JP6995102B2 - Rotating machine and manufacturing method of rotating machine - Google Patents

Description

The present application relates to a rotary electric machine and a method for manufacturing the same.

In a rotary electric machine, a power supply terminal for supplying power to the coil of an armature and a connection plate feeding part are joined by TIG welding, but in this case, heat input tends to increase because the base metal is melted and joined. , The insulating coating on the conductor surface is easily damaged. Therefore, the joint portion is made of an alloy of a conductor and a joining member having a low melting point, and the conductors are joined to each other.

Even in such a junction having a low melting point, the heat input is locally large, so it is necessary to increase the contact area between the power supply terminal and the connection plate feeding portion. Further, since there is a problem that the welding is displaced if the position of the component fitting portion to be joined at the time of welding is displaced, a structure is adopted in which the position of the fitting portion is held by a method such as press fitting or caulking. (For example, Patent Document 1)

JP-A-2007-31123 (pages 7-8, FIG. 3)

In the connection structure of the feeding portion as shown in Patent Document 1, the direction in which the displacement is possible with respect to the bent portion is only one direction, and it is difficult to sufficiently absorb the variation in the mounting dimensions with respect to the two directions perpendicular to the direction. Therefore, it is necessary to improve the accuracy of the component dimensions and the assembly dimensions in directions other than the misalignment absorption direction, which increases the cost. Further, since the bent portion has lower rigidity than other portions, there is a problem that it is difficult to provide vibration resistance as a system.

This application has been made to solve the above-mentioned problems, and absorbs variations in component dimensions and assembly dimensions when the connection plate feeding unit, which is a lead conductor, and the power supply terminal connected to the feeding terminal are connected. It is an object of the present invention to obtain a rotary electric machine having a connection structure of a power feeding unit capable of being capable of being formed and a method for manufacturing the same.

The rotary electric machine disclosed in the present application is a connection plate having a feeding protrusion that distributes a current to a plurality of coils arranged around the rotary shaft and extends in the axial direction of the rotary shaft to take in an electric current from the outside. And a terminal that feeds power to the connection plate through a fitting portion that is fitted in a clearance state to the power supply protrusion of the connection plate that extends in the radial direction of the rotation shaft. The fitting portion has a radial protrusion portion that is sandwiched and fitted from both sides by the circumferential end portions of the rotation shaft of the power feeding protrusions provided , and slits opened at both ends in the circumferential direction. It has a shaped opening .

According to the present application, a wiring plate having a power feeding protrusion that distributes a current to a plurality of coils arranged around a rotating shaft and extends in the axial direction of the rotating shaft to take in an external current, and the rotation. Positioning only by uniting parts by providing a terminal that overhangs in the radial direction of the shaft and supplies power to the connection plate through a fitting portion fitted to the power supply protrusion of the connection plate in a crevice-fitted state. Therefore, it is possible to absorb variations in component dimensions and assembly dimensions when the connection plate and the terminal are connected.
Further, since the fitting portion of the terminal has radial protrusions fitted from both sides by the circumferential ends of the plurality of power feeding protrusions, the positional deviation between the connection plate and the terminal in the circumferential direction is prevented. can do.

It is a schematic diagram which shows the cross section of the rotary electric machine which concerns on Embodiment 1 of this application. It is a perspective view which shows the whole armature of the rotary electric machine which concerns on Embodiment 1 of this application. It is a perspective view which shows the coil of the rotary electric machine which concerns on Embodiment 1 of this application. It is a figure which shows the bobbin of the rotary electric machine which concerns on Embodiment 1 of this application, (A) is a perspective view, (B) is a plan view, (C) is a side view. It is a perspective view and a partially enlarged view which shows the connection plate of the rotary electric machine which concerns on Embodiment 1 of this application. It is a perspective view which shows the manufacturing process of the armature of the rotary electric machine which concerns on Embodiment 1 of this application. It is a perspective view which shows the manufacturing process of the armature of the rotary electric machine which concerns on Embodiment 1 of this application. It is a schematic diagram which shows the manufacturing process of the armature of the rotary electric machine which concerns on Embodiment 1 of this application. It is a perspective view which shows the manufacturing process of the armature of the rotary electric machine which concerns on Embodiment 1 of this application. It is a schematic diagram which shows the fixing method of the connection plate of the rotary electric machine which concerns on Embodiment 1 of this application. It is a perspective view which shows the terminal of the rotary electric machine which concerns on Embodiment 1 of this application. It is a perspective view which shows the fitting part of the connection plate and the terminal of the rotary electric machine which concerns on Embodiment 1 of this application. It is sectional drawing which shows the fitting part of the terminal of the rotary electric machine which concerns on Embodiment 1 of this application. It is sectional drawing which shows the fitting part of the terminal of the rotary electric machine which concerns on Embodiment 2 of this application. It is sectional drawing which shows the connection method of the connection plate of the rotary electric machine which concerns on Embodiment 3 of this application, and a terminal.

