Rotary Electric Machine, Power Distribution Unit Therefor and Method for Assembling Rotary Electric Machine

• US 20080265701A1
• Filed: 04/24/2008
• Published: 10/30/2008
• Est. Priority Date: 04/25/2007
• Status: Active Grant

• Current Assignee: Hitachi Astemo Ltd. (Hitachi, Ltd.)
• Original Assignee: Hitachi, Ltd.
• Inventors: Ueda, Toshiaki, Hoshino, Katsuhiro, Obata, Koji, Toba, Akira, Onose, Shin
• Granted Patent: US 7,952,245 B2
• Time in Patent Office: Days
• US Class Current: 310/71
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

The power distribution unit for a rotary electric machine includes a connecting ring unit that connects stator coils of the same phase. The connecting ring unit includes at least one linear conductor integrally formed in a ring-like shape, and the connecting ring unit includes a terminal section integrally formed in the linear conductor. The terminal section is constituted by a hole through which a wiring end of the stator coil is inserted and a protrusion formed in a direction of the hole to which the wiring end of the stator coil is connected. Also disclosed are a rotary electric machine includes the power distribution unit and a method for assembling a rotary electric machine.

Claims

1. A power distribution unit for a rotary electric machine, comprising:

at least one connecting ring that connects stator coils of the same phase, wherein

the at least one connecting ring includes at least one linear conductor integrally formed in a ring-like shape, and

the at least one connecting ring includes a terminal section integrally formed in the linear conductor, the terminal section including a hole through which a wiring end of one of the stator coils is to be inserted and a protrusion formed in a penetrating direction of the hole to which the wiring end of one of the stator coils is to be connected.

2. A power distribution unit for a rotary electric machine according to claim 1, further comprising:

an insulating member of a torus shape, wherein

the at least one connecting ring includes connecting rings for U-, V-, and W-phases, respectively, and a connecting ring for neutral points,

the connecting rings is arranged on the insulating member substantially in the same plane and concentrically, and

at the each terminal section, the wiring ends of the stator coils are connected to the at least one connecting ring corresponding thereto.

3. A power distribution unit for a rotary electric machine according to claim 2, wherein

the connecting rings include each a coated linear conductor with a coating of an insulation material,

the terminal section of each coated linear conductor, which is provided with the hole through which the wiring end is to be inserted and the protrusion in the penetrating direction of the hole, is free of the coating of the insulation material, and

the terminal sections of the linear conductors for U, V, and W phases and the linear conductor for the neutral points are arranged at mutually different positions in the circumferential direction such that the terminal sections are not adjacent to each other.

4. A rotary electric machine comprising a power distribution unit according to claim 1, wherein

the power distribution unit is arranged on an end face of a wiring section of the stator coil in a direction of an axis of a stator.

5. A rotary electric machine comprising a power distribution unit according to claim 1, wherein

the wiring end of the stator coil is inserted in the hole, caulked for fixation by the protrusion formed in the terminal section, and connected to the protrusion of the terminal section by soldering, welding or brazing.

6. A method for assembling a rotary electric machine comprising a power distribution unit a power distribution unit according to claim 1 and stator coils, the method comprising:

inserting the wiring end of the stator coil into the hole,

caulking the wiring end of the stator coil for fixation by the protrusion formed in the terminal section, and

connecting the wiring end of the stator coil to the protrusion of the terminal section by soldering, welding or brazing.