JP2009033850A - Brushless motor, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a brushless motor in which a magnetic pole position detecting element can be highly accurately positioned to a coupler configuring the brushless motor. <P>SOLUTION: Lead terminals of Hall ICs 24a-24c sealed in a sealing resin 163 are bonded in advance at predetermined positions of bus bars 144, and hole portions drilled and formed on the bus bars 144 are closed with a resin. In executing this process, positioning pins 164a, 164b are each inserted into the through holes 162 of tub portions 160a, 160b of the bus bars 144. In addition, the bus bars 144 are set on a molding die, and a molten resin is supplied to the molding die in a state where the positioning pins 166a, 166b are each inserted into the through holes 162 to seal the bus bars 144 in a resin, thereby forming a housing. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a brushless motor that generates power when a magnet close to an electromagnetic coil rotates, and a method for manufacturing the same.

As this type of brushless motor, there is known a configuration in which an electromagnetic coil is positioned and fixed in a cylindrical shape on a casing, while a main magnet rotates in the cylindrical electromagnetic coil.

  Here, the main magnet is held by a shaft inserted into the casing. On the other hand, a secondary magnet is held at the tip of the shaft. In the brushless motor, the position of the magnetic pole of the sub-magnet, in other words, the portion where the polarity is displaced (polarity variation point) is detected by a magnetic pole position detection element such as a Hall IC.

  In addition, as for Hall IC etc., the lead terminal part is joined to a board | substrate, and it is usual to be enclosed with resin with the said board | substrate in this state (for example, refer patent document 1), and the coupler is comprised by this. .

Japanese Patent Laid-Open No. 7-22722

  When the coupler is provided through the above-described process, the Hall IC is pressed with the melt when the melt is introduced to mold the encapsulating resin. For this reason, in some cases, the Hall IC may be displaced. In other words, a problem that it is not easy to improve the positioning accuracy of the Hall IC has become apparent in the couplers constituting the brushless motor according to the related art. If the Hall IC (magnetic pole position detection element) is excessively misaligned, the polarity variation point of the secondary magnet cannot be detected accurately, resulting in a situation where the output of the brushless motor decreases. I will.

  The present invention has been made to solve the above-described problem, and can accurately position the magnetic pole position detection element, and thus can accurately detect the polarity variation point and its manufacture. It aims to provide a method.

In order to achieve the above object, the present invention is a brushless motor having a coupler provided with a magnetic pole position detecting element for detecting the position of a magnetic pole of a magnet held on a shaft,
The coupler has a bus bar coated with resin,
The magnetic pole position detecting element is characterized in that a terminal portion is bonded to the bus bar and is covered with a resin separate from the resin.

  With this configuration, the stress acting on the magnetic pole position detecting element when the coupler is provided is reduced. This is because, as will be described later, the magnetic pole position detecting element is coated with a resin, and for this reason, after the rigidity is secured, a melt of the resin that becomes the coupler body is introduced.

  For this reason, the magnetic pole position detecting element can be accurately positioned. Therefore, there is no need to provide a position adjusting hole for exposing a member for adjusting the position of the magnetic pole position detecting element. Furthermore, it is not necessary to provide a displacement means for displacing the position of the magnetic pole position detection element. Therefore, it is possible to configure a brushless motor with a simple configuration.

  The bus bar is preferably provided with a positioning through hole. In this case, the bus bar is firmly positioned and fixed by inserting a positioning member into the positioning through-hole in two steps of providing the resin for covering the magnetic pole position detecting element and providing the resin to be the coupler body. Can do. For this reason, even if the bus bar is pressed by the melted resin, it is avoided that the bus bar is displaced. For this reason, the positional accuracy of the magnetic pole position detecting element can be further improved.

  The coupler is preferably further provided with an engaging portion. On the other hand, if a member to be connected to the coupler, for example, a casing, is provided with an engaged portion and the engaged portion is engaged with the engaged portion, the coupler is displaced even after the brushless motor is configured. Waking up is avoided. Accordingly, it is possible to accurately detect the polarity mutation point over a long period of time, and as a result, the operation reliability of the brushless motor is ensured.

Further, the present invention is a method of manufacturing a brushless motor having a coupler provided with a magnetic pole position detection element for detecting the position of a magnetic pole of a magnet held on a shaft,
The step of coating the magnetic pole position detection element with resin, the step of bonding the magnetic pole position detection element coated with resin to the bus bar, the step of coating the bus bar with resin, and molding the housing of the coupler from resin And producing the coupler through a process.

  In this way, the magnetic pole position detecting element is prevented from being misaligned by encapsulating the magnetic pole position detecting element in the resin and securing the rigidity, and then molding the resin that becomes the coupler body. As a result, it is possible to accurately detect the polarity variation point of the magnet.

