JP2010057240A - Bus bar structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bus bar structure, in which the number of parts of a terminal is small and which has high reliability. <P>SOLUTION: The bus bar structure has a plurality of lead wires which extend in a circular form in the circumferential direction of a motor; the lead wire is equipped with the terminal 2, connected to the winding end 5 of a motor coil 4; and it electrically connects the same phase of motor coils 4. The lead wire includes a plurality of element wires 6, which extend severally in the circumferential direction and are electrically connected to one another at the terminal 2. Each element 6 is equipped with a hook 7, at a position corresponding to the terminal 2. A first plane 7a is formed on one side of the hook 7, and a second plane 7b, on which a fusing electrode abuts against, when making the hook 7 and the winding end 5 stick fast to each other, is formed on the other side of the hook 7. The first and second planes 7a and 7b are made angular form in cross section, by plastically transforming one part (end) of the element wire 6 round in the cross section. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a bus bar structure, and more particularly to a bus bar structure of a motor for a hybrid vehicle or a motor for an electric vehicle.

In Patent Document 1, a bus bar structure having a plurality of conductive wires, a terminal portion connected to a winding end of a motor coil is bent and adhered in the middle of the conductive wire having a round cross section. There has been proposed a bus bar structure including a close contact portion, a winding end, and a fusing terminal member connecting the close contact portion and the winding end.
JP-A-2005-229677

  In the terminal portion of the bus bar structure of Patent Document 1, in order to increase the ground contact area between the conductor on the bus bar side and the winding end on the motor coil side, a fusing terminal member interposed therebetween is used. This causes a problem that the number of component parts of the terminal portion increases. In addition, the increase in the number of parts makes it difficult to stabilize the quality of the bus bar structure, which increases costs.

  An object of the present invention is to provide a highly reliable bus bar structure with a small number of components in the terminal portion of the bus bar structure.

  In the first aspect, the present invention comprises a plurality of conductive wires extending in a ring shape along the circumferential direction of the motor, and the conductive wire includes a terminal portion connected to a winding end of the motor coil. In the bus bar structure for electrically connecting the motor coils of the same phase, the conductive wire includes a plurality of strands extending along the circumferential direction and electrically connected to each other at the terminal portion, The strand includes a hook portion at a position corresponding to the terminal portion, the hook portion includes a first flat portion on one side and a second flat portion on the other side, and the terminal portion faces A plurality of hook portions that are in close contact with each other via the first plane portion, and the winding ends that are inserted into the hook shape of the close contact multiple hook portions and are in close contact with the hook portions; A bus bar structure is provided.

  According to the present invention, in the hook portion formed on the conductor or strand on the bus bar side, the first flat portion for improving the adhesion between the hook portions is formed on one side, and the fusing electrode and sufficient on the other side. A second flat portion that can be grounded in area is formed. As a result, when connecting the conductor or element wire on the bus bar side and the winding end on the motor coil side, a sufficient joining area is secured between the hook portions without using a fusing member separately. Since a sufficient ground area with a sufficient fusing electrode is ensured, a highly reliable electrical connection can be realized. In addition, according to the present invention, since the conductor or element wire on the bus bar side and the winding end on the motor coil side are directly joined, the reliability related to electrical connection is improved. In addition, by connecting the winding ends to the plurality of hook portions joined to each other, the contact area between the bus bar side and the motor coil is also increased, and the reliability is further improved.

  In a preferred embodiment of the present invention, the fusing electrode contacts the second flat surface portion when the hook portions are connected to each other or when the hook portion and the winding end are connected. According to this embodiment, since the fusing electrode can be brought into contact with the second plane portion, the grounding property of the fusing electrode to the hook portion is improved.

  In a preferred embodiment of the present invention, the first flat portion is formed by plastically deforming a part of a strand having a round cross section to form a square cross section. According to this embodiment, it is possible to easily and inexpensively obtain a strand having a predetermined plane portion from a general-purpose conducting wire or strand.

  In a preferred embodiment of the present invention, the plurality of hook portions are at least line-contacted via the first plane portion, and more preferably, the plurality of hook portions are interposed via the first plane portion. At least surface contact. According to this embodiment, the reliability of the electrical connection is improved as compared with the joining of the round wires that are easily point-contacted.

  An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a plan view of a motor having a bus bar structure according to an embodiment of the present invention. 2A is a cross-sectional view taken along the line AA in FIG. 1, and FIG. 2B is a partially enlarged view of the hook portion shown in FIG. 3A is a partially enlarged view of FIG. 2 as viewed in the direction of arrow B, and FIG. 3B is a cross-sectional view taken along the line CC in FIG. 3A. FIG. 4 is a plan view of the bus bar structure shown in FIG. 5 is a cross-sectional view taken along the line DD of FIG. FIG. 6 is a partially enlarged view of FIG.

  Referring to FIGS. 1, 2 (A), 2 (B), 4, and 5, the bus bar structure 1 according to an embodiment of the present invention extends in an annular shape along the circumferential direction of the motor M. A plurality of conducting wires 3 are provided, and the conducting wire 3 includes a terminal portion 2 connected to the winding end 5 of the motor coil 4 to electrically connect the motor coils 4 of the same phase.

