JP2012135176A - Bus bar device, stator, brushless motor, and method of manufacturing bus bar device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a bus bar device capable of suppressing the reduction in yield and suppressing the increase in size.SOLUTION: A bus bar device 6 electrically connects twelve coils U1-U4, V1-V4, and W1-W4 by bus bars 11-13. Each bus bar 11-13 is formed of a wire material 14 obtained by coating a core wire 14a having conductivity with an insulation coating 14b and a self-fusion layer 14c having an insulation property. The bus bar 11 has a U-phase arc shape part 11a formed in an arc shape. The bus bar 12 has a V-phase arc shape part 12a formed in an arc shape. The bus bar 13 has a W-phase arc shape part 13a formed in an arc shape. The bus bars 11-13 are integrated by laminating the U-phase arc shape part 11a, the V-phase arc shape part 12a, and the W-phase arc shape part 13a and closely fixing the U-phase arc shape part 11a, the V-phase arc shape part 12a, and the W-phase arc shape part 13a with each other.

Description

  The present invention relates to a bus bar device for connecting a plurality of coils provided in a brushless motor, a stator including the bus bar device, a brushless motor including the bus bar device, and a method of manufacturing the bus bar device.

  Conventionally, in a brushless motor, a bus bar device having a plurality of bus bars for short-circuiting corresponding ends of a plurality of coils arranged in the circumferential direction and supplying a current supplied from an external power supply device to each coil There is something with. As the bus bar provided in the bus bar device, for example, a bus bar formed by bending a plurality of portions after punching a conductive metal plate material into a predetermined shape by press working is known. Further, as described in Patent Document 1, some bus bars are formed by forming a wire rod into a predetermined shape.

JP 2009-124927 A

  However, when a bus bar is formed by stamping a metal plate material by press working, the yield decreases, and the manufacturing cost of the bus bar device increases. Moreover, in order to prevent a short circuit between bus bars, a plurality of bus bars may be held by a bus bar holder formed of an insulating resin material. In this case, the bus bar device is enlarged by the bus bar holder.

  On the other hand, as described in Patent Document 1, when a bus bar is formed from a wire, the yield is improved. However, since a plurality of bus bars are held by the bus bar holder, there is a problem that the bus bar device is enlarged.

  The present invention has been made in view of such circumstances, and the object thereof is to provide a bus bar device capable of suppressing a decrease in yield and an increase in size, a stator including the bus bar device, and the bus bar device. An object of the present invention is to provide a brushless motor provided and a method of manufacturing the bus bar device.

  In order to solve the above-mentioned problem, the invention according to claim 1 is a bus bar device in which ends of a plurality of coils are electrically connected by a plurality of bus bars, and each bus bar has a conductive core wire. An arc-shaped portion formed of a wire material coated with an insulating layer having an insulating property, and having an arc-shaped portion shaped into an arc shape. The plurality of bus bars are stacked on each other so that the arc-shaped portions are in close contact with each other. The gist is that they are integrated by being fixed.

  According to this configuration, since each bus bar is formed from a wire rod, waste material hardly occurs. Accordingly, it is possible to suppress a decrease in the yield of each bus bar. In addition, since the wire is formed by covering the outer periphery of the conductive core wire with an insulating layer having insulation, the plurality of bus bars formed from the wire are not short-circuited even if they are in close contact with each other. . Therefore, it is not necessary to hold a plurality of bus bars with the bus bar holder in order to prevent a short circuit between the bus bars. In addition, since the plurality of bus bars are integrated by overlapping the arc-shaped portions and fixing the arc-shaped portions to each other, the shape is easily stabilized. Since a plurality of bus bars can be handled as a single component, the plurality of bus bars need not be held by components such as a bus bar holder as in the prior art. Further, since the plurality of bus bars are closely fixed in the arc-shaped portion, it is possible to arrange the bus bars in a narrow space as compared with the case where they are arranged apart from each other. From these things, the enlargement of a bus-bar apparatus can be suppressed.

  According to a second aspect of the present invention, in the bus bar device according to the first aspect, each of the bus bars is formed by bending or bending the wire rod so as to protrude in the radial direction from the arcuate portion. The gist of the invention is to have a connecting portion for connecting the two.

  According to this configuration, since the connection portion is formed so as to protrude in the radial direction from the arc-shaped portion, an increase in the axial size of each bus bar is suppressed. Moreover, it becomes easy to connect the edge part of a coil to a bus bar because a bus bar has a connection part.

The invention according to claim 3 is the bus bar device according to claim 2, wherein the wire is a self-bonding electric wire.
According to this configuration, since the wire rod for forming the bus bar is a self-bonding electric wire, the arc-shaped portions of the plurality of bus bars that are overlapped with each other can be easily adhered and fixed.

The gist of the invention according to claim 4 is that, in the bus bar device according to claim 2 or claim 3, the connection portion has a through-hole through which an end of the coil can be inserted.
According to this configuration, when the end of the coil is inserted into the through hole when the end of the coil is electrically connected to the connection, the end of the coil is held by the connection. Therefore, the end portion of the coil can be easily connected to the connection portion.

  According to a fifth aspect of the present invention, in the bus bar device according to any one of the second to fourth aspects, the portion to which the end portions of the coils in all the connection portions are connected has a height in the axial direction. The gist is that they are the same.

  According to this configuration, since the axial height of the portion to which the end of the coil is connected in the bus bar device is constant, the end of the coil is electrically connected between the end of the coil and the connecting portion. It is not necessary to move the jig for electrically connecting the portion and the connecting portion along the axial direction. Moreover, even when the jig is moved along the axial direction, the amount of movement can be reduced.

  According to a sixth aspect of the present invention, in the bus bar device according to any one of the second to fifth aspects, all the bus bars are formed so that the curvature of the arc-shaped portion is equal, and the arc-shaped portion is The gist is that they are laminated in the axial direction so as to be coaxial.

According to this configuration, since the arc-shaped portions of the plurality of bus bars are stacked in the axial direction without being displaced in the radial direction, the bus bar device can be downsized in the radial direction.
A seventh aspect of the present invention is the bus bar device according to any one of the second to sixth aspects, wherein the wire has a circular cross-section of the core wire and has an insulating property and has an outer periphery. A cylindrical insulating coating to be coated and a self-bonding layer covering the outer periphery of the insulating coating, and the outer shape of the self-bonding layer in the cross section of the wire is a length equal to the outer diameter of the insulating coating. The gist is to form a square shape having a side.

  According to this configuration, the outer shape of the self-bonding layer can be kept small. And since it becomes possible to suppress the height of the bus bar in the axial direction, it becomes possible to suppress the height in the axial direction of the bus bar device.

  The invention according to claim 8 is the bus bar device according to any one of claims 2 to 7, wherein each of the bus bars is formed such that a portion where the wires cross and overlap in the axial direction is not formed. The gist is that the wire is bent or curved.

  According to this configuration, each bus bar does not have a portion where the wire material overlaps in the axial direction, so that the bus bar can be prevented from becoming thick in the axial direction. Therefore, the axial height of the bus bar device can be suppressed.

  According to a ninth aspect of the present invention, in the bus bar device according to any one of the second to eighth aspects, the plurality of bus bars are adjacent to each other in four circumferential directions at 90 ° intervals. A U-phase bus bar having two connection portions formed therein, a V-phase bus bar having the same shape as the U-phase bus bar, and a W-phase bus bar having the same shape as the U-phase bus bar, The bus bar is laminated with a 30 ° shift in the circumferential direction with respect to the U-phase bus bar, and the W-phase bus bar is 60 ° in the circumferential direction with respect to the U-phase bus bar and in the circumferential direction with respect to the V-phase bus bar. The gist is that the plurality of bus bars are delta-connected to the 12 coils.

According to this configuration, twelve coils can be delta-connected by the bus bar device in which the yield reduction is suppressed and the increase in size is suppressed.
A tenth aspect of the present invention is the bus bar device according to any one of the second to eighth aspects, wherein the plurality of bus bars have the connection portions at twelve locations that are spaced 30 ° in the circumferential direction. The formed common bus bar and the arc-shaped portion curved in an arc shape with the same curvature as the arc-shaped portion of the common bus bar, and the connection portions are respectively formed at four positions spaced 90 ° in the circumferential direction. A U-phase bus bar, a V-phase bus bar having the same shape as the U-phase bus bar, and a W-phase bus bar having the same shape as the U-phase bus bar. The V-phase bus bar is arranged so as to be shifted in the circumferential direction with respect to the connection portion of the common bus bar, and the V-phase bus bar is shifted forward by 30 ° with respect to the U-phase bus bar. The W-phase bus bar is arranged so as to be shifted in the circumferential direction with respect to the connection portion of the common bus bar, and the W-phase bus bar is shifted by 60 ° in the circumferential direction with respect to the U-phase bus bar and 30 ° in the circumferential direction with respect to the V-phase bus bar. The connecting portion of the W-phase bus bar is arranged so as to be shifted in the circumferential direction with respect to the connecting portion of the common bus bar, and the plurality of bus bars are Y-connected to the 12 coils. Is the gist.

According to this configuration, 12 coils can be Y-connected by the bus bar device in which a decrease in yield is suppressed and an increase in size is suppressed.
The invention according to claim 11 is the bus bar device according to any one of claims 2 to 8, wherein the plurality of bus bars are formed by connecting the two connection portions separated by 75 ° to each other in an arc shape. Three U-phase busbars connected in the same manner, three V-phase busbars having the same shape as the U-phase busbars, three W-phase busbars having the same shape as the U-phase busbars, and circumferentially One common bus bar formed by connecting the three connection portions provided at intervals of 30 ° with the arc-shaped portion curved in an arc shape with the same curvature as the arc-shaped portion of the U-phase bus bar, and the common The bus bars are arranged in the circumferential direction together with the three U-phase bus bars, the three U-phase bus bars are arranged at 90 ° intervals in the circumferential direction, and the three V-phase bus bars are arranged at 90 ° intervals in the circumferential direction. Against the U-phase busbar The three W-phase bus bars are arranged at a 90 ° interval in the circumferential direction, and are arranged at 90 ° intervals in the circumferential direction, and 60 ° in the circumferential direction with respect to the U-phase bus bar and around the V-phase bus bar. The connecting portion of the common bus bar, the connecting portion of the U-phase bus bar, the connecting portion of the V-phase bus bar, and the connecting portion of the W-phase bus bar are shifted in the circumferential direction. The gist of the plurality of bus bars is to Y-connect the twelve coils.

According to this configuration, 12 coils can be Y-connected by the bus bar device in which a decrease in yield is suppressed and an increase in size is suppressed.
The invention according to claim 12 includes a plurality of coils arranged in the circumferential direction, and the bus bar device according to any one of claims 1 to 11 that electrically connects ends of the coils. This is the gist.

  According to the configuration, by providing the stator with a bus bar device that can suppress a decrease in yield and an increase in size, an increase in manufacturing cost of the stator can be suppressed and an increase in size of the stator can be suppressed. Can do. Moreover, the shape of the plurality of bus bars is easily stabilized by mutually fixing the arc-shaped portions in close contact with each other. Therefore, the arrangement of a plurality of bus bars with respect to the coil, that is, the arrangement of the bus bar device with respect to the coil can be easily performed. And the productivity of a stator can be improved by providing the bus-bar apparatus with which the assembly | attachment property was improved.

  According to a thirteenth aspect of the present invention, there is provided a stator in which ends of a plurality of coils arranged in the circumferential direction are electrically connected by the bus bar device according to any one of the first to eleventh aspects, The gist of the invention is that it includes a rotor disposed inside the stator.