  In this case, it is preferable to provide a positioning through hole in the bus bar. Accordingly, the positioning member can be inserted into the positioning through hole when the step of covering the bus bar with the resin and the step of molding the coupler housing from the resin. Therefore, in both steps, even if the bus bar is pressed by the melt of the resin, it is avoided that the bus bar is displaced. For this reason, the positional accuracy of the magnetic pole position detecting element can be further improved.

  In the present invention, after the magnetic pole position detecting element is sealed in resin to ensure rigidity, the bus bar to which the magnetic pole position detecting element is bonded is sealed in the resin. As described above, the resin for covering the magnetic pole position detecting element and the resin for covering the bus bar are separately provided, so that the magnetic pole position detecting element is firmly positioned and fixed. Therefore, the position accuracy of the magnetic pole position detection element is improved, and the polarity variation point of the magnet can be accurately detected.

  After all, according to the present invention, a brushless motor having excellent operation reliability can be configured.

  Hereinafter, the brushless motor according to the present invention will be described in detail with reference to the accompanying drawings by exemplifying a case where the brushless motor is mounted on an internal combustion engine mounted on an automobile as a preferred embodiment.

  1 to 3 are a schematic overall perspective configuration diagram, a side longitudinal sectional view, and a rear configuration diagram, respectively, of a brushless motor 10 according to the present embodiment. The brushless motor 10 includes a holder base 12 coupled to a cylinder head (not shown), a first coupler 18 having a connector 16 electrically connected to an electromagnetic coil 14 (see FIG. 2), the electromagnetic coil 14 and the main coil. A casing 22 that houses the magnet 20 and a second coupler 26 in which the opening end of the casing 22 is closed and the three Hall ICs 24a to 24c are positioned and fixed. A shaft 28 is inserted from the holder base 12 to the tip of the casing 22.

  A hollow projecting portion 30 is formed substantially at the center of the end surface of the holder base 12 facing the cylinder head. The shaft 28 is inserted into the hollow projecting portion 30, and an oil seal 32 and a first bearing 34 are interposed in this order from the cylinder head side between the shaft 28 and the inner wall of the hollow projecting portion 30. Yes.

  The holder base 12 is provided with three screw holes 36a to 36c (see FIG. 3), while the casing 22 is also formed with three screw holes 38a to 38c (see FIG. 2). ). The holder base 12 and the casing 22 are connected to each other through screws 40 that are passed through the screw holes 36a to 36c and screwed into the screw portions of the screw holes 38a to 38c. As can be understood from FIGS. 2 and 3, in this case, each screw 40 is passed through the screw holes 36a to 36c so that each head faces the cylinder head side. Each head is located at a location slightly recessed from the end surface of the holder base 12.

  The holder base 12 further has a substantially triangular wide portion 42 (see FIGS. 1 and 3), and through holes 44a to 44c are formed in the vicinity of the curved top portion of the wide portion 42, respectively. Yes.

  As shown in FIG. 4, the first coupler 18 includes a molding material 50 having an annular portion 46 and a plug portion 48 integrated with a side peripheral wall of the annular portion 46. Among these, a bridge portion 52 projects radially inward from the inner peripheral wall of the annular portion 46, and a total of 24 connectors 16 are provided at the ends of the bridge portions 52.

  That is, in the general brushless motor, the connector is provided so as to protrude outward of the coupler, whereas the connector 16 of the first coupler 18 in the brushless motor 10 according to the present embodiment is inward. It is provided to protrude. In other words, the brushless motor 10 does not have the connector 16 protruding outward from the annular portion 46. Accordingly, the plug portion 48 can be provided outside the annular portion 46, and the plug portion 48 and the annular portion 46 can be installed at the same height (see FIG. 2). The height dimension of the first coupler 18 can be reduced as compared with the coupler according to the prior art in which the plug portion must be disposed at a height position that does not interfere with the connector because of protruding outward. it can. For this reason, the brushless motor 10 can be reduced in size.

  The connector 16 slightly protrudes in the height direction with respect to the end face of the annular portion 46. As can be understood from FIG. 2, the first coupler 18 is attached so that the connector 16 of the annular portion 46 is inserted into the open end of the holder base 12.

  Three terminal portions 54a to 54c extend inside the plug portion 48 (see FIGS. 2 and 5), and these three terminal portions 54a to 54c have three phases of U phase, V phase, and W phase. Phase contacts are configured. That is, four of the connectors 16 are connected to each of the terminal portions 54a to 54c via terminals 56a to 56c (see FIG. 5) described later. Note that twelve connectors 16 are connected to the terminal 56d (see FIG. 5).

  As shown in FIG. 6, the bridge portion 52 is bent at approximately 90 °, and a claw portion 58 is provided in the vicinity of the bending point. The claw portion 58 is locked in a state where a conducting wire 60 extending from the electromagnetic coil 14 (see FIG. 2) is pulled. That is, tension is acting on the conducting wire 60.

