MOTOR

The present invention provides a motor including a stator, a housing disposed outside the stator, a busbar disposed on an upper side of the stator, and a connector connected to the busbar, wherein the stator includes a stator core, an insulator disposed on the stator core, and a coil disposed on the insulator, the busbar includes a first terminal and a second terminal which are connected to the coil of the stator and separated from each other in a circuit manner, the connector includes a first connector fused to the first terminal and a second connector fused to the second terminal, each of the first connector and the second connector includes a connector body seated in the housing and a power terminal inserted into the connector body and fused to the first terminal or the second terminal, the power terminal includes a first embossing in contact with the second terminal and a second embossing in contact with the first terminal, and the first embossing is disposed closer to a center of the stator than the second embossing.

TECHNICAL FIELD

The present invention relates to a motor.

BACKGROUND ART

An electric power steering (EPS) system is an apparatus which secures turning stability of a vehicle and rapidly provides a restoring force so that a driver can safely drive the vehicle. An EPS system controls a vehicle's steering shaft to be driven by driving a motor using an electronic control unit (ECU) according to driving conditions detected by a vehicle speed sensor, a torque angle sensor, a torque sensor, and the like.

A motor includes a rotor and a stator. A coil is wound around the stator. A connection end of the coil wound around the stator may be connected to a busbar. The busbar includes a body and a terminal. The terminal is connected to the connection end of the coil. In addition, the terminal may be connected to an external power source through a cable.

The terminal may be formed to have a combination of phase terminals connected to U-phase, V-phase, and W-phase power sources and a neutral terminal. In this case, two terminals combined as described above may be disposed, and the two terminals may be separated from each other in a circuit manner to secure safety of the motor. When an abnormality occurs in the circuit or an element connected to any one terminal, the motor can be driven through another terminal. The two terminals are spatially separated from each other on a body of the busbar.

The terminal includes a busbar terminal connected to a stator coil and a power terminal which is fused to the busbar terminal and through which external power is applied. In this case, when the busbar terminal and the power terminal are fused, there are problems in that a fused portion is deformed, and a contact failure occurs while a temperature increases to be greater than or equal to a melting point of Ni constituting the terminal.

DISCLOSURE

Technical Problem

The present invention is directed to providing a motor in which bonding of a fused portion of a terminal and fusing quality are improved.

Objectives that have to be solved according to the present invention 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 stator, a housing disposed outside the stator, a busbar disposed on an upper side of the stator, and a connector connected to the busbar, wherein the stator includes a stator core, an insulator disposed on the stator core, and a coil disposed on the insulator, the busbar includes a first terminal and a second terminal which are connected to the coil of the stator and separated from each other in a circuit manner, the connector includes a first connector fused to the first terminal and a second connector fused to the second terminal, each of the first connector and the second connector includes a first embossing and a second embossing disposed farther from a center of the stator than the first embossing, the first terminal is in contact with the second embossing of the first connector, and the second terminal is in contact with the first embossing of the second connector.

Each of the first connector and the second connector may include a connector body seated in the housing and a power terminal inserted into the connector body and fused to the first terminal or the second terminal, and the first embossing and the second embossing may be formed on the power terminal.

The housing may include a first seating surface on which the first connector is seated and a second seating surface on which the second connector is seated, and the first seating surface and the second seating surface are disposed at intervals of 180° based on a center of a rotor.

A longest distance between the center of the stator and the first seating surface may be shorter than a longest distance between the center of the stator and the second seating surface.

The power terminal may include a power connection part connected to a power source and a fusing portion which is bent from a lower end of the power connection part toward the center of the stator and fused to the first terminal or the second terminal, and the first embossing and the second embossing may be disposed on a side surface of the fusing portion.

A center of the first terminal in a width direction may be in contact with a most protruding point of the second embossing, and a center of the second terminal in a width direction may be in contact with a most protruding point of the first embossing.

The first terminal may not be in contact with the first embossing, and the second terminal may not be in contact with the second embossing.

The insulator may include a body around which the coil is wound and a guide extending from one side of the body, a first groove and a second groove spaced apart from the first groove in a circumferential direction may be formed in an inner surface of the guide, and the coil may be disposed in the first groove and the second groove in an axial direction.

