Motor

The present invention can provide a motor including a shaft, a rotor disposed outside the shaft, a stator disposed outside the rotor, a sensing magnet coupled to the rotor, a circuit substrate disposed above the sensing magnet and including a sensor configured to detect a magnetic flux change due to the sensing magnet, and a cap member which covers the sensor, wherein the circuit substrate includes a first substrate, a second substrate disposed to be spaced apart from the first substrate, and connecting portions connecting the first substrate to the second substrate, the sensor is mounted on the second substrate, and the cap member is disposed to pass through a separating space between the first substrate and the second substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the U.S. national stage application of International Patent Application No. PCT/KR2018/013248, filed Nov. 2, 2018, which claims the benefit under 35 U. S. C. § 119 of Korean Application Nos. 10-2017-0145510, filed Nov. 2, 2017; and 10-2017-0145511, filed Nov. 2, 2017, the disclosures of each of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a motor.

BACKGROUND ART

A motor includes a rotor and a stator. Coils are wound around the stator. The motor is required to be small in size but high in output power. However, in a case in which the output power of the motor is increased, there is a problem in that an internal temperature of the motor is increased. Accordingly, checking the internal temperature of the motor is a very important issue to secure performance of the motor.

In order to measure the internal temperature of the motor, one solution is a temperature sensor installed on the coil. However, such a solution has low adhesion between the temperature sensor and the coil, a problem occurs in that the temperature sensor is separated from the coil, and thus there is a big problem in that an error occurs in temperature measurement. In addition, there is another problem in that a process is complicated and difficult because an installation space for the temperature sensor is small.

The motor incudes a sensing magnet and a sensor which are components for detecting a position of the rotor. The sensing magnet is coupled to a shaft to operate in conjunction with the rotation of the shaft. In addition, the sensor is disposed to face the sensing magnet. The sensor detects a magnetic force of the sensing magnet.

Precisely detecting the position of the rotor is a very important factor to control the motor. However, the performance of detecting the position of the rotor may be significantly degraded due to electromagnetic waves or noise generated inside or outside the motor. In order to inhibit the performance degradation, a cap member configured to shield electromagnetic waves or noise is installed around the sensing magnet and the sensor. However, there are problems in that the number of components is increased because the cap member is installed, an assembly process becomes complicated because an installation process for the cap member is added, and it is difficult to secure the installation space for the cap member.

Technical Problem

The present invention is directed to providing a motor in which an error in temperature measurement of a temperature sensor is inhibited, and a fixing force of the temperature sensor is improved, and of which a process is simplified.

In addition, the present invention is directed to providing a motor in which a structure of a cap member is simplified, an assembly process of the cap member is simplified, and an installation space for the cap member is easily secured.

Objectives that should be solved according to embodiments are not limited to the above described objectives, and other objectives which are not described above will be clearly understood by those skilled in the art from the following specification.

Technical Solution

One aspect of the present invention provides a motor including a shaft, a rotor disposed outside the shaft, a stator disposed outside the rotor, a bus bar disposed on the stator, and a cover disposed on the bus bar, wherein the bus bar includes terminals connected to coils of the stator and an insulator which insulates the terminals from each other, and the cover includes a power source terminal portion coupled to the terminals, a temperature sensor connected to the power source terminal portion, and pad portions connected to the temperature sensor.

The motor may further include a front flange disposed between the bus bar and the cover.

The motor may further include a housing disposed outside the stator and the rotor, and a rear flange disposed at a lower side of the housing, wherein the front flange may be disposed at an upper side of the housing.

The temperature sensor may include a head portion and wires connected to the head portion, wherein the pad portions may include connecting ends connected to the wires.

The wires may include a first wire and a second wire, the pad portions may include a first pad portion and a second pad portion, the first wire may be connected to the first pad portion, and the second wire may be connected to the second pad portion.

The power source terminal portion may include a plurality of terminal ends, and a first terminal end of the plurality of terminal ends may be connected to the temperature sensor.

The front flange may include holes corresponding to positions of the terminal of the bus bar, and the terminals of the bus bar may be coupled to the plurality of terminal ends through the holes.

One end of the first terminal end of the power source terminal portion may be coupled to the terminal, and an installation groove in which the other end of the first terminal end is coupled to the head portion of the temperature sensor may be formed.

The installation groove corresponding to a shape of the head portion may be formed to be recessed in an end portion of the first terminal end.