  According to this configuration, the brushless motor is provided with a bus bar device that can suppress a decrease in yield and an increase in size, thereby suppressing an increase in manufacturing cost of the brushless motor and increasing the size of the brushless motor. Can be suppressed. Moreover, the shape of the plurality of bus bars is easily stabilized by mutually fixing the arc-shaped portions in close contact with each other. Therefore, the arrangement of a plurality of bus bars with respect to the coil, that is, the arrangement of the bus bar device with respect to the coil can be easily performed. And the productivity of a brushless motor can be improved by providing the bus-bar apparatus with which the assembly | attachment property was improved.

  The invention according to claim 14 is the method of manufacturing a bus bar device according to any one of claims 2 to 11, wherein the arc-shaped portion and the connection portion are formed by bending or bending the wire. Forming and forming the bus bar, a stacking step of stacking the plurality of bus bars so that the arc-shaped portions overlap each other, and fixing the plurality of bus bars by tightly fixing the stacked arc-shaped portions to each other. The gist of the invention is that it includes an integration step of integrating.

  According to this method, since the bus bar is formed from the wire material in the molding step, it is possible to suppress a decrease in the yield of the bus bar. Further, the bus bar can be easily formed by bending or bending the wire. And in a laminating step, a plurality of bus bars are laminated so that their arc-shaped portions overlap each other, and in the integrating step, a plurality of bus bars are integrated by closely fixing the arc-shaped portions stacked on each other, A bus bar device composed of a plurality of bus bars formed of a wire can be formed.

  According to a fifteenth aspect of the present invention, in the method of manufacturing a bus bar device according to the fourteenth aspect, the insulating layer includes an insulating insulating film covering an outer periphery of the core wire and a self covering the outer periphery of the insulating film. In the integration step, the bus bar is heated to melt the self-bonding layer, and the stacked arc-shaped portions are adhered and fixed by the self-bonding layer. This is the gist.

  According to this method, it is not necessary to separately prepare fixing materials and parts in order to tightly fix the arcuate portions on which a plurality of bus bars are stacked. Further, the plurality of bus bars can be integrated by a simple method of heating the plurality of stacked bus bars. Therefore, the productivity of the bus bar device can be improved and the manufacturing cost of the bus bar device can be reduced.

  The gist of a sixteenth aspect of the present invention is the method for manufacturing a bus bar device according to the fifteenth aspect, wherein in the integration step, the bus bar is heated by energizing the bus bar.

According to this method, the bus bar can be easily heated by energizing the bus bar.
According to a seventeenth aspect of the present invention, in the method for manufacturing a bus bar device according to any one of the fourteenth to sixteenth aspects, the insulation of a portion serving as the connecting portion in the wire rod is performed before the forming step. The gist is that a peeling step for peeling the layer is provided.

  According to this method, it is possible to satisfactorily connect the end portion of the coil and the connecting portion by peeling off the insulating layer at the portion that becomes the connecting portion in the wire in the peeling step. Moreover, since a peeling process is performed before a shaping | molding process, a deformation | transformation of the shape | molded bus bar can be suppressed.

  ADVANTAGE OF THE INVENTION According to this invention, the bus-bar apparatus which can suppress a yield fall and can suppress enlargement, the stator provided with this bus-bar apparatus, the brushless motor provided with this bus-bar apparatus, and the manufacturing method of this bus-bar apparatus can be provided. .

Sectional drawing of the motor of 1st Embodiment. The disassembled perspective view of the stator of 1st Embodiment. (A) is a half sectional view of the bus bar device of the first embodiment, (b) is a partially enlarged sectional view of the bus bar device of the first embodiment. The top view of the U-phase bus bar of 1st Embodiment. The top view of the V-phase bus-bar of 1st Embodiment. The top view of the W phase bus bar of a 1st embodiment. The schematic diagram which shows the connection state of the coil by the bus-bar apparatus of 1st Embodiment. Sectional drawing of the brushless motor of 2nd Embodiment. The top view of the common bus bar of 2nd Embodiment. The top view of the U-phase bus bar of 2nd Embodiment. The top view of the V phase bus bar of 2nd Embodiment. The top view of the W phase bus bar of a 2nd embodiment. The schematic diagram which shows the connection state of the coil by the bus-bar apparatus of 2nd Embodiment. The schematic diagram which shows the connection state of the coil by the bus-bar apparatus of 3rd Embodiment. Sectional drawing of the brushless motor of 3rd Embodiment. The top view of the common bus bar and U-phase bus bar of 3rd Embodiment. The top view of the V phase bus bar of a 3rd embodiment. The top view of the W phase bus bar of a 3rd embodiment. The perspective view of the bus-bar apparatus of another form.

(First embodiment)
A first embodiment of the present invention will be described below with reference to the drawings.
As shown in FIG. 1, the brushless motor 1 of the present embodiment includes a bottomed cylindrical housing case 2, an annular stator 3 press-fitted and fixed to the inner peripheral surface of the housing case 2, And a rotor 4 that is rotatably arranged in the circumferential direction. The stator 3 includes a substantially cylindrical stator core 5, a plurality (12 in this embodiment) of coils U1 to U4, V1 to V4, and W1 to W4 wound around the stator core 5, and the coils U1 to U4. , V1 to V4, and W1 to W4 are provided with a bus bar device 6 for supplying power.

  The stator core 5 is formed in an annular shape by connecting twelve divided cores 7 having a T-shape when viewed in the axial direction in the circumferential direction. Each divided core 7 includes a connecting portion 7a having an arc shape when viewed from the axial direction, and a tooth 7b extending radially inward from a circumferential central portion of the connecting portion 7a. The twelve divided cores 7 are rotatably connected to each other by fitting the circumferential ends of the connecting portions 7a of the adjacent divided cores 7 together. Each split core 7 has an insulator 8 covering both axial end surfaces of each split core 7, both circumferential side surfaces of teeth 7 b, and radially inner side surfaces of connecting portion 7 a from both axial sides. It is installed. The insulator 8 is made of an insulating synthetic resin material.

  As shown in FIG. 2, a conductive wire 9 is wound around each of the teeth 7b of the twelve divided cores 7 from above the insulator 8 of the insulator 8, whereby coils U1 to U4, V1 to V4, W1 to W1, respectively. W4 is wound. The connection end 10 which is the end of winding start and end of winding of each of the coils U1 to U4, V1 to V4 and W1 to W4 is drawn out to one side in the axial direction (upper side in FIG. 2) and along the axial direction. It extends. Specifically, the connection end 10 at the beginning of winding and the connection end 10 at the end of winding of each of the coils U1 to U4, V1 to V4, and W1 to W4 are respectively in the circumferential direction of the teeth 7b near the base end of the teeth 7b. It is pulled out from both sides in the axial direction. In addition, each connection end portion 10 is maintained in a posture extending along the axial direction by the vicinity of the root thereof being held by the insulator 8. As shown in FIG. 1, a total of 24 connection end portions 10 are arranged at equiangular intervals in the circumferential direction (15 ° intervals in the present embodiment) and centered on the central axis L of the stator 3. It is located on the same circle (not shown).

  The stator core 5 is formed by attaching 12 insulators 8 to each of the divided cores 7 and winding the conductors 9, and then forming 12 divided cores 7 in an annular shape so that the tips of the teeth 7 b face radially inward. Is done. And in the stator 3 of this embodiment, twelve coils U1-U4, V1-V4, W1-W4 are the coil W4, the coil U1, the coil V1, the coil W1, the coil from the upper side in FIG. U2, coil V2, coil W2, coil U3, coil V3, coil W3, coil U4, and coil V4 are arranged in this order.

  The bus bar device 6 is arranged at one end of the stator core 5 in the axial direction (end on the front side in FIG. 1). As shown in FIG. 3A, the bus bar device 6 includes three bus bars (that is, a U-phase bus bar 11, a V-phase bus bar 12, and a W-phase bus bar 13).

  Each of the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 is formed from a single wire 14. As shown in FIG. 3 (b), the wire 14 includes a conductive core wire 14a having a circular cross section, a cylindrical insulating film 14b having an insulating property and covering the outer periphery of the core wire 14a, and the insulating film. It is comprised from the self-fusion layer 14c which coat | covers the outer periphery of 14b. The core wire 14a is made of, for example, copper or a copper alloy. The self-bonding layer 14c has a self-bonding property and an insulating property. The self-bonding layer 14c of the present embodiment melts when heat is applied. The wire 14 provided with this self-bonding layer 14c is a self-bonding electric wire. An insulating layer is formed by the insulating coating 14b and the self-bonding layer 14c.

  Further, the external shape of the self-bonding layer 14c is square in the cross section orthogonal to the longitudinal direction of the wire 14 so that the cross-sectional shape of the wire 14 is square. The length of each side of the self-bonding layer 14c in the cross section orthogonal to the longitudinal direction of the wire 14 is set equal to the outer diameter of the insulating coating 14b. Further, each wire 14 constituting the U-phase bus bar 11, the V-phase bus bar 12 and the W-phase bus bar 13 has two pairs of outer surfaces of the wire 14 parallel to each other, one pair of outer surfaces being in the axial direction. The wire 14 is formed so as to be parallel and so that the other pair of outer surfaces are orthogonal to the axial direction.

  As shown in FIG. 4, the U-phase bus bar 11 is formed by bending or bending a plurality of portions of the wire 14 and forming the wire 14 into a substantially arc shape. Further, the U-phase bus bar 11 is formed by bending or bending the wire rod 14 so that a portion where the wire rod 14 intersects and does not overlap in the axial direction is formed. The U-phase bus bar 11 includes nine U-phase arc portions 11a, four pairs of U-phase connection portions 11b, and a pair of U-phase power feeding portions 11c.

  The nine U-phase arc-shaped portions 11a are all shaped into an arc shape, and the curvatures of all the U-phase arc-shaped portions 11a are equal. Further, the nine U-phase arc-shaped portions 11a are formed concentrically by being formed so as to be arranged in the circumferential direction in a state where the centers of curvature coincide with each other. Furthermore, as shown in FIG. 1, the radius of curvature R <b> 1 of each U-phase arcuate portion 11 a is larger than the inner diameter of the stator core 5 and smaller than the outer diameter of the stator core 5.

  As shown in FIG. 4, the four pairs of U-phase connection portions 11 b are formed at four locations that are equiangularly spaced in the circumferential direction (90 ° intervals in the present embodiment) in the U-phase bus bar 11. And the two U-phase connection parts 11b which make a pair are 15 degrees apart in the circumferential direction. In addition, each U-phase connection portion 11b is separated from the U-phase connection portion 11b adjacent to the circumferential direction on the opposite side of the paired U-phase connection portion 11b by 75 °.