The first groove and the second groove may be formed from an upper side of the body to an upper end of the guide.

The second groove may have a curvature facing outward, and the curvature of the second groove may increase in a circumferential direction away from the body.

On the basis of a virtual line passing through the center of the stator and a width center of the body, a distance from the second groove to the virtual line may be greater than a distance from the first groove to the virtual line.

The first groove may overlap the body in a radial direction, and the second groove may not overlap the body in the radial direction.

Advantageous Effects

According to embodiments, bonding of a terminal of a busbar and a power terminal can be improved, and fusing quality can be improved due to an embossing.

According to embodiments, separation of a coil guided by the busbar is reduced, and fusing accuracy between the terminal of the busbar and the coil can be improved.

MODES OF THE INVENTION

Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings in detail. Purposes, specific advantages, and novel features of the invention will be made clear from the exemplary embodiments and the following detailed description in connection with the accompanying drawings. In the description of the invention, when it is determined that detailed descriptions of related well-known technologies unnecessarily obscure the gist of the invention, the detailed descriptions thereof will be omitted.

It will be understood that, although the terms “first,” “second,” etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a second element could be termed a first element, and a first element could similarly be termed a second element without departing from the scope of the present invention. The term “and/or” includes combinations or any one of a plurality of associated listed items.

FIG. 1is a side cross-sectional view illustrating a motor according to an embodiment.

Referring toFIG. 1, a motor according to the embodiment may include a shaft10, a rotor20, a stator30, a housing40, a busbar50, and a connector60.

The shaft10may be coupled to the rotor20. When an electromagnetic interaction occurs between the rotor20and the stator30due to the supply of a current, the rotor20rotates, and the shaft10rotates in conjunction with the rotor20. The shaft10may be connected to a vehicle's steering shaft, and power may be transmitted to the vehicle's steering shaft.

The rotor20rotates due to the electrical interaction with the stator30.

The rotor20may include a rotor core and magnets. The rotor core may be formed in a form in which a plurality of circular thin steel plates are stacked, or in a single cylindrical form. A hole coupled to the shaft10may be disposed at a center of the rotor core. Protrusions which guide the magnets may protrude from an outer circumferential surface of the rotor core. The magnets may be attached to the outer circumferential surface of the rotor core. The plurality of magnets may be disposed along a circumference of the rotor core at predetermined intervals. The rotor20may include a can member which fixedly surrounds the magnets to prevent the magnets from being separated from the rotor core and from being exposed.

The stator30may include a stator core310, an insulator320, and a coil330. The insulator320is installed on the stator core310. The coil330is wound around the insulator320. When power is applied, an induced current is generated in the coil330. The coil330induces an electrical interaction with the rotor20.

The housing40may accommodate the rotor20and the stator30therein. The housing40is formed in a cylindrical shape.

The busbar50may be disposed on the stator30. The busbar50may include a terminal and a busbar body which insulates the terminal.

The connector60is connected to the busbar50. In this case, the connector60is electrically connected to the terminal of the busbar50. The connector60is connected to U-phase, V-phase, W-phase power sources.

FIG. 2is a perspective view illustrating a state in which the coil is wound around the insulator,FIG. 3is a perspective view illustrating the insulator,FIG. 4is a plan view illustrating the insulator, andFIG. 5is a partially enlarged view illustrating a second groove.

The insulator320is installed on the stator core310.

Referring toFIG. 2, the insulator320may include a body321and a guide322. The body321is a portion around which the coil330is wound when disposed. In addition, the guide322is disposed to extend upward at an outside of the body321.

Referring toFIG. 3, a first groove3221and a second groove3222may be formed in an inner surface of the guide322. A start end331and a stop end332of the coil330may be disposed in the first groove3221and the second groove3222.

Referring toFIG. 4, the first groove3221and the second groove3222are spaced apart from each other in a circumferential direction. In this case, the first groove3221and the second groove3222may be formed from an upper side of the body321to an upper end of the guide322. A shape of the first groove3221and a shape of the second groove3222may be different from each other.