The cover may include an accommodation portion disposed in a lower surface of the cover, and a wall protruding from the accommodation portion to be disposed between the wires.

The cover may include holes disposed in an upper surface of the cover, and parts of the pad portions may be exposed through the holes.

Another aspect of the present invention provides a motor including a shaft, a rotor disposed outside the shaft, a stator disposed outside the rotor, a sensing magnet coupled to the rotor, a circuit substrate disposed above the sensing magnet and including a sensor configured to detect a magnetic flux change due to the sensing magnet, and a cap member which covers the sensor, wherein the circuit substrate includes a first substrate, a second substrate disposed to be spaced apart from the first substrate, and connecting portions connecting the first substrate to the second substrate, the sensor is mounted on the second substrate, and the cap member is disposed to pass through a separating space between the first substrate and the second substrate.

The first substrate may include a through hole, and the second substrate may be disposed inside the through hole.

The motor may further include a fixing portion which fixes the cap member to the circuit substrate, wherein the fixing portion may include a body portion in contact with an upper surface of the cap member and leg portions disposed at both ends of the body portion and coupled to the circuit substrate.

The leg portions may be disposed to be bent from the body portion, and locking portions may be disposed at ends of the leg portions.

Slots formed upward from a lower end of the cap member may be disposed in the cap member, and the connecting portions may be disposed in the slots.

The first substrate may include grooves recessed from the through hole toward an inner side of the first substrate, and the leg portions may be disposed in the grooves.

The motor may further include a housing disposed on the rotor and the stator and a cover which covers on upper portion of the housing, the substrate may be disposed above the cover, and the cover may be coupled to the substrate.

A lower end of the cap member may be disposed at a higher level than the cover and disposed at a lower level than an upper end of the shaft.

Advantageous Effects

According to embodiments, an advantageous effect is provided in that a temperature sensor configured to measure an internal temperature of a motor has a high fixing force.

An advantageous effect is provided in that the temperature sensor is inhibited from being separated so that an error in temperature measurement is inhibited.

An advantageous effect is provided in that a process is simple.

An advantageous effect is provided in that an increase in the number of components or an increase in a manufacturing cost due to installation of the cap member is significantly reduced.

An advantageous effect is provided in that an assembly process of the cap member is simplified.

An advantageous effect is provided in that an installation space for the cap member is easily secured.

An advantageous effect is provided in that a size of the cap member is significantly decreased.

MODES OF THE INVENTION

However, the technical spirit of the present invention is not limited to some embodiments which will be described and may be realized using various other embodiments, and at least one component of the embodiments may be selectively coupled, substituted, and used to realize the technical spirit within the range of the technical spirit.

In addition, unless clearly and specifically defined otherwise by context, all terms (including technical and scientific terms) used herein can be interpreted as having customary meanings to those skilled in the art, and meanings of generally used terms, such as those defined in commonly used dictionaries, will be interpreted by considering contextual meanings of the related technology.

In addition, the terms used in the embodiments of the present invention are considered in a descriptive sense and not for limiting the present invention.

In the present specification, unless clearly indicated otherwise by the context, singular forms include the plural forms thereof, and in a case in which “at least one (or one or more) among A, B, and C” is described, this may include at least one combination among all combinations which can be combined with A, B, and C.

In addition, in descriptions of components of the present invention, terms such as “first,” “second,” “A,” “B,” “(a),” and “(b)” can be used.

The terms are only to distinguish one element from another element, and an essence, order, and the like of the element are not limited by the terms.

In addition, when an element is referred to as being “connected or coupled” to another element, such a description may include both of a case in which the element is directly connected or coupled to another element and a case in which the element is connected or coupled to another element with still another element disposed therebetween.

In addition, in a case in which any one element is described as being formed or disposed “on or under” another element, such a description includes both cases in which the two elements are formed or disposed in direct contact with each other and in which one or more other elements are interposed between the two elements. In addition, when one element is described as being disposed “on or under” another element, such a description may include a case in which the one element is disposed at an upper side or a lower side with respect to another element.

FIG.1is a cross-sectional view illustrating a motor according to an embodiment, andFIG.2is an exploded view illustrating the motor illustrated inFIG.1.

Referring toFIGS.1and2, the motor according to the embodiment may include a shaft100, a rotor200, a stator300, a bus bar400, and a housing500.

The shaft100may be coupled to the rotor200. When a current is supplied and an electromagnetic interaction occurs between the rotor200and the stator300, the rotor200is rotated and the shaft100is rotated in conjunction with the rotor200.