  Each U-phase connecting portion 11b protrudes radially outward from the U-phase arcuate portion 11a. Each U-phase connecting portion 11b connects a pair of extending portions 15 extending radially outward from the circumferential ends of the U-phase arcuate portions 11a adjacent in the circumferential direction, and the distal ends of the extending portions 15 to each other. It is comprised from the surrounding part 16. FIG. In each U-phase connecting portion 11b, the pair of extending portions 15 extend in parallel along the radial direction while being in close contact with each other. Moreover, the surrounding part 16 is a site | part to which the said connection edge part 10 is electrically connected in the U-phase connection part 11b. The surrounding portion 16 has an arc shape that opens radially inward, and the inner diameter of the surrounding portion 16 is slightly larger than the outer diameter of the connection end portion 10. Further, the surrounding portion 16 is in a state where the core wire 14a is exposed by peeling off the insulating coating 14b and the self-bonding layer 14c. Moreover, since the U-phase bus bar 11 of this embodiment is formed from the wire 14 which is a self-fusion wire, the pair of extending portions 15 in each U-phase connection portion 11b are integrated by the self-fusion layer 14c. Has been. Therefore, in each U-phase connecting portion 11 b, a through hole 17 surrounded by the surrounding portion 16 and the pair of extending portions 15 is formed inside the surrounding portion 16. The through holes 17 are open on both sides in the axial direction. As shown in FIG. 1, each U-phase connection portion 11 b has a distance between the radial center of the U-phase bus bar 11 and the through hole 17 such that the radial center of the stator core 5 and the connection end 10. The distance is equal to the distance between the two. In the U-phase bus bar 11 excluding the pair of U-phase power feeding portions 11c, the center line of the wire 14 (that is, the line extending in the axial direction of the core wire 14 through the center in the radial direction of the core wire 14a) is within one plane. The same wire 14 is bent or curved so as to be positioned.

  As shown in FIG. 4, the pair of U-phase power feeding portions 11 c are formed at both ends of one wire 14 constituting the U-phase bus bar 11. That is, one U-phase power feeding portion 11 c is formed at one end of the U-phase bus bar 11, and the other U-phase power feeding portion 11 c is formed at the other end of the U-phase bus bar 11. The pair of U-phase power feeding portions 11c are in close contact with each other in the circumferential direction. The pair of U-phase power supply portions 11c extend from the U-phase arcuate portion 11a radially outward along the radial direction and then bend at 90 ° and extend along the axial direction. Moreover, since the U-phase bus bar 11 of this embodiment is formed from the wire 14 which is a self-bonding electric wire, a pair of U-phase electric power feeding part 11c is integrated by the self-bonding layer 14c. When the U-phase bus bar 11 is viewed from the axial direction, the tip of the U-phase power feeding portion 11c is located between the tip of the U-phase connecting portion 11b (that is, the radially outer end) and the U-phase arcuate portion 11a. ing.

  As shown in FIGS. 4 and 5, the V-phase bus bar 12 is formed by bending or curving a plurality of portions of one wire 14 to form the wire 14 in a substantially arc shape, and is the same as the U-phase bus bar 11. It has a shape. That is, the V-phase bus bar 12 includes nine V-phase arc-shaped portions 12 a having the same shape as the nine U-phase arc-shaped portions 11 a of the U-phase bus bar 11, and four pairs of U-phase connection portions 11 b of the U-phase bus bar 11. It is composed of four pairs of V-phase connection portions 12b having the same shape and a pair of V-phase power supply portions 12c having the same shape as the pair of U-phase power supply portions 11c of the U-phase bus bar 11.

  As shown in FIGS. 4 and 6, the W-phase bus bar 13 is formed by bending or curving a plurality of portions of one wire 14 and forming the wire 14 into a substantially arc shape. It has the same shape as That is, the W-phase bus bar 13 includes nine W-phase arc-shaped portions 13 a having the same shape as the nine U-phase arc-shaped portions 11 a of the U-phase bus bar 11, and four pairs of U-phase connection portions 11 b of the U-phase bus bar 11. It is configured by four pairs of W-phase connection portions 13b having the same shape and a pair of W-phase power supply portions 13c having the same shape as the pair of U-phase power supply portions 11c of the U-phase bus bar 11.

  As shown in FIGS. 1, 2, and 3 (a), the U-phase bus bar 11, V-phase bus bar 12, and W-phase bus bar 13 are composed of a U-phase arcuate part 11 a, a V-phase arcuate part 12 a, and a W-phase. The arcuate portions 13a are stacked so as to overlap in the axial direction. In the present embodiment, the three bus bars 11 to 13 are stacked in the axial direction in the order of the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13. The U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a are arranged on the same axis (that is, arranged so that the central axes coincide with each other), so that they are laminated without being displaced in the radial direction. ing. The V-phase bus bar 12 is laminated with a 30 ° shift in the circumferential direction with respect to the U-phase bus bar 11, and the W-phase bus bar 13 is 60 ° in the circumferential direction with respect to the U-phase bus bar 11 and the V-phase bus bar 12. Are laminated with a 30 ° shift in the circumferential direction. Therefore, in the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 stacked on each other, a U-phase connection portion 11b that forms a pair, a V-phase connection portion 12b that forms a pair, and a W-phase connection portion 13b that forms a pair. Deviation in the circumferential direction. Further, in the U-phase bus bar 11, the V-phase bus bar 12 and the W-phase bus bar 13 stacked on each other, a pair of U-phase connection portions 11b, a pair of V-phase connection portions 12b and a pair of W-phase connection portions 13b are: A U-phase connection portion 11b that forms a pair along the clockwise direction, a V-phase connection portion 12b that forms a pair, and a W-phase connection portion 13b that forms a pair are arranged in this order. Further, the eight U-phase connection portions 11b, the eight V-phase connection portions 12b, and the eight W-phase connection portions 13b are arranged at equal angular intervals (15 ° intervals in the present embodiment) in the circumferential direction. Furthermore, the U-phase power feeding unit 11c, the V-phase power feeding unit 12c, and the W-phase power feeding unit 13c are positioned so as not to overlap with the U-phase connection unit 11b, the V-phase connection unit 12b, and the W-phase connection unit 13b in the axial direction (displacement in the circumferential direction). At 30 ° intervals in the circumferential direction. Moreover, the front-end | tip part of U phase electric power feeding part 11c, V phase electric power feeding part 12c, and W phase electric power feeding part 13c has all faced the same direction (upper side in FIG.2 and FIG.3 (a)).

  Further, as shown in FIG. 3B, in the U-phase bus bar 11, the V-phase bus bar 12 and the W-phase bus bar 13 stacked on each other, the U-phase arc-shaped portion 11a and the V-phase arc-shaped portion 12a stacked in the axial direction. And the W-phase arcuate portion 13a are in close contact with each other. In the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a that are overlapped in the axial direction, the wires 14 constituting each of them are in surface contact from the axial direction, thereby insulating adjacent to each other in the axial direction. The coatings 14b adhere to each other without being separated in the axial direction. Therefore, the height of the bus bar device 6 in the axial direction is minimized. Further, the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a that are overlapped are integrated with the self-bonding layer 14c in the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a. By doing so, they are firmly fixed to each other. The U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 are integrated by the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a that are overlapped and fixed together. Yes.

  As shown in FIG. 1, the bus bar device 6 formed as described above has a U-phase power feeding at one axial end of a stator core 5 around which coils U1 to U4, V1 to V4, and W1 to W4 are wound. The tip portions of the portion 11 c, the V-phase power feeding portion 12 c and the W-phase power feeding portion 13 c are arranged so as to face the side opposite to the stator core 5. The bus bar device 6 is arranged coaxially with the stator core 5. Further, the through-hole 17 of the U-phase connection portion 11b, the through-hole 17 of the V-phase connection portion 12b, and the through-hole 17 of the W-phase connection portion 13b are connected end portions 10 of the coils U1 to U4, V1 to V4, and W1 to W4. Each corresponds to the position where is drawn.

  As shown in FIGS. 1 and 4, the through holes 17 of the eight U-phase connection portions 11 b have one connection end portion 10 of the coil W <b> 4, one connection end portion 10 of the coil U <b> 1, and the coil W <b> 1. One connection end 10, one connection end 10 of coil U2, one connection end 10 of coil W2, one connection end 10 of coil U3, one connection end 10 of coil W3 and coil U4 One connection end 10 is inserted through each. As shown in FIGS. 1 and 5, the through-holes 17 of the eight V-phase connection portions 12b have the other connection end portion 10 of the coil U1, the one connection end portion 10 of the coil V1, and the coil U2. The other connection end 10, one connection end 10 of the coil V2, the other connection end 10 of the coil U3, one connection end 10 of the coil V3, the other connection end 10 of the coil U4 and the coil V4 One connection end 10 is inserted through each. Furthermore, as shown in FIGS. 1 and 6, the other connection end 10 of the coil W4, the other connection end 10 of the coil V1, and the coil W1 are formed in the through holes 17 of the eight W-phase connection portions 13b. The other connection end 10, the other connection end 10 of the coil V2, the other connection end 10 of the coil W2, the other connection end 10 of the coil V3, the other connection end 10 of the coil W3 and the coil V4. The other connection end 10 is inserted. And the connection edge part 10 penetrated by the through-hole 17 of the U-phase connection part 11b, the V-phase connection part 12b, and the W-phase connection part 13b is welded to the U-phase connection part 11b, the V-phase connection part 12b, and the W-phase, respectively. It is electrically connected to the connecting portion 13b. As a result, as shown in FIG. 7, U-phase coils U1 to U4 are connected in parallel via U-phase bus bar 11 and V-phase bus bar 12, and V-phase coils V1 to V4 are connected to V-phase bus bar 12 and The W-phase coils are connected in parallel via the W-phase bus bar 13, and the W-phase coils W 1 to W 4 are connected in parallel via the W-phase bus bar 13 and the U-phase bus bar 11. The twelve coils U <b> 1 to U <b> 4, V <b> 1 to V <b> 4, and W <b> 1 to W <b> 4 are electrically connected to each other via the bus bar device 6 and are delta-connected by the bus bar device 6. In FIG. 7, the U-phase bus bar 11 is illustrated by a solid line, the V-phase bus bar 12 is illustrated by a one-dot chain line, and the W-phase bus bar 13 is illustrated by a two-dot chain line.

  As shown in FIG. 1, the U-phase power supply unit 11 c is electrically connected to a power supply terminal terminal (not shown) for supplying a U-phase alternating current. The V-phase power supply unit 12c is electrically connected to a power supply terminal (not shown) for supplying a V-phase alternating current. Furthermore, the W-phase power supply unit 13c is electrically connected to a power supply terminal (not shown) for supplying a W-phase alternating current. The U-phase alternating current, the V-phase alternating current, and the W-phase alternating current are alternating currents whose phases are shifted by 120 °. In the brushless motor 1, when current is supplied to the coils U <b> 1 to U <b> 4, V <b> 1 to V <b> 4, W <b> 1 to W <b> 4 through the bus bar device 6, the rotor 4 is rotated according to the rotating magnetic field generated by the stator 3. It has become so.

  Here, the operation of the bus bar device 6 of the present embodiment will be described. Since the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 are formed from the wire rod 14, waste materials are hardly generated. Further, since the wire 14 is formed by covering the outer periphery of the conductive core wire 14a with the insulating coating 14b and the self-bonding layer 14c having insulation, the three bus bars formed from the wire 14 are formed. 11 to 13 are not short-circuited even if they are in close contact with each other. In addition, the three bus bars 11 to 13 are integrated by overlapping the U-phase arcuate part 11a, the V-phase arcuate part 12a, and the W-phase arcuate part 13a so as to be closely fixed to each other. It is easy. Furthermore, since the three bus bars 11 to 13 are closely fixed in the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a, the space is narrower than the case where they are arranged apart from each other. It is possible to arrange.

