Motor having busbar arrangement

Provided is a motor having a stator including a coil connected to a busbar assembly, a rotor disposed inside the stator; and a shaft coupled to the rotor, wherein the busbar assembly includes a busbar body and a plurality of terminals coupled to the busbar body, each terminal including a body and electrodes, the busbar body having an inner radius and an outer radius; and wherein the electrodes of the plurality of the terminals are located on different circular tracks between the inner radius and the outer radius, wherein the terminal body has a belt shape, and the electrodes are formed in a hook shape by bending the opposite end portions of the terminal body along an extending direction of the terminal body. Thus, an advantageous effect is provided in that a manufacturing cost may be reduced by significantly reducing an amount of generated scrap.

TECHNICAL FIELD

The present invention relates to a motor.

BACKGROUND ART

In a motor, a shaft formed to be rotatable, a rotor coupled to the shaft, and a stator fixed to an inside of a housing are provided, and the stator is installed along a circumference of the rotor to have a gap between the rotor and the stator. In addition, coils configured to generate rotational magnetic fields are wound around the stator to induce an electrical interaction with the rotor to rotate the rotor.

Busbars electrically connected to the coils are disposed at an upper end of the stator. The busbars generally include busbar housings having a ring shape and busbar terminals coupled to the busbar housings to be connected to the coils. Generally, the busbar terminal of the busbar is formed by pressing sheet metal such as a copper plate.

Here, a plurality of electrodes directly connected to the coils may be provided on the busbar terminals, and each of the electrodes may be formed to be bent due to spatial limitation or a location of a connection end of the coil. Due to a shape of the electrode, there are problems in that a size of a mold increases, and an amount of scrap discarded after forming the electrode significantly increases.

As a result, there are problems in that a loss rate of raw material is large and a large amount of cost and effort are needed to manufacture a mold.

Technical Problem

The present invention is directed to providing a motor with which an amount of scrap may be decreased and a motor including the same.

In addition, the present invention is also directed to providing a motor with which an amount of material thereof may be decreased.

Objectives to be achieved through embodiments are not limited to the above-described objectives, and other objectives which are not described above will be clearly understood to those skilled in the art.

Technical Solution

One aspect of the present invention provides a motor comprising a stator including a coil connected to the busbar assembly, a rotor disposed inside the stator and a shaft coupled to the rotor, wherein the busbar assembly comprising a busbar body and a plurality of terminals coupled to the busbar body, each terminal including a body and electrodes, a busbar body having an inner radius and an outer radius and wherein the electrodes of the plurality of the terminals are located on different circular tracks between the inner radius and the outer radius, wherein the terminal body has a belt shape, and the electrodes are formed in a hook shape by bending the opposite end portions of the terminal body along an extending direction of the terminal body.

The terminal bodies of the plurality of the terminals are located on three different circular tracks.

The busbar body comprises a plate like base and terminal holders extending upwardly from the base, the terminal body of the terminal being inserted into the terminal holder.

Each terminal holder comprises two walls extending upwardly from the base, the busbar body fitting between the two walls.

Further comprising a neutral terminal comprising a plurality of electrodes coupled to the busbar body and disposed on an outermost side of the busbar body.

At least two terminals among the plurality of the terminals are disposed at different locations around a center of the busbar body in radial and circumferential directions.

At least two terminals among the plurality of the terminals are disposed at different locations around a center of the busbar body in radial and circumferential directions.

Another aspect of the present invention provides a motor comprising a stator including a coil connected to the busbar assembly, a rotor disposed inside the stator and a shaft coupled to the rotor, wherein the busbar assembly comprising a busbar body and a plurality of terminals coupled to the busbar body, each terminal including a body and electrodes, wherein the busbar body having an inner radius and an outer radius wherein all of the electrodes of the plurality of the terminals are disposed in an area between the inner radius and the outer radius, the terminal body having a pair of ends and being continuously arcuate between the pair of ends, an electrode connected to each of the pair of ends of the terminal body, wherein each of the electrodes has a J-shape, with a first linear portion having a first end directly attached to one of the pair of ends of the terminal body and a second arcuate portion directly attached to and extending from a second end of the first linear portion.

Each of the plurality of terminals has a top edge of the terminal body at a same height as a top edge of the electrodes.

