Motor

• US 7,737,587 B2
• Filed: 02/29/2008
• Issued: 06/15/2010
• Est. Priority Date: 03/01/2007
• Status: Active Grant

• Current Assignee: Nidec Corporation
• Original Assignee: Nidec Corporation
• Inventors: Kataoka, Nakaba, Migita, Takayuki, Haga, Hidehiro
• Primary Examiner(s): Leung; Quyen
• Assistant Examiner(s): KENERLY, TERRANCE L
• Application Number:
  US12/039,819
• Publication Number:
  US 20080211332A1
• Time in Patent Office: 837 Days
• Field of Search: 174/68.2, 310/71, 310/68.A, 310/68.B, 310/68.C, 310/68.D
• US Class Current: 310/71
• CPC Class Codes: H02K 11/20 for measuring, monitoring, testing, protecting or switching rectifiers H02K11/04; power electronics H02K11/33
• CPC Class Codes: H02K 11/215 Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
• CPC Class Codes: H02K 29/08 using magnetic effect devices, e.g. Hall-plates, magneto-resistors H02K29/12 takes precedence
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02K 7/083 radially supporting the rotary shaft at both ends of the rotor H02K7/086, H02K7/09 take precedence

Abstract

A motor having a busbar unit which is accommodated in a housing along with an armature includes a relay wherein the connection between the armature and the relay is secured. By virtue of such a configuration, reliability of the connection between the armature and the relay is improved. In the busbar unit, a plurality of first busbars and a plurality of second busbars each having a substantially arcuate shape are arranged so as to be circumferentially spaced apart from one another. The first busbars do not overlap with the second busbars in the axial and radial directions thereby reducing the dimensions of the motor in the axial and radial directions.

Claims

1. A motor comprising:

a stator portion including an armature;

a rotor portion including a field magnet which generates, along with the armature, a torque centered about a central axis;

a bearing mechanism rotatably supporting the rotor portion with respect to the stator portion centered about the central axis;

a busbar unit arranged at one axial side of the motor to connect the armature to an external power source; and

a housing accommodating therein the stator portion, the rotor portion, the bearing mechanism, and the busbar unit;

wherein

the armature includes;

a plurality of teeth arranged in a circumferential direction centered about the central axis;

an insulator arranged to cover a surface of each tooth; and

a plurality of coils defined by a wire wound around corresponding teeth via the insulator;

the busbar unit includes;

a relay arranged to operate a control drive current conducted to the armature from the external power source;

a plurality of first busbars arranged to connect the coils and the external power source;

a plurality of second busbars arranged to connect the coils and the relay; and

a busbar holder arranged to retain the first busbars and the second busbars in a non-contact manner between the first busbars and the second busbars;

each first busbar includes at least one first terminal at which one end of each wire forming the coils is connected;

each second busbar includes at least one second terminal at which another end of each wire forming the coils is connected; and

the busbar holder has a substantially annular shape or a substantially arcuate shape centered about the central axis and is made of an insulating material.

2. The motor according to claim 1, wherein the first busbars each have a substantially arcuate shape centered about the central axis, the second busbars each have a substantially arcuate shape centered about the central axis, and the first busbar and the second busbar are arranged so as to be spaced apart from one another in a circumferential direction.

3. The motor according to claim 2, wherein a portion of the first busbar overlaps with a portion of another first busbar in an axial direction, and a portion of the second busbar overlaps with a portion of another second busbar in the axial direction.

4. The motor according to claim 2, wherein each of the first busbars and each of the second busbars include a substantially cylindrical surface facing inwardly in the radial direction and extending in the axial direction, a portion of the first busbar overlaps with a portion of another first busbar in an axial direction, and a portion of the second busbar overlaps with a portion of another second busbar in the axial direction.

5. The motor according to claim 4, wherein the busbar holder includes a plurality of groove portions having a substantially annular shape or a substantially arcuate shape centered about the central axis, and the first busbars and the second busbars are accommodated in corresponding ones of the groove portions.

6. The motor according to claim 4, wherein the coils are defined by the wire wound around each tooth in a concentrated manner, a portion of the coils are correspondingly connected in a parallel manner to a plurality of electrodes of the external power source, and a plurality of connecting wire portions which are portions of the wire connecting the coils to the first terminal and the coils to the second terminal are arranged at one axial side of the coils.

7. The motor according to claim 6, wherein a number of the first busbars and a number of the second busbars each equal a number of phases of a drive current conducted to the armature from the external power source, each of the first busbars includes a first terminal, and each of the second busbars includes a second terminal.

8. The motor according to claim 7, wherein the number of phases of the drive current is three, two of the three first busbars each include a portion overlapping each other in the radial direction, and two of the three second busbars each include a portion overlapping each other in the radial direction.

9. The motor according to claim 6, wherein the field magnet is arranged radially inward of the armature, at least one of the insulator and the busbar holder includes an inner side protruding portion arranged radially inward of the coils in a substantially annular manner and protruding toward at least one of the insulator and the busbar holder, and the inner side protruding portion covers a radially inner side of each connecting wire portion.

10. The motor according to claim 9, wherein at an end of the inner side protruding portion, an axial distance between the busbar holder and the insulator is smaller than a diameter of the connecting wire portion.

11. The motor according to claim 9, wherein the insulator includes the inner side protruding portion, and the end of the inner side protruding portion is nearer to the busbar holder than the coils.

12. The motor according to claim 4, wherein the coils are defined by the wire wound around each tooth in a concentrated manner, a portion of the coils are correspondingly connected in a series manner to a plurality of electrodes of the external power source, and a plurality of connecting wire portions which are a portion of the wire connecting the coils are arranged at one axial side of the coils.

13. The motor according to claim 12, wherein the field magnet is arranged radially inward of the armature, at least one of the insulator and the busbar holder includes an inner side protruding portion arranged radially inward of the coils in a substantially annular manner and protruding toward at least one of the insulator and the busbar holder, and the inner side protruding portion covers a radially inner side of each connecting wire portion.

14. The motor according to claim 13, wherein at an end of the inner side protruding portion, an axial distance between the busbar holder and the insulator is smaller than a diameter of the connecting wire portion.

15. The motor according to claim 13, wherein the insulator includes the inner side protruding portion, and the end of the inner side protruding portion is arranged nearer to the busbar holder than the coils.

16. The motor according to claim 1, wherein the insulator includes at a radially outer side of the coils an outer side protruding portion having a substantially annular shape protruding toward the busbar holder, and an end of the outer side protruding portion is arranged nearer to the busbar holder than the coils.

17. The motor according to claim 1, wherein the relay is arranged at an inner circumferential surface of the housing via an adhesive layer.

18. The motor according to claim 1, wherein the motor is arranged to assist operating a vehicle.

19. A vehicle comprising the motor according to claim 1.