Next, a method for manufacturing the bus bar device 6 of this embodiment will be described.
First, the peeling process which peels the self-fusion layer 14c and the insulating film 14b of the site | part used as the U-phase connection part 11b, the V-phase connection part 12b, and the W-phase connection part 13b in the core wire 14a is performed. In this stripping step, the core wire 14a is cut to a length corresponding to the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 to be formed (the length before being bent or curved). Then, in the wire 14 for forming the U-phase bus bar 11, eight self-bonding layers 14c and insulating coatings 14b to be the U-phase connecting portions 11b (at least the self-bonding layers 14c and insulating coatings to be the surrounding portions 16) 14b) is peeled to expose the core wire 14a. Similarly, in the wire 14 for forming the V-phase bus bar 12, eight self-bonding layers 14 c and insulating coatings 14 b serving as the V-phase connecting portions 12 b (at least the self-bonding layers 14 c and insulating portions serving as the surrounding portions 16) are formed. The coating 14b) is peeled off to expose the core wire 14a. Similarly, in the wire 14 for forming the W-phase bus bar 13, eight self-bonding layers 14 c and insulating coatings 14 b that become the W-phase connection portions 13 b (at least the self-bonding layers 14 c and the portions that become the surrounding portions 16) The insulation coating 14b) is peeled off to expose the core wire 14a.

  Next, a molding process is performed in which the wire 14 is molded to form the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13. As shown in FIG. 4, by bending or bending a plurality of portions of the wire 14 that becomes the U-phase bus bar 11, nine U-phase arc portions 11 a, four pairs of U-phase connection portions 11 b, and a pair of wires 14 are connected to the wire 14. A U-phase power feeding portion 11c is formed. As a result, the U-phase bus bar 11 is formed from one wire 14. When the wire 14 is bent or bent, the wire 14 is bent and bent so that a portion where the wire 14 intersects and overlaps in the axial direction does not occur. Further, the wire 14 for forming the U-phase bus bar 11 is bent or curved so that the center line of the wire 14 is located in one plane at a portion of the U-phase bus bar 11 excluding the U-phase power feeding portion 11c.

  Similarly, as shown in FIG. 5, by bending or bending a plurality of portions of the wire 14 that becomes the V-phase bus bar 12, nine V-phase arcuate portions 12 a and 4 pairs of V-phases are formed on the wire 14. A connecting portion 12b and a pair of V-phase power feeding portions 12c are formed. As a result, the V-phase bus bar 12 is formed from one wire 14. Similarly, as shown in FIG. 6, nine W-phase arcuate portions 13 a and four pairs of W-phases are formed on the wire 14 by bending or bending a plurality of portions of the wire 14 that becomes the W-phase bus bar 13. A connecting portion 13b and a pair of W-phase power feeding portions 13c are formed. As a result, the W-phase bus bar 13 is formed from one wire 14.

  Next, a laminating process of laminating the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 is performed. As shown in FIG. 2 and FIG. 3A, in the stacking process, the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 are divided into the U-phase arc portion 11a, the V-phase arc portion 12a, and the W-phase arc portion 13a. Are stacked so as to overlap in the axial direction. In the present embodiment, the three bus bars 11 to 13 are stacked in the order of the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13. The bus bars 11 to 13 are stacked so that the U-phase arcuate part 11a, the V-phase arcuate part 12a, and the W-phase arcuate part 13a are coaxial. Furthermore, the bus bars 11 to 13 are stacked such that the U-phase connection portion 11b, the V-phase connection portion 12b, and the W-phase connection portion 13b are displaced in the circumferential direction. Specifically, the V-phase bus bar 12 is laminated with a 30 ° shift in the circumferential direction with respect to the U-phase bus bar 11, and the W-phase bus bar 13 is 60 ° in the circumferential direction with respect to the U-phase bus bar 11 and the V-phase bus bar. 12 are laminated with a 30 ° shift in the circumferential direction. In the bus bars 11 to 13 stacked in the stacking step, the eight U-phase connection portions 11b, the eight V-phase connection portions 12b, and the eight W-phase connection portions 13b are equiangularly spaced in the circumferential direction ( In this embodiment, they are arranged at intervals of 15 °. Furthermore, the U-phase power feeding unit 11c, the V-phase power feeding unit 12c, and the W-phase power feeding unit 13c are positioned so as not to overlap with the U-phase connection unit 11b, the V-phase connection unit 12b, and the W-phase connection unit 13b in the axial direction (displacement in the circumferential direction). At 30 ° intervals in the circumferential direction.

  Next, an integration step of integrating the laminated U-phase bus bar 11, V-phase bus bar 12, and W-phase bus bar 13 is performed. In the integration step, the stacked bus bars 11 to 13 are heated. In the integration process of the present embodiment, the bus bars 11 to 13 are energized, and the bus bars 11 to 13 are heated using heat generated during energization. When the bus bars 11 to 13 are heated, the self-bonding layer 14c is melted. Then, the self-bonding layer 14c of the wire 14 constituting the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a stacked in the axial direction is integrated. Further, the self-bonding layer 14c of the wire 14 constituting the extending portion 15 forming a pair of each U-phase connecting portion 11b, each V-phase connecting portion 12b and each W-phase connecting portion 13b is also integrated. Then, the bus bars 11 to 13 are cooled and the self-bonding layer 14c is solidified, whereby the overlapped U-phase arc-shaped portion 11a, V-phase arc-shaped portion 12a, and W-phase arc-shaped portion 13a are tightly fixed to each other. The U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 are integrated by the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a that are overlapped with each other. Thus, the bus bar device 6 is completed.

As described above, the first embodiment has the following effects.
(1) Since the U-phase bus bar 11, the V-phase bus bar 12, and the W-phase bus bar 13 are formed from the wire rod 14, waste materials are hardly generated. Therefore, it is possible to suppress a decrease in the yield of each bus bar 11-13. Further, since the wire 14 is formed by covering the outer periphery of the conductive core wire 14a with the insulating coating 14b and the self-bonding layer 14c having insulation, the three bus bars formed from the wire 14 are formed. 11 to 13 are not short-circuited even if they are in close contact with each other. Therefore, the bus bars 11 to 13 need not be held by the bus bar holder in order to prevent a short circuit between the bus bars 11 to 13. In addition, the three bus bars 11 to 13 are integrated by overlapping the U-phase arcuate part 11a, the V-phase arcuate part 12a, and the W-phase arcuate part 13a so as to be closely fixed to each other. It is easy. Since the plurality of bus bars 11 to 13 can be handled as one component, the plurality of bus bars do not have to be held by components such as a bus bar holder as in the related art. Furthermore, since the three bus bars 11 to 13 are closely fixed in the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a, the space is narrower than the case where they are arranged apart from each other. It is possible to arrange. From these things, the enlargement of the bus-bar apparatus 6 can be suppressed.

  (2) The U-phase connecting portion 11b, the V-phase connecting portion 12b, and the W-phase connecting portion 13b are formed so as to protrude in the radial direction from the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a, respectively. ing. Therefore, each bus bar is compared with the case where the U-phase connecting portion 11b, the V-phase connecting portion 12b, and the W-phase connecting portion 13b protrude in the axial direction from the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a. The enlargement of the axial direction of 11-13 is suppressed. Moreover, it becomes easy to connect the connection edge part 10 to the bus-bars 11-13 because each bus-bar 11-13 has the U-phase connection part 11b, the V-phase connection part 12b, and the W-phase connection part 13b.

  (3) Since the wire 14 for forming the bus bars 11 to 13 is a self-bonding electric wire, the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a and the W-phase arc-shaped portions of the three bus bars 11 to 13 that are overlapped with each other. The parts 13a can be easily adhered and fixed to each other.

  (4) The U-phase connection portion 11b, the V-phase connection portion 12b, and the W-phase connection portion 13b have a through hole 17 through which the connection end portion 10 can be inserted. When the connection end 10 is electrically connected to the U-phase connection portion 11b, the V-phase connection portion 12b, and the W-phase connection portion 13b, when the connection end portion 10 is inserted into the through-hole 17, the connection end portion 10 becomes U-shaped. It is held by the phase connecting part 11b, the V phase connecting part 12b and the W phase connecting part 13b. Therefore, the connection end portion 10 can be easily connected to the U-phase connection portion 11b, the V-phase connection portion 12b, and the W-phase connection portion 13b.

  (5) All the bus bars 11 to 13 are formed so that the curvatures of the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a are equal, and the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and W The phase arc portions 13a are stacked in the axial direction so as to be coaxial. Therefore, since the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a are stacked in the axial direction without being displaced in the radial direction, the bus bar device 6 can be downsized in the radial direction.

  (6) The outer shape of the self-bonding layer 14c in the cross section of the wire 14 has a square shape with sides having a length equal to the outer diameter of the insulating coating 14b. Therefore, since the external shape of the self-bonding layer 14c can be reduced, the height of each bus bar 11-13 in the axial direction can be suppressed. Further, in the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a that are overlapped in the axial direction, the wires 14 constituting each of them are in surface contact from the axial direction, so that the insulation adjacent in the axial direction is achieved. The coatings 14b adhere to each other without being separated in the axial direction. Therefore, in the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a that are stacked in the axial direction, the insulating coating 14b adjacent in the axial direction may be separated in the axial direction by the self-bonding layer 14c. It is suppressed. As a result, the axial height of the bus bar device 6 can be suppressed.

  (7) Since each bus bar 11-13 does not have the part which the wire 14 overlaps in an axial direction, it can suppress that each bus bar 11-13 becomes thick in an axial direction. Therefore, the axial height of the bus bar device 6 can be suppressed.

(8) Twelve coils U1 to U4, V1 to V4, and W1 to W4 can be delta-connected by the bus bar device 6 in which a decrease in yield is suppressed and an increase in size is suppressed.
(9) By providing the stator 3 with the bus bar device 6 that can suppress a decrease in yield and suppress an increase in size, an increase in manufacturing cost of the stator 3 is suppressed and an increase in size of the stator 3 is suppressed. be able to. Further, by providing the bus bar device 6 in the brushless motor 1, an increase in manufacturing cost of the brushless motor 1 can be suppressed and an increase in size of the brushless motor 1 can be suppressed. The three bus bars 11 to 13 have a U-phase arc-shaped portion 11a, a V-phase arc-shaped portion 12a, and a W-phase arc-shaped portion 13a that are closely fixed and integrated with each other, so that the shapes are easily stabilized. Therefore, the arrangement of the bus bars 11 to 13 with respect to the coils U1 to U4, V1 to V4, and W1 to W4, that is, the arrangement of the bus bar device 6 with respect to the coils U1 to U4, V1 to V4, and W1 to W4 can be easily performed. And by providing the bus-bar apparatus 6 by which the assembly | attachment property was improved, the productivity of the stator 3 and by extension, the productivity of the brushless motor 1 can be improved.

  (10) Since the bus bars 11 to 13 are formed from the wire 14 in the molding step, it is possible to suppress a decrease in the yield of the bus bars 11 to 13. Further, the bus bars 11 to 13 can be easily formed by bending or bending the wire 14. In the stacking process, the three bus bars 11 to 13 are stacked so that the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a and the W-phase arc-shaped portion 13a overlap each other, and in the integrating step, the U-phase arc-shaped layers are stacked on each other. The three bus bars 11 to 13 are integrated by closely fixing the portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a. By such a simple method, the bus bar device 6 including the three bus bars 11 to 13 formed of the wire 14 can be formed.

  (11) In the integration step, the bus bars 11 to 13 are heated to melt the self-bonding layer 14c, and the overlapped U-phase arc-shaped portion 11a, V-phase arc-shaped portion 12a and W-phase arc-shaped portion 13a are melted. The self-bonding layer 14c is closely fixed. Therefore, in order to tightly fix the U-phase arcuate part 11a, the V-phase arcuate part 12a, and the W-phase arcuate part 13a on which the three bus bars 11 to 13 are overlapped, fixing materials and parts are not separately prepared. Also good. Further, the three bus bars 11 to 13 can be integrated by a simple method of heating the three stacked bus bars 11 to 13. Therefore, the productivity of the bus bar device 6 can be improved and the manufacturing cost of the bus bar device 6 can be reduced.