Embodiment 1.
FIG. 1 is a schematic view showing a cross section of a rotary electric machine according to the first embodiment of the present application. In FIG. 1, the rotary electric machine 100 includes a housing 210 composed of a bottomed cylindrical frame 211 and an end plate 212 that closes an opening of the frame 211, and an armature fixed to the cylindrical portion of the frame 211 in an inner fitting state. The 300, the bottom of the frame 211, and the end plate 212 are rotatably supported via a bearing 201, and are provided with a rotor 400 arranged on the inner peripheral side of the armature 300.

The armature 300 is composed of a plurality of coils 310 that generate magnetic flux, a connection plate 320 that distributes current to the plurality of coils 310, and an iron core 330 that allows magnetic flux to flow. The coil 310 and the iron core 330 are electrically formed by a bobbin 311. Insulated in.

The rotor 400 is, for example, a permanent magnet type rotor, and is embedded in a cylindrical rotor core 402 in which the axial center position is inserted into the rotating shaft 401 and on the outer peripheral surface side of the rotor core 402. It is provided with a permanent magnet 403 arranged at a predetermined pitch in the circumferential direction to form a magnetic pole. The rotor 400 is not limited to such a permanent magnet type rotor, and a so-called cage type rotor, winding type rotor, or the like may be used.

FIG. 2 is a perspective view showing the entire armature 300 of the rotary electric machine according to the first embodiment. As shown in FIG. 2, the armature 300 is formed in an annular shape by arranging a coil 310 composed of an iron core 330 divided in the circumferential direction and a conductor wire wound around each iron core 330 at equal pitches. Further, a terminal 340 is held on the outer peripheral surface of the frame 211 corresponding to the case of the armature 300 in the vicinity of the connection plate 320, and power is supplied to the connection plate 320 from the outside.

Further, three wiring plates 320 are provided for each of the three phases, and are connected to the coils 310 of each phase. Further, as shown in FIG. 2, three terminals 340 are provided corresponding to the connection to the three connection plates 320.

FIG. 3 shows a perspective view of the coil 310. As shown in FIG. 3, a yoke 332 for connecting the teeth 331 and the teeth 331 in the circumferential direction on the outer diameter side is provided, the iron core 330 is formed by laminating a plurality of steel plates, and the iron core 330 is composed of insulating materials at both ends. It has a coil 310 into which a bobbin 311 is inserted and a conductor wire with an insulating coating is wound. This conductor wire may be a copper wire or an aluminum wire. The iron core 330 is divided into the same number as the teeth 331 in the circumferential direction by the yoke 332. In the first embodiment, an iron core divided in the circumferential direction is used, but all the iron cores 330 may be an integral core connected by a yoke 332, or the yokes 332 may be connected by a thin wall to form a straight line. It may be an iron core that can be deployed.

As shown in FIG. 3, one tooth 331 is provided with a sheet-shaped slot cell 313 made of polyphenylene sulfide resin or meta-aramid fiber that electrically separates the coil 310 and the iron core 330, and bobbins 311 are attached to both ends of the iron core 330. By inserting it, it is fixed and insulation assembly is performed. The slot cell 313 may be fixed by attaching double-sided tape to the side surface of the iron core 330.