At least two terminals among the plurality of the terminals are disposed at different locations around a center of the busbar body in radial and circumferential directions.

The electrodes of the at least two terminals of the plurality of the terminals are located at different locations around the center of the busbar body in the radial direction.

The busbar body includes at least one electrode hole and the at least one electrode hole is disposed below the electrode of the terminal and disposed around the center of the busbar body in the circumferential direction at a location corresponding to the electrode of the terminal.

All the electrodes of the plurality of the terminals are disposed at different locations around the center of the busbar body in the circumferential direction.

The electrodes formed at the opposite end portions of the terminal body are formed to be bent in the same direction.

The electrode disposed at an outermost side around the center of the busbar in the radial direction protrudes inward.

The electrode disposed at an innermost side around the center of the busbar in the radial direction protrudes toward an outside.

All the electrodes of the plurality of the terminals are disposed at the same height.

The plurality of the terminals comprise at least a first terminal, a second terminal and a third terminal which are disposed at different locations around a center of the busbar body in the radial direction.

Yet another aspect of the present invention provides a motor including the busbar assembly, a stator including a coil connected to the busbar assembly, a rotor disposed inside the stator, and a shaft coupled to the rotor.

Advantageous Effects

As described above, since a terminal of a busbar is formed using sheet metal having a belt shape which does not have divided portions, an amount of generated scrap is significantly decreased, and thus there is an advantageous effect in that a manufacturing cost is reduced.

Since a busbar assembly is configured such that electrodes of all terminals are disposed between inner and outer radii of a busbar body, a plurality of terminals can be disposed in a single layer, and thus there are advantageous effects in that a shape of the terminal can be simplified, and a manufacturing cost of the busbar assembly can be significantly reduced.

Since a terminal holder configured to fix only the belt-shaped body of the terminal is provided, a mold material forming the busbar body can be reduced, and thus there is an advantageous effect in that a manufacturing cost is reduced.

Since the plurality of terminals are disposed at different locations at the same height in circumferential and radial directions, there are advantageous effects in that the shape of the terminal can be simplified, and the manufacturing cost of the busbar assembly can be significantly reduced.

Since the electrodes of the terminals can be disposed to be coplanar at different locations in the radial direction, heights of the busbars do not need to be increased in multiple stages or the terminals do not need to be alternately installed so as to form different terminal heights, and thus there are advantageous effects in that the shape of the terminal can be simplified, and the manufacturing cost of the busbar assembly can be significantly reduced.

MODES OF THE INVENTION

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Purposes, specific advantages, and novel features of the invention will be clear from exemplary embodiments and the following detailed descriptions in connection with the accompanying drawings. Moreover, terms and words used in this specification and claims should not be interpreted as limited to commonly used meanings or meanings in dictionaries and should be interpreted with meanings and concepts which are consistent with the technological scope of the invention based on the principle that the inventors have appropriately defined concepts of terms in order to describe the invention in the best way. In addition, in descriptions of the invention, when detailed descriptions of related well-known technology are deemed to unnecessarily obscure the gist of the invention, they will be omitted.

FIG.1is a view illustrating a motor according to an embodiment. Referring toFIG.1, the motor according to the embodiment may include a busbar assembly100, a stator200, a rotor300, and a shaft400.

Referring toFIG.1, the busbar assembly100is connected to coils20wound the stator200. The busbar assembly100is a unit disposed on the stator200and configured to connect the coils20wound around the stator200.

The stator200may be formed by stacking a plurality of steel plates including yokes having a ring shape and teeth disposed at equal angular intervals in a circumferential direction and protruding toward an inside thereof in a radius direction. The coils20configured to generate rotational magnetic fields may be wound around the teeth. Here, the stator200and the coils20may be insulated from each other by an insulator10.

The rotor300is disposed inside the stator200. The rotor300may be formed by a magnet being coupled to a rotor core, and in some cases, a rotor core and a magnet may also be integrally formed. In addition, the rotor300may be formed by a magnet being coupled to a circumferential surface of a rotor core or a magnet being inserted into a pocket of a rotor core.

When current is supplied to the coils20wound around the stator, electrical interactions are induced between the coils20and the rotor300to rotate the rotor300. When the rotor300rotates, the shaft400is rotated and power is provided.