(12) In the integration step, the bus bars 11 to 13 can be easily heated by energizing the bus bars 11 to 13.
(13) In the peeling step, by peeling off the insulating coating 14b and the self-bonding layer 14c in the portion that becomes the U-phase connecting portion 11b, the V-phase connecting portion 12b, and the W-phase connecting portion 13b in the wire rod 14, Connection with the U-phase connection part 11b, the V-phase connection part 12b, and the W-phase connection part 13b can be performed satisfactorily. Moreover, since a peeling process is performed before a shaping | molding process, the deformation | transformation of the shape | molded bus-bars 11-13 can be suppressed.

  (14) The pair of extending portions 15 in each U-phase connection portion 11b are closely fixed to each other by the self-bonding layer 14c. Therefore, the shape of the U-phase bus bar 11 is easily stabilized. Similarly, in the V-phase bus bar 12 and the W-phase bus bar 13, the extending portions 15 that make a pair are closely fixed to each other by the self-bonding layer 14 c, so that the shape is easily stabilized.

  (15) Since each bus bar 11-13 is formed from the wire 14 which is a self-bonding electric wire, the extended part 15 which extends along a radial direction and makes the pair, and the front-end | tip part of the extended part 15 which makes a pair The through-hole 17 can be formed by the arc-shaped surrounding part 16 which connects each other. That is, in order to provide the through-hole 17 in the U-phase connecting portion 11b, the V-phase connecting portion 12b, and the W-phase connecting portion 13b, the wire 14 need not be bent or curved so as to intersect. Therefore, it can suppress that each bus-bar 11-13 becomes thick in an axial direction.

  (16) The U-phase connecting portion 11 b is formed so that the through hole 17 provided at the tip thereof corresponds to the position of the connecting end portion 10. Therefore, for example, when the U-phase connecting portion 11b is formed so as to protrude radially inward from the U-phase arc-shaped portion 11a, the U-phase arc-shaped portion 11a is disposed radially outward with respect to the U-phase connecting portion 11b. As a result, the U-phase bus bar 11 becomes larger in the radial direction. However, in the U-phase bus bar 11 of the present embodiment, the U-phase connection portion 11b protrudes radially outward from the U-phase arcuate portion 11a. Therefore, it is possible to suppress the U-phase bus bar 11 from being enlarged in the radial direction. As a result, the enlargement of the bus bar device 6 in the radial direction can be suppressed. This also applies to the V-phase bus bar 12 and the W-phase bus bar 13.

  (17) The U-phase bus bar 11, the V-phase bus bar 12 and the W-phase bus bar 13 are integrated by tightly fixing the overlapped U-phase arc-shaped portion 11a, V-phase arc-shaped portion 12a and W-phase arc-shaped portion 13a. Yes. Therefore, even if the brushless motor 1 is disposed in a place where vibration is likely, such as in the vicinity of the engine of the vehicle, the bus bars 11 to 13 do not move relative to each other. Accordingly, since the bus bars 11 to 13 do not rub against each other, generation of noise in the bus bar device 6 is suppressed, and the bus bars 11 to 13 are prevented from being short-circuited due to wear of the insulating coating 14b.

(Second Embodiment)
Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.

  A brushless motor 21 according to the second embodiment shown in FIG. 8 includes a bus bar device 22 instead of the bus bar device 6 according to the first embodiment. The bus bar device 22 includes four bus bars (that is, a common bus bar 31, a U-phase bus bar 32, a V-phase bus bar 33, and a W-phase bus bar 34). Each of the common bus bar 31, the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 34 is formed from one wire 14. In the common bus bar 31, the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 13, one pair of outer surfaces of the two pairs of outer surfaces of the wire 14 parallel to each other is parallel to the axial direction. Thus, the wire 14 is formed so that the other pair of outer surfaces are orthogonal to the axial direction.

  As shown in FIG. 9, the common bus bar 31 is formed by bending or bending a plurality of portions of the wire 14 and forming the wire 14 into a substantially arc shape. Further, the common bus bar 31 is formed by bending or bending the wire rod 14 so that a portion where the wire rod 14 intersects and does not overlap in the axial direction is formed. Further, the common bus bar 31 is formed by bending or bending the wire rod 14 so that the center line of the wire rod 14 is located in one plane. The common bus bar 31 is composed of eleven common arcuate portions 31a and twelve common connection portions 31b.

  The eleven common arcuate portions 31a are all shaped into an arc shape, and the curvatures of all the common arcuate portions 31a are equal. Further, the eleven common arc-shaped portions 31a are formed concentrically by being formed so as to be arranged in the circumferential direction in a state where the centers of curvature coincide with each other. Further, as shown in FIG. 8, the radius of curvature R <b> 2 of each common arc-shaped portion 31 a is larger than the inner diameter of the stator core 5 and smaller than the outer diameter of the stator core 5.

  As shown in FIG. 9, the twelve common connection portions 31b protrude radially outward from the circumferential ends of the common arc-shaped portions 31a. The twelve common connection portions 31b are formed at twelve locations that are equiangularly spaced (30 ° intervals) in the circumferential direction of the common bus bar 31. Each common connection portion 31b includes a pair of extending portions 15 extending radially outward from the circumferential end portion of the common arc-shaped portion 31a, and the extension portion 15b, similarly to the U-phase connection portion 11b of the first embodiment. It is comprised from the surrounding part 16 which connects the front-end | tip parts of the installation part 15. FIG. Furthermore, in each common connection portion 31 b, a through hole 17 surrounded by the surrounding portion 16 and the pair of extending portions 15 is formed inside the surrounding portion 16. As shown in FIG. 8, each common connection portion 31 b has a distance between the radial center of the common bus bar 31 and the through hole 17 between the radial center of the stator core 5 and the connection end portion 10. It is formed so that it may become a distance equal to this distance.

  Further, as shown in FIG. 10, the U-phase bus bar 32 is formed by bending or bending a plurality of portions of the wire 14 and forming the wire 14 into a substantially arc shape. Further, the U-phase bus bar 32 is formed by bending or bending the wire 14 so that a portion where the wire 14 intersects and does not overlap in the axial direction is formed. The U-phase bus bar 32 includes five U-phase arc-shaped portions 32a, four U-phase connection portions 32b, and a pair of U-phase power feeding portions 32c.

  The five U-phase arc-shaped portions 32a are all shaped into an arc shape, and the curvatures of all the U-phase arc-shaped portions 32a are equal. Further, the curvature of each U-phase arcuate portion 32a is equal to the curvature of the common arcuate portion 31a. Further, the five U-phase arcuate portions 32a are formed concentrically by being formed so as to be arranged in the circumferential direction in a state where the centers of curvature coincide with each other. Furthermore, as shown in FIG. 8, the radius of curvature R <b> 3 of each U-phase arcuate portion 32 a is larger than the inner diameter of the stator core 5 and smaller than the outer diameter of the stator core 5.

  In addition, the four U-phase connecting portions 32b are formed at four locations that are equiangularly spaced in the circumferential direction (90 ° intervals in the present embodiment) in the U-phase bus bar 32, and the diameter from the U-phase arc-shaped portion 32a. Projects outward in the direction. Each U-phase connection portion 32b has the same shape as the U-phase connection portion 11b provided in the U-phase bus bar 11 of the first embodiment, and has a diameter from the end portion of the U-phase arc-shaped portion 32a adjacent in the circumferential direction. It is comprised from a pair of extension part 15 extended in the direction outer side, and the surrounding part 16 which connects the front-end | tip parts of this extension part 15. Further, in each U-phase connecting portion 32 b, a through hole 17 surrounded by the surrounding portion 16 and the pair of extending portions 15 is formed inside the surrounding portion 16. Each U-phase connecting portion 32b has a distance between the radial center of the U-phase bus bar 32 and the through hole 17 equal to the distance between the radial center of the stator 3 and the connecting end portion 10. It is formed to become. The pair of U-phase power feeding portions 32c has the same shape as the pair of U-phase power feeding portions 11c provided in the U-phase bus bar 11 of the first embodiment. The portion of the U-phase bus bar 32 excluding the pair of U-phase power feeding portions 32c is formed by bending or bending the wire 14 so that the center line of the wire 14 is located in one plane.

  As shown in FIGS. 10 and 11, the V-phase bus bar 33 is formed by bending or bending a plurality of portions of one wire 14 and forming the wire 14 into a substantially arc shape, and is the same as the U-phase bus bar 32. It has a shape. That is, the V-phase bus bar 33 includes five V-phase arc-shaped portions 33 a having the same shape as the five U-phase arc-shaped portions 32 a of the U-phase bus bar 32, and four U-phase connection portions 32 b of the U-phase bus bar 32. The four V-phase connection portions 33b having the same shape and the pair of V-phase power supply portions 33c having the same shape as the pair of U-phase power supply portions 32c of the U-phase bus bar 32 are configured.

  As shown in FIGS. 10 and 12, the W-phase bus bar 34 is formed by bending or bending a plurality of portions of one wire 14 and forming the wire 14 into a substantially arc shape. It has the same shape as That is, the W-phase bus bar 34 includes five W-phase arc-shaped portions 34 a having the same shape as the five U-phase arc-shaped portions 32 a of the U-phase bus bar 32, and four U-phase connection portions 32 b of the U-phase bus bar 32. The four W-phase connection portions 34b having the same shape and the pair of W-phase power supply portions 34c having the same shape as the pair of U-phase power supply portions 32c of the U-phase bus bar 32 are configured.

  As shown in FIGS. 8 to 12, the common bus bar 31, the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 34 have a common arc-shaped portion 31a, a U-phase arc-shaped portion 32a, and a V-phase arc-shaped portion 33a. And the W-phase arc-shaped portion 34a are stacked so as to overlap in the axial direction. In the present embodiment, the four bus bars 31 to 34 are laminated in the axial direction in the order of the common bus bar 31, the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 34. The common arc-shaped portion 31a, the U-phase arc-shaped portion 32a, the V-phase arc-shaped portion 33a, and the W-phase arc-shaped portion 34a are arranged coaxially so that they are stacked without being displaced in the radial direction. The U-phase bus bar 32 is arranged such that the U-phase connection portion 32b is displaced in the circumferential direction with respect to the common connection portion 31b. The V-phase bus bar 33 is disposed so as to be shifted from the U-phase bus bar 32 by 30 ° in the circumferential direction, and the V-phase connection portion 33b is shifted from the common connection portion 31b in the circumferential direction. Further, the W-phase bus bar 34 is shifted by 60 ° in the circumferential direction with respect to the U-phase bus bar 32 and is shifted by 30 ° in the circumferential direction with respect to the V-phase bus bar 33, and the W-phase connection portion 34b is changed to the common connection portion 31b. In contrast, they are arranged so as to be displaced in the circumferential direction. Therefore, in the common bus bar 31, the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 34 stacked on each other, the common connection part 31b, the U-phase connection part 32b, the V-phase connection part 33b, and the W-phase connection part 34b are provided. Deviation in the circumferential direction. Furthermore, the U-phase connection portion 32b, the V-phase connection portion 33b, and the W-phase connection portion 34b are arranged in the circumferential direction in the order of the U-phase connection portion 32b, the V-phase connection portion 33b, and the W-phase connection portion 34b, and are adjacent in the circumferential direction. One common connection portion 31b is interposed between the matching U-phase connection portion 32b, V-phase connection portion 33b, and W-phase connection portion 34b. In addition, twelve common connection portions 31b, four U-phase connection portions 32b, four V-phase connection portions 33b, and four W-phase connection portions 34b are equiangularly spaced in the circumferential direction (15 in this embodiment). Lined up at intervals. Furthermore, the U-phase power feeding part 32c, the V-phase power feeding part 33c, and the W-phase power feeding part 34c are positions that do not overlap with the common connection part 31b, the U-phase connection part 32b, the V-phase connection part 33b, and the W-phase connection part 34b in the axial direction. (Positions shifted in the circumferential direction) and arranged at 30 ° intervals in the circumferential direction. Further, the leading ends of the U-phase power feeding unit 32c, the V-phase power feeding unit 33c, and the W-phase power feeding unit 34c all face the same direction (the front side in FIG. 8).