As shown in FIG. 4, the bobbin 311 includes a body portion 315 around which the coil 310 is wound and a wall portion 316 for arranging the conductor wire at a predetermined position. A holder portion 317 provided with a comb-shaped support wall 317a so as to support the connection plate 320 on the yoke 332 side of the wall portion 316, and an adhesive for fixing the connection plate 320 are stored in the lower portion of the holder portion 317. There is a container-shaped groove 318. The groove portion 318 is provided between the support wall 317a of the holder portion 317 in the circumferential direction of the rotating shaft 401, and is formed in a container shape by providing partition walls 317b at both ends in the circumferential direction. In the first embodiment, the holder portion 317 is arranged on the yoke 332 side, but may be arranged on the rotor 400 side in consideration of mountability on a vehicle.

FIG. 5 shows an overall view of the connection plate 320 of the first embodiment and an enlarged view of a part thereof. The connection plate 320 is formed by punching a strip-shaped guiding material with a press. When the connection plate 320 is held by the holder portion 317 of the bobbin 311 as shown in FIG. 5, the connection plate 320 is formed into an annular shape in which a band-shaped guiding material is partially opened. Further, the connection plate 320 has a coil power distribution portion 321 and a coil power distribution portion 321 to be joined to the conductor wire of the coil 310 at the upper end portion in the drawing with respect to the main body portion in which the strip-shaped conductor is molded in an annular shape. A power feeding protrusion 322 to which electric power is supplied is provided. The coil power distribution unit 321 and the power supply protrusion 322 are protrusions that are pulled out from the main body of the connection plate 320 in the axial direction of the rotary shaft 401. As shown in the figure, the power feeding protrusion 322 of the first embodiment is provided with two protrusions adjacent to each other, and a concave shape is provided between the two protrusions. Further, the tip of each protrusion is chamfered so that it can be easily inserted into the opening 341 provided in the terminal 340 described later or the radial protrusion 342 provided between the openings 341 can be easily sandwiched. ing.

On the other hand, in the main body portion of the connection plate 320, a protruding portion 323 to be coupled to the bobbin 311 is provided on the opposite side of the rotating shaft 401 in the axial direction. The protruding portion 323 is provided with a pull-out prevention portion 324 protruding on both sides of the connection plate 320 in the longitudinal direction.

The manufacturing process of the armature 300 will be described with reference to FIGS. 6 to 9. FIG. 6 shows a state in which iron cores 330 having coils 310 are arranged in an annular shape. The iron core 330 is press-fitted into the frame 211 and integrated as shown in FIG. 7. Here, in order to integrate them, a method such as welding or adhering the iron cores 330 to each other may be used.

After integrating the iron core 330, the adhesive 500 is injected into the container-shaped groove 318 of the bobbin 311 using the nozzle 501 as shown in FIG. After that, as shown in FIG. 9, the connection plate 320 is rolled into an annular shape, and the protruding portion 323 is inserted so as to be immersed in the adhesive 500 stored in the groove portion 318. FIG. 10 shows the states of the groove portion 318, the protrusion portion 323, and the adhesive 500 at this time. In this way, the connection plate can be fixed corresponding to a plurality of coils arranged in the circumferential direction of the rotating shaft.

FIG. 11 shows a perspective view of the terminal 340 of the first embodiment. Further, FIG. 12 shows a perspective view showing a state in which the terminal 340 is attached to the feeding protrusion 322 to the fitting portion 350 of the terminal 340. As shown in FIGS. 11 and 12, the terminal 340 is bent at the broken line portion in the drawing, and is axially oriented (not shown because it overlaps) the cylindrical frame 211 (not shown because it overlaps) on the feeding side. A feeding side connection portion 343 to which a feeding line from the outside is connected is provided on the surface extending in the direction). Further, a fitting portion 350 that fits with the feeding protrusion 322 of the connection plate 320 is provided on the surface extending in the radial direction of the other rotating shaft 401.

Further, the fitting portion 350 to the connecting plate 320 is provided with a slit-shaped opening 341. The opening 341 is provided for fitting the feeding protrusion 322 by inserting it into the opening.

