WO2012070752A1

WO2012070752A1 - Bus bar housing of motor having improved work efficiency and method of wiring coils using the same

Info

Publication number: WO2012070752A1
Application number: PCT/KR2011/006507
Authority: WO
Inventors: Jeong Cheol Jang; Je Hyung Seo; Hugh Jin Cho
Original assignee: New Motech Co Ltd
Current assignee: New Motech Co Ltd
Priority date: 2010-11-22
Filing date: 2011-09-02
Publication date: 2012-05-31
Anticipated expiration: 2013-05-22
Also published as: KR101146440B1

Abstract

A bus bar housing according to the present invention includes a ring-shaped main body 10; a plurality of bus bar insertion grooves 11 sequentially formed in a radial direction in the upper part of the main body and configured to have a bus bar 20 inserted therein; and a plurality of coil guide grooves 13 formed along the outer circumferential surface of the main body 10.

Description

BUS BAR HOUSING OF MOTOR HAVING IMPROVED WORK EFFICIENCY AND METHOD OF WIRING COILS USING THE SAME

The present invention relates to a motor and, more particularly, to a motor having an easy work by introducing a bus bar housing of a new structure for the wiring of the coils of the motor.

In general, a motor, particularly, a brushless motor for vehicles has a parallel connection structure of 3 (U, V, and W) phases. The I/O terminals of the 3 phases are electrically connected to a ring-shaped bus bar, and the ends of coils wound on stator cores are wired with the respective connection taps of the bus bar.

The wiring structure of the coils using the bus bars is disclosed in Korean Patent Unexamined Publication Nos. 10-2008-0068437, 10-2010-46922, and 10-2010-0059548. The conventional bus bar structures have a problem in that a work is difficult because the end of each of coils must be connected to each of the connection taps of the bus bar in the state in which a plurality of stator cores is upwardly protruded.

More particularly, in the case of the disclosure No. 10-2008-0068437, electrical wiring is performed by inserting the end of the coil, disposed upwardly, into a coil insertion hole formed in the bus bar. In this case, when the end of the coil is inserted into the hole, the ends of some coils that have not been inserted generate interference. It is thus difficult to insert the ends of a plurality of the coils into the respective holes at the same time. Furthermore, in the disclosure Nos. 10-2010-46922 and 10-2010-0059548, the connection taps of the bus bar must be connected in the state in which the ends of the coils are upwardly protruded. Accordingly, a work is very difficult, and there is a possibility that the coil is erroneously wired with other connection tap.

The inventors of the present invention propose a bus bar housing of a new structure and a method of wiring coils using the same in order to improve work efficiency.

It is an object of the present invention to provide a bus bar housing having improved work efficiency when coils are wired.

It is another object of the present invention to provide a bus bar housing capable of preventing cross by providing accurate wiring when coils are wired.

All the above and other objects of the present invention can be achieved by the present invention to be described below.

A bus bar housing according to an embodiment of the present invention includes a ring-shaped main body 10; a plurality of bus bar insertion grooves 11 sequentially formed in a radial direction in the upper part of the main body and configured to have a bus bar 20 inserted therein; and a plurality of coil guide grooves 13 formed along the outer circumferential surface of the main body 10.

In the present invention, the bus bar housing may further include a plurality of connection tap guides 12 formed between the bus bar insertion grooves 11 and the outer circumferential portion of the main body 10 and placed on the same radius line with the coil guide grooves 13.

A bus bar housing according to another embodiment of the present invention includes a ring-shaped main body 10; a plurality of bus bar insertion grooves 11 sequentially formed in a radial direction in the upper part of the main body and configured to have a bus bar 20 inserted therein; and a plurality of coil guide grooves 13 formed along the inner circumferential surface of the main body 10.

In another embodiment of the present invention, the bus bar housing may further include a plurality of connection tap guides 12 formed between the bus bar insertion grooves 11 and an inner circumferential portion of the main body 10 and placed on an identical radius line with the coil guide grooves 13.