  In the common bus bar 31, the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 34 that are stacked on each other, the common arc-shaped portion 31a, the U-phase arc-shaped portion 32a, the V-phase arc-shaped portion 33a, and the like W-phase arcs 34a are in close contact with each other. In the common arc-shaped portion 31a, the U-phase arc-shaped portion 32a, the V-phase arc-shaped portion 33a, and the W-phase arc-shaped portion 34a that are overlapped in the axial direction, the wire 14 constituting each of the common arc-shaped portion 31a makes surface contact from the axial direction. The insulating coatings 14b adjacent to each other are in close contact with each other without being separated in the axial direction. Further, the common arc-shaped portion 31a, the U-phase arc-shaped portion 32a, the V-phase arc-shaped portion 33a, and the W-phase arc-shaped portion 34a that are overlapped are the common arc-shaped portion 31a, the U-phase arc-shaped portion 32a, the V-phase arc-shaped portion 33a, and the W-phase arc-shaped portion. The self-bonding layers 14c in 34a are integrated and fixed to each other. The common bus bar 31, the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 34 have the common arc-shaped portion 31a, the U-phase arc-shaped portion 32a, the V-phase arc-shaped portion 33a, and the W-phase arc-shaped portion 34a closely attached to each other. It is integrated by being fixed.

  The bus bar device 22 formed as described above includes a U-phase power feeding portion 32c and a V-phase power feeding portion at one end in the axial direction of the stator core 5 around which the coils U1 to U4, V1 to V4, and W1 to W4 are wound. 33c and the front end of the W-phase power feeding portion 34c are arranged so as to face the opposite side of the stator core 5. The bus bar device 22 is arranged coaxially with the stator core 5. Furthermore, the through hole 17 of the common connection part 31b, the through hole 17 of the U phase connection part 32b, the through hole 17 of the V phase connection part 33b, and the through hole 17 of the W phase connection part 34b are coils U1 to U4 and V1 to V4. , W1 to W4 respectively correspond to the positions where the connection end portions 10 are pulled out.

  As shown in FIGS. 8 and 9, the connection end portions 10 on one side of the coils U1 to U4, V1 to V4, and W1 to W4 are inserted into the through holes 17 of the twelve common connection portions 31b, respectively. ing. Moreover, as shown in FIG.8 and FIG.10, the other connection edge part 10 of the coils U1-U4 is each penetrated by the through-hole 17 of the four U-phase connection parts 32b. Further, as shown in FIGS. 8 and 11, the other connection end portions 10 of the coils V1 to V4 are inserted through the through holes 17 of the four V-phase connection portions 33b. Further, as shown in FIGS. 8 and 12, the other connection end portions 10 of the coils W1 to W4 are inserted through the through holes 17 of the four W-phase connection portions 34b. And the connection end part 10 inserted in the through-hole 17 of the common connection part 31b, the U-phase connection part 32b, the V-phase connection part 33b, and the W-phase connection part 34b is connected to the common connection part 31b and the U-phase connection part, respectively. 32b, V-phase connecting portion 33b and W-phase connecting portion 34b are electrically connected. As a result, as shown in FIG. 13, the U-phase coils U1 to U4 are connected in parallel by the U-phase bus bar 32 and the common bus bar 31, and the V-phase coils V1 to V4 are connected to the V-phase bus bar 33 and the common bus bar 31. The W-phase coils W1 to W4 are further connected in parallel by the W-phase bus bar 34 and the common bus bar 31. Further, the common bus bar 31 serves as a neutral point. The twelve coils U <b> 1 to U <b> 4, V <b> 1 to V <b> 4, W <b> 1 to W <b> 4 are electrically connected to each other via the bus bar device 22 and are Y-connected by the bus bar device 22. In FIG. 13, the common bus bar 31 is indicated by a broken line, the U-phase bus bar 32 is indicated by a solid line, the V-phase bus bar 33 is indicated by a one-dot chain line, and the W-phase bus bar 34 is indicated by a two-dot chain line. It is shown.

  In addition, the U-phase power feeding unit 32c, the V-phase power feeding unit 33c, and the W-phase power feeding unit 34c are mutually in phase like the U-phase power feeding unit 11c, the V-phase power feeding unit 12c, and the W-phase power feeding unit 13c of the first embodiment. Are electrically connected to power supply terminals (not shown) for supplying AC power that is shifted by 120 °.

  And the bus-bar apparatus 22 of this embodiment is manufactured through a peeling process, a formation process, a lamination process, and an integration process similarly to the bus-bar apparatus 6 of the said 1st Embodiment. The common bus bar 31 is also formed from the wire 14 through a peeling process and a molding process. The common bus bar 31 is laminated together with the U-phase bus bar 32, the V-phase bus bar 33, and the W-phase bus bar 34 in the laminating process, and then integrated with these bus bars 32-34 in the integrating process.

As described above, according to the second embodiment, in addition to the same effects as (1) to (7) and (9) to (17) of the first embodiment, the following effects are obtained.
(18) Twelve coils U1 to U4, V1 to V4, and W1 to W4 can be Y-connected by the bus bar device 22 in which a decrease in yield is suppressed and an increase in size is suppressed.

(Third embodiment)
Hereinafter, a third embodiment of the present invention will be described with reference to the drawings. Note that in the third embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and description thereof is omitted.

  A brushless motor 41 according to the third embodiment shown in FIG. 15 includes a bus bar device 42 instead of the bus bar device 6 according to the first embodiment. The bus bar device 42 includes ten bus bars (that is, one common bus bar 51, three U-phase bus bars 52, three V-phase bus bars 53, and three W-phase bus bars 54). Each of the bus bars 51 to 54 is formed by molding one wire 14. The common bus bar 51, the U-phase bus bar 52, the V-phase bus bar 53, and the W-phase bus bar 54 have one pair of outer surfaces parallel to the axial direction of the two pairs of outer surfaces that are parallel to each other. Thus, the wire 14 is formed so that the other pair of outer surfaces are orthogonal to the axial direction.

  As shown in FIG. 16, the common bus bar 51 is formed by bending or bending a plurality of portions of the wire 14 and forming the wire 14 into a substantially arc shape. Further, the common bus bar 51 is formed by bending or bending the wire rod 14 so that a portion where the wire rod 14 intersects and does not overlap in the axial direction is formed. Further, the common bus bar 51 is formed by bending or bending the wire rod 14 so that the center line of the wire rod 14 is located in one plane. The common bus bar 51 includes two common arc-shaped portions 51a and three common connection portions 51b.

  Each of the two common arc-shaped portions 51a is shaped into an arc shape and has the same curvature. Further, the two common arc-shaped portions 51a are formed concentrically by being formed so as to be arranged in the circumferential direction in a state where the centers of curvature coincide with each other. Furthermore, as shown in FIG. 15, the radius of curvature R <b> 4 of each common arc-shaped portion 51 a is larger than the inner diameter of the stator core 5 and smaller than the outer diameter of the stator core 5.

  As shown in FIG. 16, the three common connection portions 51b protrude radially outward from the circumferential ends of the common arc-shaped portions 51a. The three common connection portions 51b are formed at three locations that are equiangularly spaced (30 ° intervals) in the circumferential direction of the common bus bar 51. Similarly to the U-phase connection portion 11b of the first embodiment, each common connection portion 51b includes a pair of extending portions 15 extending radially outward from the circumferential end portion of the common arc-shaped portion 51a, and the extension portions 15b. It is comprised from the surrounding part 16 which connects the front-end | tip parts of the installation part 15. FIG. Further, in each common connection portion 51 b, a through hole 17 surrounded by the surrounding portion 16 and the pair of extending portions 15 is formed inside the surrounding portion 16. As shown in FIG. 15, each common connection portion 51 b has a distance between the radial center of the common bus bar 51 and the through hole 17 between the radial center of the stator core 5 and the connection end portion 10. It is formed so that it may become a distance equal to this distance.

  Also, as shown in FIG. 16, the three U-phase bus bars 52 are formed by bending or bending a plurality of portions of the wire 14 to form the wire 14 into a substantially arc shape, and having the same shape as each other. There is no. In addition, each U-phase bus bar 52 is formed by bending or bending the wire 14 so that a portion where the wire 14 intersects and does not overlap in the axial direction is formed. Further, each U-phase bus bar 52 is formed by bending or bending the wire rod 14 so that the center line of the wire rod 14 is located in one plane. Each U-phase bus bar 52 is composed of one U-phase arcuate portion 52a and two U-phase connection portions 52b.

  In each U-phase bus bar 52, the U-phase arcuate portion 52 a is shaped into an arc shape along the circumferential direction of the stator 3. The curvature of the U-phase arcuate portion 52a is equal to the national of the common arcuate portion 51a. As shown in FIG. 15, the curvature radius R <b> 5 of each U-phase arcuate portion 52 a is larger than the inner diameter of the stator core 5 and smaller than the outer diameter of the stator core 5.

  In each U-phase bus bar 52, the two U-phase connection portions 52b protrude radially outward from both ends in the circumferential direction of the U-phase arcuate portion 52a. And the two U-phase connection parts 52b in each U-phase bus bar 52 are separated by 75 ° in the circumferential direction. Each U-phase connection part 52b has the same shape as the U-phase connection part 11b provided in the U-phase bus bar 11 of the first embodiment, and is radially outward from the circumferential end of the U-phase arcuate part 52a. A pair of extending portions 15 extending in the direction of the extension portion 15 and a surrounding portion 16 that connects the distal end portions of the extending portion 15 to each other. Further, in each U-phase connecting portion 52 b, a through hole 17 surrounded by the surrounding portion 16 and the pair of extending portions 15 is formed inside the surrounding portion 16. Each U-phase connecting portion 52b has a distance between the center in the radial direction of the U-phase bus bar 32 (same as the center of curvature of the U-phase arc-shaped portion 52a) and the through-hole 17 in the radial center of the stator core 5. It is formed to be a distance equal to the distance to the connection end 10.

  As shown in FIG. 17, the three V-phase bus bars 53 are formed by bending or bending a plurality of portions of the wire 14 to form the wire 14 in a substantially arc shape, and are the same as the three U-phase bus bars 52. It has a shape. That is, each V-phase bus bar 53 has one V-phase arc-shaped portion 53 a having the same shape as one U-phase arc-shaped portion 52 a of the U-phase bus bar 52, and two U-phase connection portions 52 b of the U-phase bus bar 52. And two V-phase connecting portions 53b having the same shape as the above.

  As shown in FIG. 18, the three W-phase bus bars 54 are formed by bending or bending a plurality of portions of the wire 14 to form the wire 14 into a substantially arc shape, and three U-phase bus bars 52. It has the same shape as That is, each W-phase bus bar 54 has one W-phase arc-shaped portion 54 a having the same shape as one U-phase arc-shaped portion 52 a of the U-phase bus bar 52, and two U-phase connection portions 52 b of the U-phase bus bar 52. And two W-phase connection portions 54b having the same shape.

