (connecting) to the coil terminal 22 of the split core 20. The high power terminal 72 is for supplying power and is connected to a power source (battery module).

The wire rod 60 of the

bus bars

50, 52, and 54 is composed of a wire rod piece 62 that is divided for each coil, and the

bus bars

50, 52, and 54 have a divided structure constituted by the wire rod pieces 62. Therefore, it is possible to improve the yield as compared with the case where the bus bars 50, 52, 54 are integrally formed for each phase of the AC power source.

As shown in FIG. 7, the wire piece 62 includes an arc portion 63, a leg 64 projecting in the center direction (direction toward the center of the bus bars 50, 52, 54, 56) from both ends of the arc portion 63, Have The leg 64 has a base portion 65 on the arc portion 63 side and a tip portion 66 on the center direction side. As shown in FIG. 8, the base portion 65 is joined to the base portion 65 of another adjacent wire rod 62. As shown in FIG. 9, the distal end portion 66 is integrated with another adjacent wire rod piece 62 to form a connection terminal 70, and is joined to the coil terminal 22 of the split core 20. Note that a U-shaped tab 68 protruding in the outer direction (the reverse direction of the central direction) is provided on one of the wire pieces 62 constituting each

bus bar

50, 52, 54. The tab 68 constitutes a high voltage terminal 72.

The bus bar 56 is used for a neutral phase, and has a connection terminal 70 as shown in FIG. The wire rod 60 of the bus bar 56 is composed of wire rod pieces 62 similar to those of the bus bars 50, 52, and 54. The split core 20 is connected to any one of a neutral wire (bus bar 56) of the bus bar and a three-phase electric wire (bus bars 50, 52, 54). Therefore, the number of connection terminals 70 of the bus bar 56 corresponds to the number of the split cores 20 and is three times the number of connection terminals 70 of the bus bars 50, 52, 54.

Next, a method for manufacturing the bus ring according to the present embodiment will be described.

FIG. 11 is a block diagram for explaining a method of manufacturing a bus ring according to the embodiment of the present invention, and FIG. 12 explains joining of leg base portions of wire pieces according to the laminate assembly process shown in FIG. FIG. 13 is a perspective view for explaining the joining of the leg tip portion of the wire rod piece and the coil terminal according to the bus ring assembling step shown in FIG.

The bus ring manufacturing method according to the present embodiment includes a wire piece forming process, a bus bar assembly process, a laminate assembly process, and a bus ring assembly process, as shown in FIG.

In the wire piece forming step, for example, bending (wire forming) is applied to a wire made of one round copper wire. The wire is partially bent at a predetermined position, and is formed into an annular shape while maintaining the shape of the bent portion, and has a shape substantially corresponding to the shape of the bus bar. The bent portion constitutes the leg 64 or the tab 68 of the wire piece 62. That is, since the bus bar is formed from a bent wire, the yield can be significantly improved as compared with a case where the bus bar is formed by cutting out a plate material (for example, press punching).

The wire rod formed into an annular shape is cut (divided) at a bent portion (position corresponding to each coil) that constitutes the leg 64, and a plurality of wire rod pieces 62 having the leg 64 and the leg 64 are formed. And a single wire piece 62 having a tab 68 is formed. That is, the bent wire is cut to form the wire pieces 62 divided between the coils, and the bus bar has a divided structure constituted by the wire pieces, so that the bus bar is provided for each phase of the AC power supply. It is possible to improve the yield as compared with the case of being integrally molded with the metal.

The flattening molding is applied to the wire piece 62. Then, coining molding is applied to the leg 64 to form the base portion 65 and the tip portion 66. For the tab 68, after coining, piercing is applied to form a through hole.

In the bus bar assembling process, the leg bases 65 of the adjacent wire pieces 62 are joined together to assemble the bus bars 50, 52, 54, and 56. For the joining, fusing (heat caulking) is applied. For example, as shown in FIG. 12, the leg base portions 65 of adjacent wire pieces 62 are overlapped with each other, and both side surfaces thereof are pressed by

electrodes

90 and 92 to make an electric current. And heating the base 65 by heat generation based on electric resistance.

In the laminate assembly process, the surface of the bus bar 56, between the bus bar 56 and the bus bar 50, between the bus bar 50 and the bus bar 52, between the bus bar 52 and the bus bar 54, and between the bus bar 54 and the mounting stay 80. Then, after the insulating film 40 is arranged and laminated, it is bonded and laminated (see FIG. 3). Thereby, the laminated body (bus ring 30) of the bus bars 50, 52, 54, and 56 integrated in an insulated state is assembled. That is, since the insulating members of the bus bars 50, 52, 54, and 56 are made of the insulating film 40, the cost of the insulating members is reduced and the axial direction of the motor is reduced as compared with the case where a resin case is used. It is possible to reduce the thickness of the bus ring (shorten the motor shaft length).