The rotor200is rotated due to the electrical interaction with the stator300.

The rotor200may include a rotor core and magnets. The rotor core may be formed such that a plurality of circular thin steel plates are stacked or may be formed to have a cylindrical shape. A hole into which the shaft100is inserted may be formed at a center of the rotor core. The magnets may be attached to an outer circumferential surface of the rotor core. The plurality of magnets may be disposed at predetermined intervals along a circumference of the rotor core. Alternatively, one ring type magnet may be attached to the rotor core.

Coils may be wound around the stator300to induce an electrical interaction with the rotor200. A specific structure of the stator300to wind the coils will be described. The stator300may include a stator core including a plurality of teeth. A yoke portion having an annual shape and the teeth, around which the coils are wound toward a center of the stator core from the yoke portion, are provided to the stator core. The teeth may be provided at predetermined intervals along an outer circumferential surface of the yoke portion. Meanwhile, the stator core may be formed such that a plurality of thin steel plates are stacked on each other. In addition, the stator core may be formed such that a plurality of divided cores are coupled or connected to each other.

The bus bar400may be disposed on the stator300. The bus bar400may include terminals410and a body420which insulates the terminals410from each other. The body420may have an annual shape. The terminals410may include phase terminals, which are connected to U-phase, V-phase, and W-phase power sources, and a neutral terminal electrically connecting the phase terminals.

The housing500may be disposed outside the rotor200and the stator300. The housing500may be a cylindrical member of which an upper portion and a lower portion are open. A space accommodating the rotor200and the stator300is formed inside the housing500.

A front flange600may be disposed on the stator300. A bearing610may be disposed on a central portion of the front flange600. In addition, holes620through which the terminals410pass may be disposed in the front flange600. The front flange600is coupled to the upper portion of the housing500to cover the open upper portion of the housing500.

The rear cover700may be disposed under the stator300. A hole may be disposed in a central portion of the rear cover700. The rear cover700is coupled to the lower portion of the housing500to cover the open lower portion of the housing500.

A sensing magnet800may be coupled to an end of the rotating shaft100. The sensing magnet800is a component configured to detect a position of the rotor200.

A cover900may be disposed on the front flange600. The cover900may be seated on the front flange600. The cover900and the front flange600may be coupled to each other using a coupling structure extending from the cover900or an additional coupling member.

A sensor1010configured to detect a magnetic force of the sensing magnet800may be disposed on a circuit substrate1000. In this case, the sensor1010may be a Hall integrated circuit (IC). The sensor1010detects changes of an N pole and an S pole of the sensing magnet800to generate a sensing signal.

FIG.3is a view illustrating an upper surface of the cover, andFIG.4is a view illustrating a lower surface of the cover.

Referring toFIGS.3and4, the cover900may include a power source terminal portion910, a temperature sensor920, and pad portions930.

The cover900may include a cover body901. The cover body901may have a disc shape. A hole901amay be disposed at a center of the cover body901. In addition, a coupling boss901bmay protrude from an upper surface of the cover body901. The coupling boss901bis to be coupled to the circuit substrate1000.

An external power source and the coils wound around the stator300are connected through the power source terminal portion910.

FIG.5is a view illustrating the power source terminal portion, the temperature sensor, and the pad portion.

Referring toFIG.5, the power source terminal portion910includes a plurality of terminal ends911,912, and913. The terminal ends911,912, and913may be connected to the U-phase, V-phase, and W-phase power sources. A connecting end912amay extend to be connected to a first terminal end912which is any one of the plurality of terminal ends911,912, and913. The connecting end912ais electrically connected to the temperature sensor920.

The temperature sensor920may include a head portion921and wires922. The head portion921may be an electric element of which a resistance value is changed according to a change in temperature. The head portion921may be formed of a composite of manganese, cobalt, nickel, and the like. The head portion921may have a circular round shape. The wires922are electrically connected to the head portion921. The connecting end912ais connected to the head portion921. In addition, the wires922are connected to the pad portions930. The wires922may include a first wire922aand a second wire922b.

The pad portions930are electrically connected to the wires922. In addition, the pad portions930may be connected to an electric control unit of a vehicle. The pad portions930may include a first pad portion931and a second pad portion932. The first pad portion931is connected to the first wire922a. The second pad portion932is connected to the second wire922b.