  15 to 18, the common bus bar 51, the U-phase bus bar 52, the V-phase bus bar 53, and the W-phase bus bar 54 have a common arc-shaped portion 51a, a U-phase arc-shaped portion 52a, and a V-phase arc-shaped portion 53a. And the W-phase arcuate portion 54a are stacked so as to overlap in the axial direction. The common arc-shaped portion 51a, the U-phase arc-shaped portion 52a, the V-phase arc-shaped portion 53a, and the W-phase arc-shaped portion 54a are arranged coaxially so that they are stacked without being displaced in the radial direction. In the present embodiment, the common bus bar 51 is arranged in the circumferential direction together with the three U-phase bus bars 52. That is, the common bus bar 51 has the same axial position as the three U-phase bus bars 52. The three U-phase bus bars 52 are arranged at 90 ° intervals in the circumferential direction and have the same axial height. Further, the common bus bar 51 is between the two U-phase bus bars 52 at the end of the three U-phase bus bars 52 arranged in the circumferential direction, and between the ones where the central U-phase bus bar 52 is not arranged. Further, the three U-phase bus bars 52 are arranged so as to have the same height in the axial direction. The three V-phase bus bars 53 are arranged at 90 ° intervals in the circumferential direction and have the same axial height. The three V-phase bus bars 53 are arranged so as to be shifted from the U-phase bus bar 52 by 30 ° in the circumferential direction. The three W-phase bus bars 54 are arranged at 90 ° intervals in the circumferential direction and have the same height in the axial direction. The three W-phase bus bars 54 are arranged so as to be offset by 60 ° in the circumferential direction with respect to the U-phase bus bar 52 and 30 ° in the circumferential direction with respect to the V-phase bus bar 53. Furthermore, the common connection part 51b, the U-phase connection part 52b, the V-phase connection part 53b, and the W-phase connection part 54b are shifted in the circumferential direction.

  In the bus bars 51 to 54 stacked on each other, the common arc-shaped portion 51a, the U-phase arc-shaped portion 52a, the V-phase arc-shaped portion 53a, and the W-phase arc-shaped portion 54a that are stacked in the axial direction are in close contact with each other. In the common arc-shaped portion 51a, the U-phase arc-shaped portion 52a, the V-phase arc-shaped portion 53a, and the W-phase arc-shaped portion 54a that are overlapped in the axial direction, the wire rods 14 that make up each of the common arc-shaped portions 51a are adjacent to each other in the axial direction. The matching insulating coatings 14b adhere to each other without being separated in the axial direction. Further, the common arc-shaped portion 51a, the U-phase arc-shaped portion 52a, the V-phase arc-shaped portion 53a, and the W-phase arc-shaped portion 54a that are overlapped are the common arc-shaped portion 51a, the U-phase arc-shaped portion 52a, the V-phase arc-shaped portion 53a, and the W-phase arc-shaped portion. The self-bonding layer 14c in 54a is integrated and fixed to each other. The common bus bar 51, the U-phase bus bar 52, the V-phase bus bar 53, and the W-phase bus bar 54 have the common arc-shaped portion 51a, the U-phase arc-shaped portion 52a, the V-phase arc-shaped portion 53a, and the W-phase arc-shaped portion 54a closely attached to each other. It is integrated by being fixed.

  The bus bar device 42 formed as described above is disposed at one end portion in the axial direction of the stator core 5 around which the coils U1 to U4, V1 to V4, and W1 to W4 are wound. The bus bar device 42 is arranged coaxially with the stator core 5. Furthermore, the through hole 17 of the common connection part 51b, the through hole 17 of the U phase connection part 52b, the through hole 17 of the V phase connection part 53b, and the through hole 17 of the W phase connection part 54b are coils U1 to U4 and V1 to V4. , W1 to W4 respectively correspond to the positions where the connection end portions 10 are pulled out.

  As shown in FIGS. 15 and 16, the through-hole 17 of the two U-phase connection portions 52 b of the U-phase bus bar 52 located on the clockwise side of the common bus bar 51 among the three U-phase bus bars 52 is formed in the through-hole 17. The one connection end 10 of the coil U1 and the one connection end 10 of the coil U2 are respectively inserted. In addition, the other connection end 10 of the coil U2 and one connection end of the coil U3 are inserted into the through holes 17 of the two U-phase connection portions 52b of the central U-phase bus bar 52 among the three U-phase bus bars 52. Each part 10 is inserted. Further, the other connection end 10 of the coil U3 and one connection end 10 of the coil U4 are inserted through the through holes 17 of the two U-phase connection portions 52b of the remaining U-phase bus bar 52, respectively.

  Similarly, as shown in FIG. 15 and FIG. 17, in the through holes 17 of the two V-phase connection parts 53 b of the V-phase bus bar 53 located on the clockwise side of the common bus bar 51 among the three V-phase bus bars 53. Is inserted through one connecting end 10 of the coil V1 and one connecting end 10 of the coil V2. In addition, the other connection end 10 of the coil V2 and one connection end of the coil V3 are inserted into the through holes 17 of the two V-phase connection bars 53b of the central V-phase bus bar 53 among the three V-phase bus bars 53. Each part 10 is inserted. Further, the other connection end 10 of the coil V3 and one connection end 10 of the coil V4 are inserted through the through holes 17 of the two V-phase connection portions 53b of the remaining V-phase bus bar 53, respectively.

  Similarly, as shown in FIGS. 15 and 18, through-holes of two W-phase connection portions 54 b of the W-phase bus bar 54 located on the clockwise side of the common bus bar 51 among the three W-phase bus bars 54. 17, one connection end 10 of the coil W1 and one connection end 10 of the coil W2 are respectively inserted. In addition, in the through hole 17 of the two W-phase connection portions 54b of the central W-phase bus bar 54 among the three W-phase bus bars 54, the other connection end 10 of the coil W2 and one connection end of the coil W3. Each part 10 is inserted. Further, the other connection end 10 of the coil W3 and one connection end 10 of the coil W4 are inserted through the through holes 17 of the two W-phase connection portions 54b of the remaining W-phase bus bar 54, respectively.

  Further, as shown in FIG. 15 and FIG. 16, the other connection end 10 of the coil U4, the other connection end 10 of the coil V4, and the through holes 17 of the three common connection portions 51b of the common bus bar 51 The other connection end 10 of the coil W4 is inserted.

  And the connection end part 10 inserted in the through-hole 17 of the common connection part 51b, the U-phase connection part 52b, the V-phase connection part 53b, and the W-phase connection part 54b is connected to the common connection part 51b and the U-phase connection part, respectively. 52b, V-phase connecting portion 53b and W-phase connecting portion 54b are electrically connected. As a result, as shown in FIG. 14, the U-phase coils U1 to U4 are connected in series by the U-phase bus bar 52, and the V-phase coils V1 to V4 are connected in series by the V-phase bus bar 53. W-phase coils W <b> 1 to W <b> 4 are connected in series by a W-phase bus bar 54. Further, the common bus bar 51 serves as a neutral point. The 12 coils U <b> 1 to U <b> 4, V <b> 1 to V <b> 4, and W <b> 1 to W <b> 4 are electrically connected to each other via the bus bar device 42 and are Y-connected by the bus bar device 42.

  The other connection end 10 of the coil U1, the other connection end 10 of the coil V1, and the other connection end 10 of the coil W1 that are not connected to the bus bar device 42 are AC power sources whose phases are shifted by 120 °. Are electrically connected to power supply terminals (not shown).

And the bus-bar apparatus 42 of this embodiment is manufactured through a peeling process, a formation process, a lamination process, and an integration process similarly to the bus-bar apparatus 22 of the said 2nd Embodiment.
As described above, the third embodiment has the following effects in addition to the same effects as (1) to (7) and (9) to (17) of the first embodiment.

(19) Twelve coils U1 to U4, V1 to V4, and W1 to W4 can be Y-connected by the bus bar device 42 in which a decrease in yield is suppressed and an increase in size is suppressed.
Each embodiment of the present invention may be modified as follows.

  -In each above-mentioned embodiment, when manufacturing bus bar devices 6, 22, and 42, a exfoliation process is performed before a forming process. However, the peeling process may be performed after the molding process. Further, the peeling step is not necessarily performed.

  In the integration process of the first embodiment, the bus bars 11 to 13 are energized in order to heat the bus bars 11 to 13. However, the method of heating the bus bars 11 to 13 in the integration step is not limited to energizing the bus bars 11 to 13. For example, the bus bars 11 to 13 may be heated by applying hot air to the stacked bus bars 11 to 13. If it does in this way, even if it is a case where the number of bus-bars 11-13 laminated | stacked on an axial direction is few, the bus-bars 11-13 can be heated easily. Further, for example, the bus bars 11 to 13 may be heated by placing the stacked bus bars 11 to 13 in a high-temperature bath maintained at a temperature at which the self-bonding layer 14c can be melted for a certain period of time. This also applies to the integration process of the second embodiment and the integration process of the third embodiment.

  In the integration process of the first embodiment, the U-phase arcuate portion 11a, the V-phase arcuate portion 12a, and the W-phase arcuate portion 13a that are overlaid by heating the bus bars 11 to 13 are fixedly fixed. However, the method for integrating the bus bars 11 to 13 is not limited to heating. For example, by applying varnish to the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a that are overlapped, the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a are applied by the varnish. May be tightly fixed. The varnish preferably has insulating properties. In place of the varnish, an insulating adhesive may be applied. Moreover, you may immerse the laminated | stacked bus bars 11-13 in a varnish. In this case, the varnish tends to adhere to the U-phase connection portion 11b, the V-phase connection portion 12b, and the W-phase connection portion 13b. When the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a are tightly fixed by varnish or adhesive, the wire rod 14 constituting the bus bars 11 to 13 includes a self-bonding layer 14c. It does not have to be. This also applies to the integration process of the second embodiment and the integration process of the third embodiment.

  In each of the above embodiments, the wire 14 for forming the bus bars 11 to 13, 31 to 34, 51 to 54 is bent or curved so as not to cross and overlap in the axial direction. However, the wire 14 may be bent or curved so as to form a portion that intersects and overlaps in the axial direction.

  In each of the above embodiments, the external shape of the self-bonding layer 14c in the cross section of the wire 14 is a square shape having sides with a length equal to the outer diameter of the insulating coating 14b. However, the outer shape of the self-bonding layer 14c in the cross section of the wire 14 is not limited to the shape of each of the above embodiments. For example, the outer shape of the self-bonding layer 14c in the cross section of the wire 14 may be a square shape having sides longer than the outer diameter of the insulating coating 14b. Further, the outer shape of the self-bonding layer 14c in the cross section of the wire 14 may be a circular shape, a polygonal shape, or the like.

  -In the bus-bar apparatus 6 of the said 1st Embodiment, the U-phase arcuate part 11a, the V-phase arcuate part 12a, and the W-phase arcuate part 13a are shape | molded by the arc shape of the same curvature. However, the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a have portions that overlap each other in the axial direction when the bus bars 11 to 13 are stacked, and are closely fixed to each other so that the bus bar 11 If it is the shape which can integrate ~ 13, you may shape in the circular arc shape of a mutually different curvature. The same applies to the bus bar device 22 of the second embodiment and the bus bar device 42 of the third embodiment.