A method of wiring coils using a bus bar housing according to yet another embodiment of the present invention includes the steps of bending the coils wound on a stator assembly; coupling the bus bar housing, having coil guide grooves formed therein, over the stator assembly; bending the coils along the coil guide grooves; and connecting ends of the coils to respective connection taps of a bus bar coupled within the bus bar housing.

A bus bar housing and a method of wiring coils using the same according to the present invention are advantageous in that they can improve productivity by facilitating a work when coils are wired and prevent cross due to a mistake in a work.

FIG. 1 is a perspective view showing the structure of a bus bar housing according to the present invention;

FIG. 2 is a front view showing the structure of the bus bar housing according to the present invention;

FIG. 3 is a perspective view showing a state in which bus bars have been inserted into the bus bar housing according to the present invention;

FIG. 4 is a perspective view showing a first step of a method of wiring coils using the bus bar housing according to the present invention;

FIG. 5 is a perspective view showing a second step of a method of wiring coils using the bus bar housing according to the present invention; and

FIG. 6 is a perspective view showing a third step of a method of wiring coils using the bus bar housing according to the present invention.

Some embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a perspective view showing the structure of a bus bar housing according to the present invention, and FIG. 2 is a front view showing the structure of the bus bar housing according to the present invention.

As shown in FIGS. 1 and 2, the bus bar housing 1 according to the present invention includes a main body 10, a bus bar insertion groove 11, connection tap guides 12, coil guide grooves 13, and coupling protrusions 14.

The main body 10 is chiefly made of plastic resin material and fabricated by ejection molding. The main body 10 chiefly has a circular empty shape. The bottom of the main body 10 is seated on the top of a stator assembly 30 (refer to FIG. 4) and coupled thereto.

A plurality of the bus bar insertion grooves 11 is formed, if necessary. In FIGS. 1 and 2, for 3-phase parallel wiring, four grooves are formed for the 3-phases u, v, and w and neutral point wiring. The four grooves include first to fourth bus

bar insertion grooves

111, 112, 113, and 114. The first to fourth bus bar insertion grooves are electrically insulated from respective neighboring bus bar insertion grooves. The first to fourth bus bar insertion grooves are formed by resin molding and are sequentially formed in a radial outside direction from an upper inside of the main body 10 so that they have an increasing diameter.

A plurality of connection taps 21 (refer to FIG. 3) formed in a bus bar 20 (refer to FIG. 3) is placed in the connection tap guides 12. The connection taps 21 are seated in and fixed to the respective connection tap guides 12. The connection tap guides 12 function to fix the connection taps 21. If the connection tap 21 has a structure not requiring fixing, the connection tap guides 12 may not be formed in the bus bar housing 1. The connection tap guides 12, as shown in FIGS. 1 and 2, are formed on in the outer circumferential portion of the bus bar insertion grooves 11. If the coil guide grooves 13 are formed in the inner circumferential portion of the main body as will be described below, however, the connection tap guides 12 are placed toward the inner circumferential portions of the bus bar insertion grooves 11. Meanwhile, it is preferred that like the bus bar insertion grooves 11, the connection tap guides 12 be formed by resin molding when the main body 10 is ejected.

The coil guide grooves 13 are portions through which respective coils pass. In FIGS. 1 and 2, the plurality of coil guide grooves 13 is formed on the outer circumferential surface of the main body 10. The coils wound on the stator assembly are bent toward the inside of the main body 10 along the coil guide grooves 13 and then coupled to the respective connection tap 21. For this connection, the connection tap 21 is placed at a portion corresponding to the coil guide groove 13, that is, on the same radius line.

Meanwhile, in FIGS. 1 and 2, the coil guide grooves 13 are illustrated to be formed on the outer circumferential surface of the main body 10, but may be formed along the inner circumferential surface of the main body 10, if necessary. In this case, the coil is bent through the inside of the main body and then connected to the connection tap 21 of the connection tap guide 12 formed in the inside of the coil guide groove 11 of the coil guide groove 13.