Further, in the first embodiment, the opening 341 of the terminal 340 is in the width direction of the terminal 340, corresponding to the configuration in which the protrusion 322 for feeding is arranged so as to be adjacent to each other. Two notches are provided from both end portions, and the width of the terminal 340 is narrowed between the two openings 341, and the portion extends radially in the rotation shaft 401. A radial protrusion 342 is provided.

Further, in the longitudinal direction of the opening 341, there are circumferential beam portions 341a and 341b extending in the circumferential direction of the rotary shaft 401, and the circumferential beam portions 341a on the inner side and the outer side in the radial direction of the rotary shaft 401. The peripheral beam portion 341b sandwiches the surface extending in the circumferential direction of the power feeding protrusion 322 from both sides so as to restrain the radial deviation of the connection plate 320.

Further, the width between the two openings 341 of the terminal 340, that is, the width of the radial protrusion 342 described above, so that the opening 341 of the terminal 340 and the feeding protrusion 322 can be fitted to each other. The distance between the two protrusions of the power feeding protrusion 322 is designed to be the same, and the width of each opening 341 in the lateral direction and the thickness (plate thickness) of the feeding protrusion 322 are also designed to be the same. ..

FIG. 13 is a cross-sectional view of the fitting portion 350 of the terminal 340 as seen from above in FIG. As shown in the figure, power is supplied in a state where two protrusions provided adjacent to the rotation shaft 401 of the power feeding protrusion 322 in the circumferential direction are inserted into two openings 341 configured in the radial direction of the terminal 340. The terminal 340 is attached to the protrusion 322. The connection plate 320 and the terminal 340 have the above-mentioned radial protrusion 342 between the two openings 341 of the terminal 340 of the two feeding protrusions 322 due to the dimensional relationship between the opening 341 and the feeding protrusion 322. It is sandwiched from both sides at the end in the circumferential direction, and is fitted in the circumferential direction. On the other hand, in the thickness direction of the feeding protrusion 322, the circumferential beam portions 341a and 341b are sandwiched from both sides in the radial direction in the slit-shaped opening 341 of the terminal 340, and are fitted in the radial direction. In this way, the terminal 340 is in a state where the movement in the radial direction and the circumferential direction on the rotating shaft 401 is restricted. That is, the terminal 340 is fixed to the feeding protrusion 322 by inserting and fitting the feeding protrusion 322 into the opening 341 of the terminal 340.

By adopting the structure of the feeding portion of the first embodiment as described above, the feeding protrusion 322 is inserted into the opening 341 of the terminal 340 and fitted, so that the terminal 340 is assembled to the connection plate 320. In addition to being able to prevent the rotational shaft 401 from being displaced in the radial direction while ensuring ease of assembly, it is also possible to prevent the rotational shaft 401 from being displaced in the circumferential direction.

Further, in the feeding protrusion of the first embodiment, as shown in FIG. 13, there is a gap between the opening 341 in the fitting portion 350 of the terminal 340 and the feeding protrusion 322 to be inserted. It is fitted in a crevice-fitted state provided with. It has a structure that is not adhesively fixed by welding or adhesive, and is positioned only by fitting parts. In this way, in the feeding protrusion 322, by providing a gap between the fitting portion 350 of the terminal 340 and the feeding protruding portion 322, a configuration in which positioning is performed only by fitting the parts is adopted, and the component dimensions vary. It is possible to obtain a structure that can absorb even if the position shift occurs.

In the first embodiment, the configuration in which two openings 341 are provided in the terminal 340 and the two power feeding protrusions 322 are inserted and fitted is described, but the circumferential direction of the connection plate 320 is described. In order to prevent deviation, it is possible to provide a radial protrusion 342 which is a portion of the rotating shaft 401 that protrudes and extends in the radial direction. That is, in FIG. 13, even if the circumferential beam portions 341a and 341b that project in the circumferential direction are not provided, only the radial projecting portion 342 that is a portion that protrudes in the radial direction and extends is arranged and two power supplies are supplied. The configuration may be changed so that the radial protruding portion 342 is sandwiched from both sides in the circumferential direction by the circumferential end portion of the protruding portion of the protruding portion 322. With this configuration, it is possible to prevent at least a circumferential deviation.