A sensing magnet500is a unit coupled to the shaft400to be in conjunction with the rotor300so as to detect a location of the rotor10.

A sensor configured to detect a magnetic force of the sensing magnet500may be disposed on a printed circuit board600. Here, the sensor may be a hall integrated circuit (IC). The sensor detects a change in N and S poles of the sensing magnet500to generate a sensing signal.

FIG.2is a view illustrating a busbar assembly according to the embodiment. Such aFIG.2is a view clearly illustrating only main features for the purpose of clear conceptual understanding of the embodiment, and as a result, various modifications are expected and the scope of the embodiment is not limited to specific shapes illustrated in the drawing.

Referring toFIG.2, the busbar assembly100may include a terminal110and a busbar body120.

The terminal110is a portion connected to the coil20, and may be provided with a plurality of terminals110. The busbar body120may be formed to be a frame type having a ring shape.

FIG.3is a view illustrating the busbar assembly and a stator, andFIG.4is a view illustrating connection ends of coils connected to terminals.

Referring toFIGS.3and4, the busbar assembly100may be disposed on the stator200. Some connection ends21aamong connection ends21of the coils20wound around the stator200may be connected to the terminals110for connecting the coils20wound around divided cores of the stator200. Other connection ends21bamong the connection ends21of the coils20may be connected to neutral terminals30. In addition, still other connection ends21camong the connection ends21of the coils20may be directly connected to power terminals (not shown) having U-, V-, and W-phases.

FIG.5is a view illustrating the coils wound around the stator, andFIG.6is a view illustrating locations of the connection ends of the coils illustrated inFIG.5.

Referring toFIGS.5and6, some of the connection ends21of the coils20wound around the stator200may be disposed at different locations around a center C of the stator200in a radial direction. For example, a plurality of connection ends21may be divided and disposed on a plurality of tracks O1, O2, and O3around the center C. Here, the center C may be a center of the stator200. The connection ends21of the coils may be divided into connection ends located at an outermost side, connection ends located at a middle, and connection ends located at an innermost side.

Since the connection ends21of the coils20are divided and distributed on the tracks having different radii, the terminals110connected to the connection ends21of the coils20may be formed to have a more simple shape. That is, in a case in which the connection ends21of the coils20are located on the same track, the electrodes of the terminal110are located in multiple layers or formed to be bent due to a limitation of a coupling space, but in a case in which the connection ends21of the coils20are divided and distributed on different tracks, the shape of the terminal110may be designed to be simple.

FIG.7is a view illustrating a busbar body, andFIG.8is a view illustrating an inner radius and an outer radius of the busbar body illustrated inFIG.7.

Referring toFIG.7, the busbar body120may include a base121and terminal holders122. The base121and the terminal holders122may only be separately described according to shapes and functional properties thereof, and may be one mold member in which the base121and the terminal holders122are vertically connected to each other.

Referring toFIG.8, the base121may be formed to be a type of plate in a ring shape having an inner radius R1and an outer radius R2. In addition, the base121may include electrode holes123. The electrode holes123are disposed below the terminals110(seeFIG.4). In addition, the electrode holes123may be disposed to be arranged at locations of the electrodes112around the center C in the circumferential direction. Here, the center C may be a center of the busbar body120.

Referring toFIGS.3and8, the connection ends21of the coils20pass through the arranged corresponding electrode holes123and are located above the base121. Bodies111of the terminals110are inserted into the terminal holders122.

FIG.9is a view illustrating a region in which electrodes of the terminals are disposed,FIG.1

is a perspective view illustrating the terminal, andFIG.11is a side view illustrating the terminal.

Referring toFIGS.8to10, the electrodes112of all the terminals110are disposed between the inner radius R1and the outer radius R2of the base121. That is, the terminals110may be coupled to the busbar body120such that all the electrodes112are disposed in a gap A (shadow region) between a reference line P1formed along the inner radius R1of the base121and a reference line P2formed along the outer radius R2of the base121.

The electrodes112may be located such that the connection ends21of the coils20wound around the stator200are disposed at different locations around the center C of the stator200in a radial direction. In addition, the locations of the electrodes112may simplify the shape of the terminals110.