The plurality of coupling protrusions 14 is formed at the bottom of the bus bar housing 1 and, preferably, three coupling protrusions 14 are formed. The coupling protrusions 14 function to fix the bus bar housing 1 to the top of the stator assembly 30. It is preferred that the coupling protrusions 14, together with the main body 10, be formed by resin molding when the main body 10 is ejected.

FIG. 3 is a perspective view showing a state in which the bus bars 20 have been inserted into the bus bar housing 10 according to the present invention.

Each of the bus bars 20 includes the plurality of connection taps 21. FIG. 3 shows four bus bars for u, v, and w phases and a neutral point. For convenience of description, the bus bar of each of the phases and the connection tap are assigned

reference numerals

20 and 21, respectively.

The bus bar of each phase includes the plurality of connection taps 21 and I/O terminal units 22. The bus bar 20 is inserted into the bus bar insertion groove 11 and fixed thereto. The connection tap 21 is placed in the connection tap guide 12 of the main body 10. The coil guided along the coil guide groove 13 is connected to the connection tap 21. FIG. 3 shows a state in which the coil guide grooves 13 are formed along the outer circumferential surface of the main body 10. Accordingly, the connection taps 21 are also formed in the outside direction of the main body. If the coil guide grooves 13 are formed along the inner circumferential surface of the main body 10, the connection taps 21 are also formed along the inside direction of the main body.

In the bus bar housing 1 having the above structure according to the present invention, the coils are guided along the coil guide grooves 11 and then fixed. Accordingly, the end of each of the coils wound on the stator assembly can be easily connected to the connection tap 21 of the bus bar 20. A detailed work process is described below.

FIGS. 4 to 6 are perspective views showing the steps of a method of wiring coils using the bus bar housing according to the present invention. In each of the steps to be described below, it is assumed that the coil guide grooves 13 are formed in the outside direction of the main body 10.

As shown in FIG. 4, the coils 40 wound of the stator assembly 30 are bent in the outside direction. In this state, the bus bar housing 1 into which the bus bars 20 have been inserted are coupled to the top of the stator assembly 30. Next, the coils 40 are bent so that they pass through the respective coil guide grooves 13.

As shown in FIG. 6, the ends of the bent coils are connected to the respective connection taps 21 and then wired. The redundant portions of coils are cut off.

If the coils are formed in the inside direction of the main body 10 of the coil guide grooves 13, the coils 40 are wired with the bus bars20 except that the coils 40 are bent toward the inside of the main body 10 in a first step.

If the coils are wired using the bus bar housing 1 according to the present invention as described above, the ends of the coils can be easily connected to the respective connection tap 21 of the bus bar 20 because they are arranged through the coil guide grooves 13.

While the invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

A bus bar housing, comprising:

a ring-shaped main body 10;

a plurality of bus bar insertion grooves 11 sequentially formed in a radial direction in an upper part of the main body and configured to have a bus bar 20 inserted therein; and

a plurality of coil guide grooves 13 formed along an outer circumferential surface of the main body 10.
The bus bar housing of claim 1, further comprising a plurality of connection tap guides 12 formed between the bus bar insertion grooves 11 and an outer circumferential portion of the main body 10 and placed on an identical radius line with the coil guide grooves 13.
A bus bar housing, comprising:

a ring-shaped main body 10;

a plurality of bus bar insertion grooves 11 sequentially formed in a radial direction in an upper part of the main body and configured to have a bus bar 20 inserted therein; and

a plurality of coil guide grooves 13 formed along an inner circumferential surface of the main body 10.
The bus bar housing of claim 3, further comprising a plurality of connection tap guides 12 formed between the bus bar insertion grooves 11 and an inner circumferential portion of the main body 10 and placed on an identical radius line with the coil guide grooves 13.
A method of wiring coils using a bus bar housing, comprising the steps of:

bending the coils wound on a stator assembly;

coupling the bus bar housing, having coil guide grooves formed therein, over the stator assembly;

bending the coils along the coil guide grooves; and

connecting ends of the coils to respective connection taps of a bus bar coupled within the bus bar housing.