The power source terminal portion910is disposed to be spaced apart from the pad portions930on the cover body901, and the temperature sensor920is connected to the power source terminal portion910and the pad portions930. The terminal end, on which the connecting end912ais disposed, among the plurality of terminal ends911,912, and913of the power source terminal portion910may be the first terminal end912disposed closest to the pad portion930.

Referring toFIG.4, an accommodation portion901caccommodating the temperature sensor920may be disposed on a lower surface of the cover body901. The connecting end912aof the first terminal end912and connecting ends931aand932aof the pad portions930may be disposed to be exposed in the accommodation portion901c. In addition, a wall901dmay be disposed to protrude from the accommodation portion901c. The wall901dis disposed between the first wire922aand the second wire922bto serve as a partition between an accommodation space for the first wire922aand an accommodation space for the second wire922b.

Heat generated by the coil of the stator300is transferred to the connecting end912aof the power source terminal portion910, and the heat transferred to the connecting end912ais transferred to the head portion921. When the heat is transferred to the head portion921, a resistance value of the head portion921is changed, and the changed resistance value is transferred to the wires922and the pad portions930and transferred to the electric control unit of the vehicle through the pad portions930. The electric control unit of the vehicle converts the changed resistance value of the head portion921to detect an internal temperature of the motor. Internal temperature data, which corresponds to the changed resistance value of the head portion921, of the motor may be prestored in the electric control unit of the vehicle.

FIGS.6(a)-6(c)are views illustrating a process of connecting the head portion of the temperature sensor to the connecting end of the terminal end.

As illustrated inFIG.6A, the connecting end912aof the first terminal end912is disposed to be exposed at the accommodation portion901c. An installation groove912aahaving a round shape corresponding to a shape of the head portion921may be disposed in the connecting end912aof the first terminal end912. As illustrated inFIG.6B, in a state in which the head portion921is installed in the installation groove912aaand is connected to the connecting end912a, an adhesive902may be applied thereon. As illustrated inFIG.6C, when the adhesive902is cured, the head portion921of the temperature sensor920is fixed to the connecting end912aof the first terminal end912.

FIGS.7(a)-7(b)are views illustrating a process of connecting the wire of the temperature sensor to the pad portion.

As illustrated inFIGS.7A and7B, the wires922are fixed to the connecting ends931aand932aof the pad portions930through solders903.

FIG.8is a view illustrating the temperature sensor connected to the power source terminal portion and the pad portion.

Referring toFIG.8, the head portion921of the temperature sensor920is connected to the power source terminal portion910. In addition, the wires922of the temperature sensor920are connected to the pad portions930.

FIG.9is a view illustrating a connector of the pad portion.

Referring toFIG.9, a connector901eby which connecting ends931band932bof the pad portions930are exposed may be disposed on the upper surface of the cover body901. The connector901eis disposed to be recessed in the upper surface of the cover body901. In addition, the connector901emay include two holes901fthrough which the connecting ends931band932bof the pad portions930are exposed. An external connector connected to the electric control unit of the vehicle may be inserted into the connector901e.

FIG.10is a view illustrating the circuit substrate, a cap member, and a fixing portion.

Referring toFIG.10, a cap member2000is disposed to pass through the circuit substrate1000, a fixing portion3000presses the cap member2000to fix the cap member2000to the circuit substrate1000. An upper portion of the cap member2000has a form in which the cap member2000is disposed to protrude upward at a higher level than an upper surface of the circuit substrate1000, and a lower portion of the cap member2000has a form in which the cap member2000is disposed to protrude downward at a lower level than a lower surface of the circuit substrate1000.

FIG.11is a view illustrating the circuit substrate.

Referring toFIG.11, the circuit substrate1000may include a first substrate1100, a second substrate1200, and connecting portions1300. The first substrate1100includes through holes1110. The second substrate1200is disposed inside the through holes1110. The second substrate1200may have a disc shape. The first substrate1100and the second substrate1200are disposed to be spaced apart from each other and connected through the connecting portions1300. The plurality of connecting portions1300may be provided. The connecting portions1300may be disposed at predetermined intervals along the through holes1110. An overall form of the circuit substrate1000is that the second substrate1200is disposed inside the through holes1110and the first substrate1100is disposed outside the through holes1110.

The first substrate1100may include grooves1120. The grooves1120are disposed to be recessed from the through holes1110toward the first substrate1100. The fixing portion3000is inserted into the grooves1120. The number of grooves1120may be two, and the two grooves1120may be symmetrically disposed with respect to a center of the second substrate1200.