Referring toFIGS.11and12, the electrode112may be formed by both end portions of the body111being bent to have a hook shape. Here, the electrode112may be formed to be bent in a longitudinal direction of the body111. In addition, the body111may be formed to be curved or bent to form an arc around the center C of the busbar body120.

The electrodes112connected to both end portions of the body111and having the hook shape may be formed by the end portions of the body111being bent in a predetermined direction, such as a counterclockwise direction W. Here, the electrodes112of all the terminals110coupled to the busbar body120may be formed to be bent from the bodies111in the same direction.

This is for minimizing generation of scrap and simplifying a manufacturing process to reduce a manufacturing cost by equalizing sizes and shapes of the terminals110included in the busbar assembly100. In addition, this is also for effectively ensuring a space for coupling to the connection ends21of the coils20.

FIG.12is a view illustrating a sheet metal material.

Referring toFIGS.10and12, the terminal110may be formed such that a width W1of the body111having a belt shape is the same as a width W2of the electrode. Here, an unfolded shape of a raw material11included in the terminal110may be a belt shape which does not have divided portions because the width W1of a raw material11acorresponding to the body111of the terminal110is the same as the width W2of a raw material11bcorresponding to the electrode112of the terminal110. In this case, a portion of a scrap12other than the raw material11may be minimized in a sheet metal material10.

FIG.13is a view illustrating locations of the electrodes of the terminals.

Referring toFIGS.8and13, all the electrodes of the plurality of terminals110are located in the gap A between the reference line P1formed along the inner radius R1of the base121and the reference line P2formed along the outer radius R2of the base121. In addition, the electrodes112may be arranged on the plurality of tracks around the center C of the busbar body120. The locations of the electrodes112correspond to the locations of the connection ends21of the coils20. Accordingly, the connection ends21of the coils20passing through the electrode holes123from under the base121are located inside the electrodes112having the hook shape.

The terminals110are mainly divided into the terminals located at the outermost side, the terminals located at the middle, and the terminals located at the innermost side around the center C of the busbar body120in the radial direction. Two terminals110may be disposed on the same track. In addition, neutral terminals30may be disposed on the outermost side. The electrodes31of the neutral terminals30may also be disposed in the gap A between the reference line P1formed along the inner radius R1of the base121and the reference line P2formed along the outer radius R2of the base121.

Meanwhile, the electrodes112of all the terminals110other than the neutral terminals30may be formed in the same shape. Particularly, all the shapes and sizes of the terminals110arranged on the same track may be the same.

FIG.14is a view illustrating directions of the electrodes of the terminals.

Referring toFIG.14, a terminal110A located at the outermost side may be disposed such that an electrode112A protrudes inward toward the center C in the radial direction. Here, the center C may be the center of the busbar body110(seeFIG.8). In addition, terminals110B located at the innermost side and terminals110C located at the middle may be disposed such that the electrodes112protrude toward the outside from the center C in the radial direction. This is for placing all the electrodes112in the gap A between the reference line P1and the reference line P2. In addition, this is also for effectively ensuring a space for coupling with the connection ends21of the coils20in a limited space of the busbar body120.

FIG.15is a view illustrating locations of the electrodes in a circumferential direction.

Referring toFIG.15, the electrodes112of all the terminal110may be arranged at different locations around the center C in the circumferential direction. For example, even the electrodes112disposed on the different tracks are also arranged at different locations in the circumferential direction. When the locations of the electrodes112arranged at the different tracks are C1, C2, and C3inFIG.15, locations of the terminals110may be determined such that the C1, C2, and C3are different in the circumferential direction.

FIG.16is a view illustrating the terminals, andFIG.17is a view illustrating the terminals as seen in a direction indicated by S ofFIG.16.

The electrodes112of all the terminals110may be disposed at the same height. Here, the term “height” may be based on a direction parallel to a direction of the shaft of the motor. Referring toFIGS.16and17particularly, the electrodes112of all the terminals110may be disposed on a coplane h. Here, when a z-axis ofFIG.16is the direction of the shaft of the motor, and an x-axis ofFIG.16is a radial direction of the motor, the coplane h may be a plane formed in the radial direction of the motor.

FIG.18is a view illustrating terminal holders.