The start end331of the coil330wound around the insulator320is disposed in the first groove3221. That is, winding of the coil330may start from the first groove3221formed in the insulator320. In this case, at a side of the body321, a width of the first groove3221may be greater than a width of the second groove3222. In addition, the first groove3221may be disposed to be closer to the body321than the second groove3222. In this case, at least a part of the first groove3221may overlap the body321in a radial direction.

Conversely, the stop end332of the coil330wound around the insulator320is disposed in the second groove3222. That is, the winding of the coil330may end in the second groove3222formed in the insulator320. At the side of the body321, the width of the second groove3222may be smaller than the width of the first groove3221. In addition, the second groove3222may be disposed farther from the body321than the first groove3221. Preferably, when it is assumed that a virtual line L passes through a rotor center C and a width center of the body321, a distance from the second groove3222to the virtual line L may be greater than a distance from the first groove3221to the virtual line L. In this case, the second groove3222may not overlap the body321in the radial direction.

Referring toFIG. 5, a curvature of the second groove3222may vary in the circumferential direction. In this case, the curvature of the second groove3222may increase in a direction away from the body321. In addition, the second groove3222may be formed to correspond to a shape of a cross section of the stop end332of the coil330.

FIG. 6is a plan view illustrating a state in which a first connector and a second connector are seated in a housing.

Referring toFIG. 6, the busbar50may include a terminal510to apply a current to the coil of the stator and a busbar body520formed of an insulation material. In this case, the terminal510may include a plurality of first terminals (not shown) and a plurality of second terminals (not shown).

The first terminal (not shown) and the second terminal (not shown) are electrically connected to the coil330of the stator30. In this case, the first terminal (not shown) and the second terminal (not shown) are separated from each other in a circuit manner. In this case, a layout of the first terminal (not shown) and the second terminal (not shown) is not limited and may vary.

The first terminal (not shown) and the second terminal (not shown) may include terminal bodies (not shown), protruding parts511, and power parts512and513. In this case, the terminal body (not shown) is disposed in the busbar body520. In addition, the protruding parts511and the power parts512and513may be formed to extend from the terminal body (not shown).

The protruding parts511may protrude outward from the terminal body in the radial direction. In this case, the protruding parts511may be exposed from a side surface of the busbar body520. In addition, the protruding parts511are electrically connected to the coil330. The protruding parts511may be fused to the stop end332of the coil330.

Meanwhile, the power parts512and513may extend upward from the terminal bodies. In this case, the power parts512and513may be exposed from an upper surface of the busbar body520. In addition, the power parts512and513are electrically connected to the connector60. In this case, the power parts512and513may be fused to the connector60.

Power is individually applied to the first terminal (not shown) and the second terminal (not shown) through the connector60. To this end, the connector60may include a first connector610and a second connector620.

The first connector610is disposed at a side of the power part512of the first terminal. In addition, the first connector610is fused to the power part512of the first terminal. In this case, the power may be supplied through the first connector610and the first terminal so that an induced current may be generated in the coil330of half of the stator30.

Meanwhile, the second connector620is disposed at a side of the power part513of the second terminal. In addition, the second connector620is fused to the power part513of the second terminal. In this case, the power may be supplied through the second connector620and the second terminal so that an induced current may be generated in the coil330of the remaining half of the stator30. Accordingly, even when the current supplied through either of the first connector610and the second connector620is stopped, the power supplied through the remaining one of the second connector620and the first connector610is continued so that a half region of the stator30may be driven.

FIG. 7is a perspective view illustrating the state in which the first connector and the second connector are being seated in the housing, andFIG. 8is a plan view illustrating a state in which the housing is disposed on a stator.

Referring toFIGS. 7 and 8, the first connector610and the second connector620are seated in the housing40. In this case, a first seating surface401on which the first connector610is seated is formed at one side of the housing40. In addition, a second seating surface402on which the second connector620is seated is formed at the other side of the housing40. The first seating surface401and the second seating surface402may be disposed at intervals of 180° based on the rotor center C.

