Rotating electrical machine and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-12034337-B2
Application number	US-202117512854-A
Country	US
Kind code	B2
Filing date	Oct 28, 2021
Priority date	Oct 29, 2020
Publication date	Jul 9, 2024
Grant date	Jul 9, 2024

Abstract

In an armature, a busbar unit includes at least first-, second-, and third-phase busbars electrically connected to respective first-, second-, and third-phase armature windings. The first-phase busbar serves as a lowermost busbar in the axial direction, the second-phase busbar serves as an intermediate busbar stacked over the lowermost busbar in the axial direction, and the third-phase busbar serves as an uppermost busbar stacked over the intermediate busbar in the axial direction. A resin member of the busbar unit covers the lowermost busbar, intermediate busbar, and uppermost busbar stacked in the axial direction, so that the lowermost busbar, intermediate busbar, and uppermost busbar are integrated to constitute a busbar stack. A protrusion member is mounted to the intermediate busbar and protruding radially outward from the intermediate busbar. At least part of the protrusion member is located to be nonoverlapped with the uppermost busbar and the lowermost busbar.

First claim

What is claimed is:

1. A rotary electric machine comprising:
an armature that comprises an armature core and first-, second-, and third-phase armature windings wound at least around the armature core;
a magnetic field generator that generates a magnetic field;
a busbar unit that comprises:
at least first-, second-, and third-phase busbars electrically connected to the respective first-, second-, and third-phase armature windings,
the first-phase busbar serving as a lowermost busbar located to face the armature core in an axial direction,
the second-phase busbar serving as an intermediate busbar stacked over the lowermost busbar in the axial direction, and
the third-phase busbar serving as an uppermost busbar stacked over the intermediate busbar in the axial direction so that the lowermost busbar, the intermediate busbar, and the uppermost busbar are stacked in the axial direction; and

a resin member that covers the lowermost busbar, the intermediate busbar, and the uppermost busbar stacked in the axial direction so that the lowermost busbar, the intermediate busbar, and the uppermost busbar are integrated to constitute a busbar stack; and

a protrusion member mounted to the intermediate busbar and protruding radially outward from the intermediate busbar, at least part of the protrusion member being located so as to be nonoverlapped with the uppermost busbar and the lowermost busbar in the axial direction, wherein:
the intermediate busbar is covered with first resin;
at least part of the protrusion member is an exposed part that is non-covered with the first resin;
the exposed part of the protrusion member is radially offset with respect to the uppermost busbar and the lowermost busbar; and
the resin member is a second resin that covers the uppermost busbar, the resin-covered intermediate busbar and the exposed part, and the lowermost busbar.

2. The rotary electric machine according to claim 1 , wherein:
each of the lowermost busbar, the intermediate busbar, and the uppermost busbar has a circular-arc shape;
each of the lowermost busbar, the intermediate busbar, and the uppermost busbar has opposing first and second ends and a middle portion positioned between the first and second ends; and
the protrusion member is mounted to the middle portion of the intermediate busbar.

3. The rotary electric machine according to claim 1 , wherein:
each of the first-, second-, and third-phase armature windings has opposing first and second ends;
each of the lowermost busbar, the intermediate busbar, and the uppermost busbar has a circular-arc shape;
each of the lowermost busbar, the intermediate busbar, and the uppermost busbar has opposing first and second ends;
the rotary electric machine further comprises:
at least one first connection terminal mounted to at least the first end of the lowermost busbar and connected to the first end of the first-phase armature winding;
at least one second connection terminal mounted to at least the first end of the intermediate busbar and connected to the first end of the second-phase armature winding; and
at least one third connection terminal mounted to the first end of the uppermost busbar and connected to the first end of the third-phase armature winding;

each of the at least one first connection terminal, the at least one second connection terminal, and the at least one third connection terminal is configured to extend in a first side of the axial direction opposite to a second side thereof, the second side of the axial direction approaching the armature core; and
the lowermost busbar, the intermediate busbar, and the uppermost busbar are stacked in the axial direction while being offset relative to one another by respective predetermined angles in a circumferential direction of the armature core so that
the at least one first connection terminal mounted to the first end of the lowermost busbar is located between the at least one second connection terminal mounted to the first end of the intermediate busbar and the at least one third connection terminal mounted to the first end of the uppermost busbar in the circumferential direction.

4. The rotary electric machine according to claim 3 , wherein:
the at least one first connection terminal comprises a plurality of first connection terminals mounted respectively to the outer peripheral surface of at least the first end of the lowermost busbar;
the at least one second connection terminal comprises a plurality of second connection terminals mounted respectively to the outer peripheral surface of at least the first end of the intermediate busbar; and
the at least one third connection terminal comprises a plurality of third connection terminals mounted respectively to the outer peripheral surface of at least the first end of the uppermost busbar.

5. The rotary electric machine according to claim 1 , wherein:
each of the first-, second-, and third-phase armature windings has opposing first and second ends;
each of the lowermost busbar, the intermediate busbar, and the uppermost busbar has a circular-arc shape;
each of the lowermost busbar, the intermediate busbar, and the uppermost busbar has opposing first and second ends;
the rotary electric machine further comprises:
at least one first connection terminal mounted to an inner peripheral surface or an outer peripheral surface of at least the first end of the lowermost busbar and connected to the first end of the first-phase armature winding, the at least one first connection terminal extending in the axial direction;
at least one second connection terminal mounted to an inner peripheral surface or an outer peripheral surface of at least the first end of the intermediate busbar and connected to the first end of the second-phase armature winding, the at least one second connection terminal extending in the axial direction; and
at least one third connection terminal mounted to an inner peripheral surface or an outer peripheral surface of the first end of the uppermost busbar and connected to the first end of the third-phase armature winding, the at least one third connection terminal extending in the axial direction; and

each of the lowermost, intermediate, and uppermost busbars includes a recess formed inwardly in a portion thereof,
the portion with the recess of each of the lowermost, intermediate, and uppermost busbars being located to radially face one of the first, second, and third connection terminals of another of the lowermost, intermediate, and uppermost busbars, and
the recess of each of the lowermost, intermediate, and uppermost busbars being configured to enable the one of the first, second, and third connection terminals of the other of the lowermost, intermediate, and uppermost busbars to bypass the corresponding one of the lowermost, intermediate, and uppermost busbars.

6. A method of manufacturing a rotary electric machine that comprises:
an armature that comprises an armature core and first-, second-, and third-phase armature windings wound at least around the armature core;
a magnetic field generator that generates a magnetic field;
a busbar unit that comprises:
at least first-, second-, and third-phase busbars electrically connected to the respective first-, second-, and third-phase armature windings,
the first-phase busbar serving as a lowermost busbar located to face the armature core in an axial direction,
the second-phase busbar serving as an intermediate busbar stacked over the lowermost busbar in the axial direction, and
the third-phase busbar serving as an uppermost busbar stacked over the intermediate busbar in the axial direction so that the lowermost busbar, the intermediate busbar, and the uppermost busbar are stacked in the axial direction; and

a resin member that covers the lowermost

Assignees

• Denso Corp

Inventors

• Okamura Tomoyuki
• Hirai Kensuke
• Kurasawa Tadahiro

Classifications

• H02K35/06

  with moving flux distributors, and both coil systems and magnets stationary · CPC title

• H02K1/265

  Shape, form or location of the slots · CPC title

• H02K5/08

  Insulating casings · CPC title

• H02K2203/09

  Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations · CPC title

• H02K3/04

  Windings characterised by the conductor shape, form or construction, e.g. with bar conductors · CPC title