Referring toFIG.18, the terminal holder122may be formed to perpendicularly protrude from the base121. The terminal holder122includes a slot122ainto which the body111of the terminal110is inserted to serve to fix the terminal110. The terminal holder122may be formed on the base121to arrange the slot122aon the body111of the terminals110.

For example, the terminal holder122may include a first sidewall122band a second sidewall122c. The first sidewall122band the second sidewall122care formed to perpendicularly protrude from the base121. In addition, the first sidewall122band the second sidewall122care disposed to be spaced a predetermined distance apart and face each other to form the slot122atherebetween, wherein the body111of the terminal110is inserted into the slot122a. Since the terminal holder122is formed to be a thin sidewall structure forming the slot122aas described above, an amount of mold member forming the busbar body120may be significantly decreased.

FIG.19is a plan view which illustrates the busbar assembly and in which locations of the electrode holes are illustrated.

Referring toFIG.19, all the electrode holes123formed in the base121may be arranged at different locations around the center C in the circumferential direction. For example, when reference locations of any electrode holes123arranged on the different tracks in the circumferential direction are L1, L2, and L3ofFIG.19, the locations of electrode holes123may be determined such that the L1, L2, and L3are different.

FIG.20andFIG.21are views illustrating a region in which the terminals are disposed.

All the terminals110may be coplanar. In addition, at least two terminals110among the plurality of terminals110may be disposed at different locations around the center C of the busbar body120in the radial direction, and the different locations may also be different in the circumferential direction.

Referring toFIG.20, at least two terminals of the plurality of terminals110may be disposed at different locations in the radial direction first. That is, the terminals110may be arranged on the plurality of circular tracks O1, O2, and O3around the center C of the busbar body120. For example, any one terminal110A may be disposed on the circular track O1located at the outermost side in the radial direction. In addition, another terminal110B may be disposed on the circular track O2located at the middle in the radial direction.

In addition, at least two terminals of the plurality of terminals110may be disposed at different locations in the circumferential direction. For example, any one terminal110B may be disposed in a first region S1in the circumferential direction. In addition, another terminal110A may be disposed in the circumferential direction in a second region S2which is different from the first region S1.

Referring toFIG.21, for example, any one terminal110C may be disposed on the circular track O3located on the innermost side in the radial direction. In addition, another terminal110B may be disposed on the circular track O2located at the middle in the radial direction. In addition, any one terminal110C may be disposed in the third region S3in the circumferential direction. In addition, another terminal110B may be disposed in the circumferential direction in a fourth region4different from the third region S3.

While the embodiments have been described, locations of two terminals110have been compared to describe locations thereof. However, the present invention is not limited thereto, and two or more locations of the terminals110may also be different in the circumferential and radial directions.

FIG.22is a view illustrating the locations of the electrodes of the terminals in a radial direction.

Referring toFIG.22, electrodes112a,112b, and112cof the terminals110may be arranged to be located at different locations to be coplanar around the center C in the radial direction. For example, the electrodes112a,112b, and112cof the terminals110may be arranged on the circular tracks O1, O2, and O3, respectively, which have different radii, around the center C. The circular tracks O1, O2, and O3correspond to the locations of the connection ends21of the coils20. Although not illustrated in the drawings, all the electrodes112a,112b, and112cof the terminals110may be arranged at different locations around the center C in the radial direction.

As described above, the electrodes112a,112b, and112care located to be coplanar at different locations in the embodiments. Accordingly, heights of the busbars do not need to be increased in multiple stages or the terminals do not need to be alternately installed so as to form different heights of the terminals.

In addition, the electrodes112a,112b, and112cof all the terminals110may be arranged to be located at different locations around the center C in the circumferential direction. When the locations of the electrodes112a,112b, and112carranged at different tracks are C3, C2, and C1ofFIG.22, locations of the terminals110A,110B, and110C may be determined such the C3, C2, and C1are different.

As described above, the motor according to one exemplary embodiment of the present invention have been specifically described with reference to the accompanying drawings.

While the present invention has been particularly described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the present invention. Therefore, the exemplary embodiments should be considered in a descriptive sense only and not for purposes of limitation. The scope of the invention is defined not by the detailed description of the invention but by the appended claims, and encompasses all modifications and equivalents that fall within the scope of the appended claims.