In this case, a longest distance R1between the rotor center C and the first seating surface401may be different from a longest distance R2between the rotor center C and the second seating surface402. In this case, the longest distance R1from the rotor center C to the first seating surface401may be shorter than the longest distance R2from the rotor center C to the second seating surface402.

FIG. 9is a view illustrating the first connector and the second connector.

A shape of the first connector610is the same as a shape of the second connector620.

Referring toFIG. 9, the first connector610and the second connector620may include bodies611and621and plurality of power terminals612and622.

The bodies611and621are seated in the housing40. In this case, the body611of the first connector610is in contact with the first seating surface401, and the body621of the second connector620is in contact with the second seating surface402.

The power terminals612and622are coupled to the bodies611and621. The power terminal612may be provided as three power terminals612, and the power terminal622may be provided as three power terminals622. The power terminals612and622are connected to U-phase, V-phase, and W-phase power sources. In this case, each of the power terminals612and622is connected to one of the first terminal and the second terminal in a fusing manner.

FIG. 10is a perspective view illustrating the power terminal.

A material and a shape of the power terminal612of the first connector610are the same as a material and a shape of the power terminal622of the second connector620.

Referring toFIG. 10, the power terminals612and622may include power connection parts612C and622C and fusing portions612fand622f.

The power connection parts612C and622C are connected to the U-phase, V-phase, and W-phase power sources. The power connection parts612C and622C may be formed to extend in an axial direction. In addition, the fusing portions612fand622fextend from lower end portions of the power connection parts612C and622C.

The fusing portions612fand622fmay be disposed to be bent from the power connection parts612C and622C. In this case, at least one bent portions may be formed between the fusing portions612fand622fand the power connection parts612C and622C. In this case, in the fusing portions612fand622f,widths in a vertical direction may be greater than widths in a horizontal direction. Areas of upper and lower surfaces of the fusing portions612fand622fmay be greater than areas of side surfaces thereof.

The fusing portions612fand622fmay protrude inward from the power connection parts612C and622C in the radial direction.

In addition, the fusing portions612fand622fmay be fused to the power parts512and513of the first terminal or the second terminal. In this case, the side surfaces of the fusing portions612fand622fmay be fused to the power parts512and513of the first terminal or the second terminal. The side surface of each of the fusing portions612fand622ffused to the power parts512and513may include at least one of embossings601and602.

The embossings601and602may include a first embossing601and a second embossing602. The first embossing601and the second embossing602may be spaced apart from each other in the radial direction. In this case, the first embossing601may be disposed closer to a stator center than the second embossing602. In addition, the second embossing602may be disposed closer to the body611or621than the first embossing601.

FIG. 6is a plan view illustrating the state in which the first connector and the second connector are seated in the housing,FIG. 8is a plan view illustrating the state in which the housing is disposed on the stator,FIG. 11is a view illustrating the fused portion of the first terminal and the first connector, andFIG. 12is a view illustrating a fused portion area of the second terminal and the second connector.

Referring toFIG. 8, a longest distance from the rotor center C to the first seating surface401and a longest distance from the rotor center C to the second seating surface402are different. Accordingly, a distance from the rotor center C to the fusing portion612fof the first connector610and a distance from the rotor center C to the fusing portion622fof the second connector620may be different. Meanwhile, a distance from the rotor center C to the power part512of the first terminal and a distance from the rotor center C to the power part513of the second terminal may be the same. Accordingly, a fusing position of the fusing portion612fof the first connector and a fusing position of the fusing portion622fof the second connector may be different. For example, the fusing position of the fusing portion622fof the second connector may be disposed closer to an end portion than the fusing position of the fusing portion612fof the first connector.

Referring toFIGS. 6, 11, and 12, the power part512of the first terminal may be in contact with the second embossing602of the first connector610. Meanwhile, the power part513of the second terminal may be in contact with the first embossing601of the second connector620. In this case, the power part512of the first terminal may not be in contact with the first embossing601, and the power part513of the second terminal may not be in contact with the second embossing602.

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

The above-described embodiments 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 detailed description but by the appended claims. In addition, it should be interpreted that the scope of the present invention encompasses all modifications and alterations derived from meanings and the scope and equivalents of the appended claims.