  Referring to FIGS. 1 and 6, the conducting wire 3 includes a plurality of strands 6 that extend along the circumferential direction and are electrically connected to each other at the terminal portion 2. The motor M has a plurality of integrated divided stator cores 8 arranged in an annular shape, and the motor coils 4 shown in FIG. When the motor M is, for example, a three-phase motor, the terminal unit 2 electrically connects a plurality of predetermined strands 6 corresponding to three phases (U, V, and W phases) and neutral wires, Power the phase.

  Referring to FIGS. 2A and 2B, the element wire 6 constituting the conducting wire 3 includes a hook portion 7 at a position corresponding to the terminal portion 2. The hook portion 7 is formed at each end of the strand 6.

  Referring to FIGS. 3A and 3B, the hook portion 7 has first and second plane portions 7a and 7b formed on both sides thereof. In the hook portion 7, the second flat surface portion 7b is formed on the side portion opposite to the first flat surface portion 7a. When the first flat surface portions 7a of the plurality of hook portions 7 and 7 are brought into close contact with each other, the plurality of hook portions 7 and 7 are connected to each other. The plurality of hook portions 7 and 7 are in line contact at least via the first flat surface portion 7a, and preferably in surface contact. The fusing electrode contacts the second flat surface portion 7b when the hook portions 7 or the hook portion 7 and the winding end 5 are brought into close contact with each other. The 1st and 2nd plane parts 7a and 7b are formed by plastically deforming a part (end part) of the strand 6 having a round cross section to form a square cross section.

  3A and 3B, the terminal portion 2 includes a plurality of hook portions 7 and 7 that are in close contact with each other via the first plane portions 7a and 7a that face each other. And the winding end 5 of the motor coil 4 which is inserted into the hook shape (U-shape) of the hook portions 7 and 7 and is in close contact with the hook portions 7 and 7.

  A method for forming the terminal portion 2 of the bus bar structure 1 described above will be described. First, the covering of the end portion of the strand 6 of the round copper wire that becomes the conducting wire 3 corresponding to the predetermined phase is peeled off. Next, the hook portion 7 is formed by bending the end portion of the wire 6 into a U shape so that the winding end 5 can be inserted in a later process. Next, the hook portion 7 is crushed from both sides and plastically deformed, and at least the first and second plane portions 7a and 7b are formed on both sides of the hook portion 7, respectively. In addition, you may form a 3rd plane part in the part which contacts the coil | winding end 5 in the hook part 7, ie, the hook part 7, inside.

  Subsequently, in the adjacent hook portions 7 and 7, the opposing first flat surface portions 7a and 7a are brought into close contact with each other and welded or joined by fusing or the like, and the adjacent hook portions 7 and 7 are integrated to form a predetermined phase. Conductive wire 3 corresponding to is formed. Furthermore, the winding end 5 is inserted into the hook shape (U-shape) of the plurality of hook portions 7 and 7 that are bonded and in close contact, and the fusing electrode is brought into contact with the second plane portion 7b. The hook portions 7 and 7 and the winding end 5 are joined. In this way, the terminal portion 2 is created. In addition, joining of hook parts 7 and 7 and joining of hook parts 7 and 7 and the coil end 5 can also be performed simultaneously.

  The present invention relates to a bus bar structure, and is particularly used for a bus bar structure of a motor for a hybrid vehicle or a motor for an electric vehicle.

It is a top view of the motor which has a bus-bar structure concerning one example of the present invention. (A) is AA sectional drawing of FIG. 1, (B) is the elements on larger scale of the hook part shown to (A). (A) is a B arrow partial enlarged view of FIG. 2, (B) is CC sectional drawing of (A). It is a top view of the bus-bar structure shown in FIG. It is DD sectional drawing of FIG. It is the E arrow partial enlarged view of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Busbar structure 2 Terminal part 3 Conductor 4 Motor coil 5 Winding end 6 Element 7 Hook part 7a 1st plane part 7b 2nd plane part 8 Split stator core M Motor

Claims (5)

A plurality of conductors extending in a ring shape along the circumferential direction of the motor are provided, and the conductor includes a terminal portion connected to a winding end of the motor coil, and the motor coils of the same phase are electrically connected to each other. A bus bar structure to be connected,
The conducting wire includes a plurality of strands extending along the circumferential direction and electrically connected to each other at the terminal portion,
The strand includes a hook portion at a position corresponding to the terminal portion,
The hook portion includes a first plane portion on one side and a second plane portion on the other side,
The terminal portion is inserted into a hook shape of the plurality of hook portions that are in close contact with each other via the first flat portion facing each other, and is in close contact with the hook portion. A bus bar structure comprising the winding ends.   2. The bus bar structure according to claim 1, wherein the fusing electrode contacts the second flat surface portion when the hook portions are connected to each other or when the hook portion is connected to the winding end.   The said 1st and 2nd plane part is formed by carrying out the plastic deformation of one part of the said strand with a circular cross section, and making it a cross-sectional angle | corner, The said 1 or 2 characterized by the above-mentioned. The described busbar structure.   The bus bar structure according to claim 1, wherein the plurality of hook portions are in line contact with each other via the first plane portion.   The bus bar structure according to any one of claims 1 to 3, wherein the plurality of hook portions are at least in surface contact with each other via the first plane portion.

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