Embodiment 2.
The method of connecting the power feeding unit according to the second embodiment is the same as that described in FIGS. 1 to 13 of the first embodiment in the method of connecting the power feeding protrusion 322 and the terminal 340. In the second embodiment, the unevenness of the fitting portion 350 is increased to ensure the positioning accuracy and the reliability of the connection of the fitting portion 350.

FIG. 14 is a diagram showing a fitting portion 350 of the feeding portion according to the second embodiment, and is a cross-sectional view schematically showing a cross section of the fitting portion 350 of the feeding portion 322 and the terminal 340. In the second embodiment, as shown in FIG. 14, the number of protrusions of the power feeding protrusion 322 is changed from two to three in the first embodiment, and the opening 341 provided in the terminal 340 into which these protrusions are inserted is provided. Is also changed from two to three, and the radial protrusion 342 formed between the openings 341 is changed from one to two in the first embodiment.

With the above configuration, the fitting portion 350 of the terminal 340 has more fitting portions with the protruding portion 322 for feeding, and the positioning can be further ensured. In addition, the connection area is increased, the vibration resistance of the fitting portion 350 can be enhanced, the thermal influence can be dispersed, and the reliability at the time of connection can be further improved.

It should be noted that the number of protrusions 322 for feeding is not limited to two or three, but four or more protrusions may be formed at a level at which connection is possible.

On the contrary, it is also possible to have one protruding portion of the feeding protrusion 322. In that case, the protruding portion of the feeding protruding portion 322 is sandwiched from both sides of the opening 341 provided in the terminal 340. It is preferable to provide an opening 341 having a closed opening shape instead of the notch-shaped opening shape as in the first embodiment so as to restrict the movement in the circumferential direction. As a result, two radial protrusions 342, which are portions extending in the radial direction of the rotation shaft 401, are provided on both sides of the opening 341, and the protrusions of the power feeding protrusion 322 are sandwiched from both sides. It is possible to regulate the movement in the circumferential direction with. Further, by inserting and fitting the protrusion 322 for feeding into the opening 341, the circumferential beam portions 341a and 341b are configured on both sides of the opening 341 in the radial direction, and the movement in the radial direction is formed. Is also regulated, so that the same effect as that of the first embodiment can be obtained.

Embodiment 3.
The shape of the fitting portion 350 between the connection plate 320 and the terminal 340 in the method of connecting the feeding portion according to the third embodiment is the same as that described with reference to FIGS. 1 to 14 of the first embodiment and the second embodiment. .. The third embodiment is characterized in that the connection portion is further heated and melted to ensure the connection.

FIG. 15 is a diagram showing a method of connecting the feeding portion projecting portion 322 and the fitting portion 350 of the terminal 340 according to the third embodiment, and is a side sectional view of FIG. 12 as viewed in the A direction. The protrusion of the feeding protrusion 322, which protrudes axially from the opening 341 of the terminal 340, includes the opening 341 by a heating means capable of applying energy over a wide range, for example, a gas burner or arc welding. By heating and melting the parts and welding them with the melting part 360, it is possible to connect more firmly and at the same time, it is possible to reduce the electric resistance, so that the energy loss can be reduced. Therefore, by applying this method of connecting the feeding unit as a method of manufacturing the rotary electric machine, it is possible to improve the characteristics of the motor.

Further, by supplying the raw material to the molten portion at the time of heating and melting, the molten raw material melts into the gap between the opening 341 of the terminal 340 and the protruding portion of the feeding protrusion 322, and both are welded more firmly. Can be fixed. Therefore, the electric resistance value can be further reduced.

As described above, according to the method of connecting the feeding portion of the third embodiment, the protruding portion of the feeding portion 322 protruding in the axial direction from the fitting portion 350 is heated and melted and welded. It can be connected more firmly, and the electrical resistance can be reduced to reduce the loss.

Further, since the brazing material is supplied to the vicinity of the melting portion at the time of heating and melting, the molten brazing material melts into the fitting portion 350 and is welded, so that the fitting portion 350 can be more firmly fixed and connected.