In the bus ring assembly process, the connection terminals 70 of the bus bars 50, 52, 54, 56 are joined to the coil terminals 22 of the split core 20, and then sealed by, for example, impregnating varnish. For the joining, fusing is applied. For example, as shown in FIG. 13, the leg tip portion 66 of the wire piece 62 and the leg tip portion 66 of the adjacent wire piece 62 are overlapped with each other with the coil terminal 22 interposed. In addition, the both side surfaces are pressed by the

electrodes

90 and 92 to pass a current, and the tip portion 66 and the coil terminal 22 are heated by heat generation based on electric resistance.

In addition, since the joining of the leg bases 65 of the wire piece 62 is also joined by fusing, the equipment for joining the wire pieces and the equipment for joining the bus bar and the coil are shared. Thus, the equipment cost can be reduced.

Next, modified examples 1 to 4 according to the embodiment of the present invention will be sequentially described.

FIG. 14 and FIG. 15 are plan views for explaining Modification 1 and Modification 2 according to the embodiment of the present invention.

The bus bars 50, 52, 54, 56 are not limited to the form formed from the wire 60, and for example, press punching is performed on the circular plate 60A shown in FIG. 14 or the strip-like plate 60 shown in FIG. It is also possible to mold by applying.

FIG. 16 is a cross-sectional view for explaining a third modification according to the embodiment of the present invention.

The insulating film 40 has a main body portion 40A and a closing portion 40B as shown in FIG. The main body portion 40A is a portion disposed between the stacked bus bars 50, 52, 54, and 56. The blocking portion 40B is a portion disposed around the bus bars 50, 52, 54, and 56 so as to cover the open surfaces of the bus bars 50, 52, 54, and 56, and the overlapping portions are joined to each other. In this case, since the bus bars 50, 52, 54, and 56 do not have an open surface and are isolated from the outside, the concern of a decrease in insulation performance due to the influence of impurities such as moisture and oil is eliminated. . Further, since it is not necessary to consider the creepage distance in the insulation performance design, it is possible to reduce the man-hours for guaranteeing (securing) the quality of the insulation performance.

The joining method of the blocking part 40B (insulating film 40) is not particularly limited. For example, when the insulating film 40 provided with an adhesive layer that can be fused by heat is used in advance, the overlapping blocking part is overlapped. It is possible to join by heating 40B. Moreover, it is also possible to join by applying the adhesive to the closing portion 40B and then stacking it.

In addition, in the laminated body assembly process according to the modified example 3, the step of arranging the insulating film 40 so as to have the main body part 40A and the blocking part 40B, and the process of joining the overlapping parts in the blocking part 40B to each other It will have.

17 and 18 are a plan view and an exploded view for explaining a fourth modification according to the embodiment of the present invention, and FIG. 19 explains a method for manufacturing the insulating film piece shown in FIGS. 17 and 18. FIG.

As shown in FIGS. 17 and 18, the insulating film 40 can be manufactured by joining a plurality of insulating film pieces 42. Since the insulating film piece 42 has an arc shape and is not annular, a plurality of sheets can be produced from the material sheet 44 as shown in FIG. In addition, the code | symbol 43 has shown the edge part of the insulating film piece 42 overlapped and joined.

For example, while only one insulating film 40 can be manufactured from the material sheet 44 (see FIG. 5), 10 insulating film pieces 42 are manufactured from the material sheet 44 in the arrangement shown in FIG. Is possible. In the modified example 4, since the insulating film 40 is composed of four insulating film pieces 42, it also means that 2.5 insulating films 40 can be manufactured from the material sheet 44. That is, since the material sheet 44 is effectively used, the yield can be improved and the manufacturing cost of the insulating film 40 can be reduced.

In addition, the insulating film 40 is not limited to the form constituted by the four insulating film pieces 42. Moreover, the joining method of the insulating film piece 42 is not specifically limited, For example, when using the insulating film piece 42 manufactured from the raw material sheet | seat 44 in which the contact bonding layer which can be fuse | melted with a heat | fever is provided previously. By joining the end portions 43 of the insulating film pieces 42 to each other and heating them, it is possible to join them. Moreover, it is also possible to join by overlapping after applying an adhesive to the end portion 43 of the insulating film piece 42.

The production of the insulating film 40 from the insulating film piece 42 can be carried out separately, but it is preferably incorporated into the manufacturing method of the bus ring from the viewpoint of positioning and the like. In this case, the laminated body assembly step further includes a step of forming the insulating film 40 by overlapping and joining the end portions 43 of the plurality of insulating film pieces 42.

As described above, in the present embodiment, since the insulating member of the bus bar is made of an insulating film, for example, the cost of the insulating member is reduced as compared with the case of using a resin case, and the motor It is possible to reduce the thickness of the bus ring with respect to the axial direction (shortening the motor shaft length). Therefore, an inexpensive and compact motor bus ring and a method for manufacturing the same can be provided.