The first substrate1100may be coupled to the cover900. To this end, the first substrate1100may include a coupling hole1130. The coupling hole1130may be provided as a plurality of coupling holes. The coupling hole1130has a coupling structure extending from the cover900or is a hole to which an additional coupling member is coupled. The coupling hole1130may be aligned with the coupling boss901bof the cover900.

FIG.12is a view illustrating the cap member to be installed on the circuit substrate.

Referring toFIG.12, the cap member2000may be installed on the circuit substrate1000to pass through the circuit substrate1000from an upper side to a lower side of the circuit substrate1000. The cap member2000may be a cylindrical member in which the upper portion of the cap member2000is closed by an upper surface of the cap member2000and the lower portion of the cap member2000is open. Slots2100may be disposed in a side surface of the cap member2000. The slots2100may be long and be disposed upward from a lower end of the cap member2000toward an upper end of the cap member2000. The connecting portions130are inserted into the slots2100. When the cap member2000passes through the circuit substrate1000and is installed on the circuit substrate1000, the connecting portions1300are moved along the slots2100. The number of the slots2100is equal to the number of the connecting portions1300.

FIG.13is a view illustrating the fixing portion to be coupled to the circuit substrate.

Referring toFIG.13, the cap member2000is disposed to pass through the circuit substrate1000until upper ends of the slots2100touch the connecting portions1300. In a state in which the cap member2000is installed on the circuit substrate1000, the fixing portion3000may be disposed above the cap member2000and coupled to the circuit substrate1000.

The fixing portion3000may include a body portion3100and leg portions3200. The fixing portion3000may be a band type member. The body portion3100is in contact with the upper surface of the cap member2000. The body portion3100elastically presses the upper surface of the cap member2000to fix the cap member2000to the circuit substrate1000. The leg portions3200are inserted into the grooves1120. Locking portions3210having a hook form may be disposed on lower ends of the leg portions3200.

FIG.14is a side cross-sectional view illustrating a state in which the circuit substrate, the cap member, and the fixing portion are coupled.

Referring toFIGS.13and14, the circuit substrate1000is disposed above the sensing magnet800. The sensor1010is disposed on a lower surface of the second substrate1200of the circuit substrate1000. The sensor1010is disposed to face the sensing magnet800. Hereinafter, the upper portion of the cap member2000is referred to as a part of the cap member2000positioned on the circuit substrate1000when the cap member2000is fixed to the circuit substrate1000. In addition, the lower portion of the cap member2000is referred to as a part of the cap member2000positioned below the circuit substrate1000when the cap member2000is fixed to the circuit substrate1000.

The upper portion of the cap member2000surrounds a space above the second substrate1200. In addition, the lower portion of the cap member2000surrounds a space under the second substrate1200on which the sensor1010is mounted. Since the space above the second substrate1200is covered by the upper portion of the cap member2000, electromagnetic waves applied to the sensor1010from an upper side of the second substrate1200may be blocked. In addition, since the space under the second substrate1200is surrounded by the lower portion of the cap member2000, electromagnetic waves applied to the sensor1010from a lower side of the second substrate1200may be blocked.

In this case, a length of the lower portion of the cap member2000is determined such that a position H2of the lower end of the cap member2000is disposed at a lower level than a position H1of an upper end of the shaft100in a state in which the upper ends of the slots2100are blocked by the connecting portions1300. Such a structure is to block the electromagnetic waves applied to the sensing magnet800disposed at the upper end of the shaft100and the sensor1010disposed above the sensing magnet800.

Meanwhile, the locking portions3210of the leg portions3200inserted into the grooves1120are hooked to a lower surface of the first substrate1100to fix the fixing portion3000to the circuit substrate1000such that the fixing portion3000is not separated from the circuit substrate1000.

Since the cap member2000may be assembled to the circuit substrate1000using the fixing portion3000with one-touch in a state in which the cap member2000is inserted into the circuit substrate1000, there is an advantage in that an assembly process is very simple.

As described above, the motor according to the exemplary embodiments of the present invention has been described with reference to the accompanying drawings.

The above-described embodiments of the present invention should be considered in a descriptive sense only and not for purposes of limitation, and the scope of the present invention is defined not by the above-described detailed description but by the appended claims and encompasses all modifications or alterations derived from meanings and the scope of the appended claims, and equivalents thereof.

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