  -You may comprise the bus-bar apparatus 6 of the said 1st Embodiment as shown in FIG. In the example shown in FIG. 19, in the stacked bus bars 11 to 13, the height in the axial direction of the surrounding portion 16 of the U-phase connecting portion 11 b, the surrounding portion 16 of the V-phase connecting portion 12 b, and the surrounding portion 16 of the W-phase connecting portion 13 b. Are all the same. If it does in this way, the height of the direction of an axis of the part to which connecting end part 10 is connected in bus bar device 6 will become constant. Therefore, when the connection end 10 is electrically connected to the U-phase connection 11b, the V-phase connection 12b, and the W-phase connection 13b, the connection end 10, the U-phase connection 11b, and the V-phase connection 12b. And the jig | tool for electrically connecting with the W-phase connection part 13b does not need to move along an axial direction. Moreover, even when the jig is moved along the axial direction, the amount of movement can be reduced. Therefore, the productivity of the stator 3 can be improved. Furthermore, the productivity of the brushless motor 1 can be improved. And it is good also as the same structure also in the bus-bar apparatus 22 of 2nd Embodiment, and the bus-bar apparatus 42 of 3rd Embodiment.

  In the U-phase bus bar 11 of the first embodiment, the U-phase connecting portion 11b is formed in a shape that protrudes radially outward from the U-phase arc-shaped portion 11a and has the through hole 17. However, the U-phase connecting portion 11b may be formed so as to protrude radially inward from the U-phase arcuate portion 11a. Further, the U-phase connecting portion 11b does not necessarily include the through hole 17. In this case, for example, the U-phase connecting portion 11b may be formed such that the shape viewed from the axial direction is a U-shape that opens radially inward or radially outward. This is because the common connection portions 31b and 51b of the common bus bars 31 and 51, the U phase connection portions 32b and 52b of the U phase bus bars 32 and 52, and the V phase connection portions 12b, 33b and 53b of the V phase bus bars 12, 33 and 53. The same applies to the W-phase connection portions 13b, 34b, 54b of the W-phase bus bars 13, 34, 54.

  In each of the above embodiments, the wire 14 may be the same wire as the conductor 9 that constitutes the coils U1 to U4, V1 to V4, and W1 to W4. In general, the conductive wire 9 is formed by covering a conductive core wire with an insulating insulating film. Therefore, when the bus bars (for example, the bus bars 11 to 13 of the first embodiment) are formed from the conductive wires 9, even if the bus bars come into contact with each other, they are not short-circuited with each other. Therefore, it is possible to reduce the size of the bus bar device.

  In the first embodiment, the U-phase arcuate portion 11a is shaped into an arc shape, but is not limited to an arc shape. The U-phase arc portion 11a may be formed in an arc shape. The “arc shape” is not limited to the arc shape, but includes a shape in which a plurality of portions of the wire are bent and shaped into a bow. The same applies to the common arc-shaped portions 31a and 51a, the U-phase arc-shaped portions 32a and 52a, the V-phase arc-shaped portions 12a, 33a, and 53a, and the W-phase arc-shaped portions 13a, 34a, and 54a.

  -In the bus-bar apparatus 6 of the said 1st Embodiment, the U-phase arcuate part 11a, the V-phase arcuate part 12a, and the W-phase arcuate part 13a are piled up in the axial direction. However, the U-phase arc-shaped portion 11a, the V-phase arc-shaped portion 12a, and the W-phase arc-shaped portion 13a may be formed so as to overlap and be fixed in a radial direction. The same applies to the bus bar device 22 of the second embodiment and the bus bar device 42 of the third embodiment.

  The brushless motors 1, 21 and 41 of the above-described embodiment are each configured with twelve coils U1 to U4, V1 to V4, and W1 to W4. However, the number of coils provided in the brushless motors 1, 21, 41 may be changed as appropriate. In this case, the number of bus bars constituting the bus bar devices 6, 22, and 42 is changed according to the number of coils and the way of connecting the coils.

  DESCRIPTION OF SYMBOLS 3 ... Stator, 4 ... Rotor, 6, 22, 42 ... Bus bar apparatus, 10 ... Connection end part as an end part of a coil, 11, 32, 52 ... U-phase bus bar as a bus bar, 11a, 32a, 52a ... Arc-shaped part U-phase arc-shaped portion as 11b, 32b, 52b ... U-phase connecting portion as connecting portion, 12, 33, 53 ... V-phase bus bar as bus bar, 12a, 33a, 53a ... V-phase arc-shaped portion as arc-shaped portion, 12b, 33b, 53b ... V-phase connection part as connection part, 13, 34, 54 ... W-phase bus bar as bus bar, 13a, 34a, 54a ... W-phase arc part as arc part, 13b, 34b, 54b ... connection W-phase connecting part as a part, 14 ... wire rod, 14a ... core wire, 14b ... insulating coating constituting the insulating layer, 14c ... self-bonding layer constituting the insulating layer, 16 ... end of the coil in the connecting part Enclosed part as a part to be connected, 17 through hole, 31, 51 ... common bus bar as bus bar, 31a, 51a ... common arced part as arc-shaped part, 31b, 51b ... common connecting part as connecting part, U1 U4, V1 to V4, W1 to W4 ... coils.

Claims (17)

A bus bar device for electrically connecting ends of a plurality of coils by a plurality of bus bars,
Each of the bus bars is formed of a wire formed by covering a conductive core wire with an insulating layer having an insulating property, and has an arc-shaped portion shaped into an arc shape,
The bus bar device, wherein the plurality of bus bars are integrated by overlapping the arc-shaped portions and fixing the arc-shaped portions to each other. The bus bar device according to claim 1,
Each bus bar is formed by bending or bending the wire rod so as to protrude in the radial direction from the arc-shaped portion, and has a connection portion for connecting the end portions of the coils. In the bus-bar apparatus of Claim 2,
The bus bar device, wherein the wire is a self-bonding electric wire. In the bus bar device according to claim 2 or claim 3,
The said connection part has a through-hole which can penetrate the edge part of the said coil, The bus-bar apparatus characterized by the above-mentioned. In the bus-bar apparatus of any one of Claim 2 thru | or 4,
The bus bar apparatus characterized in that the heights in the axial direction are the same in the portions to which the end portions of the coils in all the connection portions are connected. In the bus-bar apparatus of any one of Claim 2 thru | or 5,
All the bus bars are stacked in the axial direction so that the arc-shaped portions have the same curvature and the arc-shaped portions are coaxial. The bus bar device according to any one of claims 2 to 6,
The wire is composed of the core wire having a circular cross section, a cylindrical insulating film having insulation and covering the outer periphery of the core wire, and a self-bonding layer covering the outer periphery of the insulating film, and the wire An external shape of the self-bonding layer in the cross section is a square shape having a side having a length equal to the outer diameter of the insulating coating. The busbar device according to any one of claims 2 to 7,
Each of the bus bars is formed by bending or bending the wire material so that the wire material intersects and does not form a portion overlapping in the axial direction. The bus bar device according to any one of claims 2 to 8,
The plurality of bus bars include a U-phase bus bar in which each of the two adjacent connecting portions in the circumferential direction is formed at four positions that are 90 ° apart in the circumferential direction, and a V-phase having the same shape as the U-phase bus bar. A bus bar and a W-phase bus bar having the same shape as the U-phase bus bar,
The V-phase bus bar is laminated with a 30 ° shift in the circumferential direction with respect to the U-phase bus bar, and the W-phase bus bar is 60 ° in the circumferential direction with respect to the U-phase bus bar and with respect to the V-phase bus bar. The bus bar device is characterized in that the bus bars are stacked by being shifted by 30 ° in the circumferential direction, and the plurality of bus bars delta-connect 12 coils. The bus bar device according to any one of claims 2 to 8,
The plurality of bus bars include a common bus bar in which the connection portions are respectively formed at 12 positions that are spaced 30 ° in the circumferential direction, and the arc-shaped portion that is curved in an arc shape with the same curvature as the arc-shaped portion of the common bus bar. It has a U-phase bus bar in which the connection portions are formed at four locations that are 90 ° apart in the circumferential direction, a V-phase bus bar that has the same shape as the U-phase bus bar, and a W that has the same shape as the U-phase bus bar. With a phase bus bar,
The U-phase bus bar is disposed such that the connection portion of the U-phase bus bar is displaced in the circumferential direction with respect to the connection portion of the common bus bar, and the V-phase bus bar is disposed in the circumferential direction with respect to the U-phase bus bar. The V-phase bus bar is disposed so as to be displaced by 30 ° and the connection portion of the V-phase bus bar is displaced in the circumferential direction with respect to the connection portion of the common bus bar. The connection portion of the W-phase bus bar is arranged so as to be shifted by 60 ° and shifted in the circumferential direction by 30 ° with respect to the V-phase bus bar, and so as to be shifted in the circumferential direction with respect to the connection portion of the common bus bar. The bus bar device is characterized in that twelve coils are Y-connected. The bus bar device according to any one of claims 2 to 8,
The plurality of bus bars are composed of three U-phase bus bars formed by connecting two connecting portions separated by 75 ° with the arc-shaped arc-shaped portion, and three V-phase bus bars having the same shape as the U-phase bus bar. And three W-phase bus bars having the same shape as the U-phase bus bar, and three connecting portions provided at intervals of 30 ° in the circumferential direction are formed in an arc shape with the same curvature as the arc-shaped portion of the U-phase bus bar. A common bus bar connected by the curved arc-shaped portions;
The common bus bars are arranged in the circumferential direction together with the three U-phase bus bars, the three U-phase bus bars are arranged at 90 ° intervals in the circumferential direction, and the three V-phase bus bars are arranged at 90 ° intervals in the circumferential direction. And the three W-phase bus bars are arranged at 90 ° intervals in the circumferential direction and circumferentially with respect to the U-phase bus bar. 60 ° and 30 ° shifted in the circumferential direction with respect to the V-phase bus bar, the connection portion of the common bus bar, the connection portion of the U-phase bus bar, the connection portion of the V-phase bus bar, and the W-phase The bus bar device is characterized in that the connecting portion of the bus bar is shifted in the circumferential direction, and the plurality of bus bars are Y-connected to the 12 coils.   A stator comprising: a plurality of coils arranged in a circumferential direction; and the bus bar device according to any one of claims 1 to 11, which electrically connects ends of the coils. A stator formed by electrically connecting ends of a plurality of coils arranged in the circumferential direction with the bus bar device according to any one of claims 1 to 11.
A brushless motor comprising a rotor disposed inside the stator. A method of manufacturing a bus bar device according to any one of claims 2 to 11,
Forming the busbar by forming the arc-shaped portion and the connecting portion by bending or bending the wire; and
A laminating step of laminating a plurality of the bus bars so that the arc-shaped portions of each other overlap;
A method of manufacturing a bus bar device, comprising: an integrating step in which the plurality of bus bars are integrated by closely fixing the arc-shaped portions stacked. In the manufacturing method of the bus-bar apparatus of Claim 14,
The insulating layer is composed of an insulating insulating coating that covers the outer periphery of the core wire, and a self-bonding layer that covers the outer periphery of the insulating coating,
In the integration step, the bus bar is heated to melt the self-bonding layer, and the stacked arc-shaped portions are closely fixed by the melted self-bonding layer. . In the manufacturing method of the bus-bar apparatus of Claim 15,
In the integration step, the bus bar device is heated by energizing the bus bar. In the manufacturing method of the bus-bar apparatus of any one of Claim 14 thru | or 16,
A method of manufacturing a bus bar device, comprising: a peeling step of peeling off the insulating layer at a portion to be the connecting portion in the wire before the forming step.

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