The bus bar is, for example, in a plate shape, and a plurality of bus bars are provided, and the bus bars are stacked so that the surfaces of the bus bars overlap. In this case, it is possible to ensure a good insulating effect by setting the width of the insulating film disposed between the bus bars to be stacked to be larger than the width of the bus bar based on the creepage distance. Further, the insulating film has a main body portion that is a portion disposed between the bus bars to be laminated, and a closed portion that is disposed around the bus bar so as to cover the open surface of the bus bar, and overlaps with the closed portion. Since the bus bars do not have an open surface and are isolated from the outside by being configured to be joined to each other, the insulation performance due to the influence of impurities such as moisture and oil The fear of decline is dispelled. Further, since it is not necessary to consider the creepage distance in the insulation performance design, it is possible to reduce the man-hours for guaranteeing (securing) the quality of the insulation performance.

When the insulating film is manufactured by joining a plurality of pieces of insulating film, it is possible to effectively use the material sheet to improve the yield and reduce the manufacturing cost of the insulating film.

When the bus bar is formed from a bent wire, the yield can be greatly improved as compared with the case where the bus bar is formed by cutting a plate material.

When the bus bar has a divided structure composed of wire pieces divided between the coils, the yield can be improved as compared with the case where the bus bar is integrally formed for each phase of the AC power source. Is possible.

When fusing is applied to the joining of the wire pieces and the joining of the bus bar connection terminal and the coil terminal, the equipment for joining the wire pieces and the equipment for joining the bus bar and the coil It is possible to reduce the equipment cost by sharing.

The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims. For example, the motor is not limited to a form driven by a three-phase alternating current. Moreover, it is also possible to apply to the form in which the split core is disposed on the outer peripheral side of the bus ring. Further, a neutral phase bus bar can be arranged outside the bus ring.

This application is based on Japanese Patent Application No. 2012-225199 filed on October 10, 2012 and Japanese Patent Application No. 2013-199839 filed on September 26, 2013. Are referenced and incorporated in their entirety.

10 stator,
20 split cores,
22 coil terminal,
30 bus ring,
40 Insulating film (insulating member),
40A body,
40B obstruction,
42 insulation film pieces,
43 end,
44 Insulating film material sheet,
50, 52, 54, 56 Busbar,
60 wire rod,
60A, 60B board,
62 wire rod,
63 Arc part,
64 legs,
65 base,
66 tip,
68 tabs,
70 connection terminal,
72 High voltage terminal,
80 mounting stay,
82 tabs,
84 through hole,
90,92 electrodes,
W ₁ , W ₂ width.

Claims

An annular bus bar that electrically connects coils of the same phase of the motor;
An insulating member for integrating the bus bar in an insulated state,
The said insulating member is a bus ring for motors comprised from the insulating film.
The bus ring for a motor according to claim 1, wherein the bus bar has a plate shape, a plurality of bus bars are provided, and the bus bars are stacked so that the surfaces of the bus bars overlap each other.
The insulating film is disposed between the bus bars to be laminated;
The motor bus ring according to claim 2, wherein a width of the insulating film is set to be larger than a width of the bus bar based on a creepage distance.
The insulating film has a main body portion which is a portion disposed between the bus bars to be laminated, and a closing portion which is disposed around the bus bar so as to cover an open surface of the bus bar,
The motor bus ring according to claim 2, wherein overlapping portions of the blocking portions are joined to each other.
The motor bus ring according to any one of claims 1 to 4, wherein the insulating film is manufactured by joining a plurality of insulating film pieces.
The motor bus ring according to any one of claims 1 to 5, wherein the bus bar is formed of a bent wire.
The motor bus ring according to claim 6, wherein the wire includes a wire piece divided for each coil, and the bus bar has a divided structure constituted by the wire piece.
A step (A) of integrating an annular bus bar that electrically connects coils of the same phase of the motor with an insulating member in an insulated state;
The said insulating member is a manufacturing method of the bus ring for motors comprised from the insulating film.
The step (A) includes a step of disposing the insulating film between the bus bars to be laminated,
The method for manufacturing a motor bus ring according to claim 8, wherein the width of the insulating film is set to be larger than the width of the bus bar based on a creepage distance.
The step (A)
The insulating film is disposed so as to have a main body portion that is a portion disposed between the bus bars to be stacked, and a closing portion that is disposed around the bus bar so as to cover an open surface of the bus bar. Process,
Joining the overlapping parts in the obstruction, and
The manufacturing method of the bus ring for motors of Claim 8 which has these.
The method for manufacturing a motor bus ring according to any one of claims 8 to 10, further comprising a step of joining a plurality of insulating film pieces to form the insulating film.
The method for manufacturing a bus ring for a motor according to any one of claims 8 to 11, further comprising a step (C) of forming the bus bar from a bent wire.
The step (C)
Cutting the bent wire, and forming a wire piece divided for each coil (C1);
A step (C2) of forming the annular bus bar having a divided structure constituted by the wire pieces by joining the wire pieces;
The manufacturing method of the bus ring for motors of Claim 12 which has these.
A step (D) of joining the connection terminal of the bus bar and the terminal of the coil by fusing;
The method for manufacturing a motor bus ring according to claim 13, wherein fusing is applied to the joining of the wire pieces in the step (C2).