Although the present application describes various exemplary embodiments and examples, the various features, embodiments, and functions described in one or more embodiments are applications of a particular embodiment. It is not limited to, but can be applied to embodiments alone or in various combinations. Therefore, innumerable variations not illustrated are envisioned within the scope of the techniques disclosed herein. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments.

100 rotary machine, 201 bearing, 210 housing, 211 frame, 212 end plate, 300 armature, 310 coil, 311 bobbin, 313 slot cell, 315 body, 316 wall, 317 holder, 317a support wall, 317b partition, 318 groove part, 320 connection plate, 321 coil power distribution part, 322 power supply protrusion part, 323 protrusion part, 324 disconnection prevention part, 330 iron core, 331 teeth, 332 yoke, 340 terminal, 341 opening, 341a circumferential beam part, 341b Circumferential beam part, 342 radial protrusion part, 343 feeding side connection part, 350 fitting part, 360 melting part, 400 rotor, 401 rotating shaft, 402 rotor core, 403 permanent magnet, 500 adhesive, 501 nozzle

Claims (10)

A connection plate having a feeding protrusion that distributes current to a plurality of coils arranged around the rotating shaft and extends in the axial direction of the rotating shaft to take in current from the outside.
A terminal that feeds power to the connection plate through a fitting portion that extends in the radial direction of the rotation shaft and is fitted to the power supply protrusion of the connection plate in a clearance state.
Equipped with
The fitting portion of the terminal has radial protrusions that are sandwiched and fitted from both sides by the circumferential ends of the rotation shaft of the plurality of feeding protrusions , and both ends in the circumferential direction. A rotary electric machine with a slit-shaped opening that opens to the surface . The first aspect of claim 1, wherein the fitting portion of the terminal is provided with a plurality of radial protrusions extending in the radial direction, and is fitted to the feeding protrusions protruding in the axial direction of the connection plate. Rotating electric machine. The rotary electric machine according to claim 1 or 2, wherein the fitting portion of the terminal has a circumferential beam portion fitted so as to be in contact with a surface extending in the circumferential direction of the feeding protrusion. The rotary electric machine according to any one of claims 1 to 3, wherein the fitting portion has an opening, and the feeding protrusion of the connection plate is inserted into the opening. The rotary electric machine according to any one of claims 1 to 4, wherein the fitting portion and the feeding protrusion are fitted at a plurality of places. The connection plate is provided with two feeding protrusions extending in the axial direction, and the fitting portion of the terminal has two openings arranged in a slit shape, and the two feeding protrusions are provided. The rotary electric machine according to claim 1, wherein the portion and the two openings are fitted to each other. The rotary electric machine according to any one of claims 1 to 6, wherein the fitting portion and the feeding protrusion are welded together. The rotary electric machine according to claim 7, wherein the fitting portion and the feeding protrusion are welded together with a brazing material. A wiring plate having a power feeding protrusion that distributes current to a plurality of coils arranged around the rotating shaft and is extended in the axial direction of the rotating shaft to take in current from the outside, and in the radial direction of the rotating shaft. It is provided with a terminal for supplying power to the connection plate through a fitting portion fitted in a clearance state to the power supply protrusion of the connection plate.
The fitting portion of the terminal has radial protrusions that are sandwiched and fitted from both sides by the circumferential ends of the rotation shaft of the plurality of feeding protrusions , and both ends in the circumferential direction. It is a method of manufacturing a rotary electric machine having a slit-shaped opening that is open to the outside .
A process of arranging iron cores having a plurality of the coils in an annular shape and press-fitting them into a frame to integrate them.
The process of rolling the connection plate into an annular shape and adhering it to the container-shaped groove of the bobbin inserted at both ends of the iron core.
The process of connecting the connection plate and the plurality of the coils, and
The step of fitting the power feeding protrusion of the connection plate to the fitting portion of the terminal, and
A method of manufacturing a rotary electric machine equipped with. The method for manufacturing a rotary electric machine according to claim 9, further comprising a step of welding the fitting portion and the feeding protrusion.

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