  The connector 16 has a portion joined to the tip of the bridge portion 52 as a starting point, and has a substantially V-shaped shape with its approximately middle abdomen being bent by about 300 °. As shown in FIG. 7, the corners are chamfered on the surface of the connector 16 facing the conductor 60. In other words, the portion of the connector 16 that contacts the conductive wire 60 is curved, so that the stress acting on the conductive wire 60 is reduced.

  The leading end of the conducting wire 60 is bent approximately 90 ° in the vicinity of the connector 16, and then passed through the connector 16 and locked to the claw portion 58 (see FIG. 6). Thereafter, the connector 16 is crushed (see FIG. 7), and the connector 16 and the conductive wire 60 are joined to each other by electrodeposition.

  As shown in FIG. 4, the bridge portions 52 are adjacent to each other to form a bridge portion pair 62. The two bridge portions 52, 52 forming the bridge portion pair 62 protrude from the inner wall of the annular portion 46 so as to extend in parallel with each other. Therefore, when joining the connector 16 and the conducting wire 60, after electrodeposition is performed on one pair of bridge portions 62, the angle may be changed and the next bridge portion pair 62 may be joined. That is, although the number of times that electrodeposition should be performed is 24, the angle change at the time of joining needs to be performed only 12 times. As described above, according to the present embodiment, since the number of angle changes is small, the production tact of the brushless motor 10 can be shortened.

  Here, the first coupler 18 is manufactured as follows. That is, first, as shown in FIG. 5, the terminal 56 a provided with the terminal portion 54 a at the end and connected to the connector 16 via the bridge portion 52 in the extending direction is bent into a polygonal shape. Similarly, the terminals 56b and 56c provided with the terminal portion 54b or the terminal portion 54c are bent into a polygonal shape, and further, the terminal 56d without the terminal portion is bent into a polygonal shape, and then the terminals 56a. To 56d, the polygonal bodies are brought close to each other so that the terminal portions 54a to 54c are adjacent to each other and extend in the same direction.

  Next, the polygonal terminals 56a to 56d adjacent to each other are accommodated in the guide member 64 (see FIG. 2), and in this state, set in the mold apparatus. And the molding material 50 which has the annular part 46 and the plug part 48 is provided by supplying the molten material of resin to a metal mold apparatus, and cooling and solidifying this resin. As a result, the first coupler 18 shown in FIG. 4 is obtained.

  When the polygonal body (see FIG. 5) is provided in this way, the springback is smaller than when the terminals 56a to 56d are circular. For this reason, there exists an advantage that a dimensional accuracy becomes favorable.

  Moreover, when the polygonal bodies are brought close to each other, positional displacement is unlikely to occur. This is because if a positional shift occurs, the vertex interferes with an adjacent polygonal body. Therefore, it becomes extremely easy to insert the terminals 56a to 56d into the guide member 64. In addition, since the terminals 56a to 56d (polygonal bodies) are sealed in the molding material 50, the terminals 56a to 56d can be connected even when vibration is applied as the automobile equipped with the brushless motor 10 is operated. The occurrence of displacement is remarkably suppressed.

  That is, by forming the terminals 56a to 56d into polygonal bodies and encapsulating them in the molding material 50, the terminals 56a to 56d have excellent dimensional accuracy and are easy to handle, and have extremely good earthquake resistance and the terminals 56a to 56d. Thus, it is possible to obtain the first coupler 18 that is less likely to be displaced.

  The casing 22 accommodates the electromagnetic coil 14 along the inner wall (see FIG. 2). On the other hand, a magnet holder 66 is fitted on the side wall of the shaft 28, and the main magnet 20 is held by the magnet holder 66 so as to face the electromagnetic coil 14. Accordingly, the magnet holder 66 and the main magnet 20 rotate around the shaft 28 as the shaft 28 rotates, and repeat relative position changes with respect to the electromagnetic coil 14. The magnet holder 66 is a hollow body having an open end, and the inner wall thereof is separated from the side peripheral wall of the shaft 28 at a predetermined interval.

  The shaft 28 is provided with an annular step portion 68, and a wedge member 70 is fitted to the shaft 28 so as to contact the annular step portion 68. The annular holder of the wedge member 70 is press-fitted between the inner wall of the magnet holder 66 and the side peripheral wall of the shaft 28, so that the magnet holder 66 is positioned and fixed.

  A narrow portion 74 that narrows the inner diameter of the casing 22 is formed at the end of the casing 22 on the second coupler 26 side so as to protrude radially inward. A second bearing 76 is held in the narrow portion 74.

  A tooth portion 78 such as a spline is formed at the end of the shaft 28 on the holder base 12 side. The tooth portion 78 meshes with a tooth portion of a rotating shaft (not shown) provided in the internal combustion engine including the cylinder head. On the other hand, a bottomed screw hole 80 is provided at the end on the second coupler 26 side, and the secondary magnet 84 is connected to the tip of the shaft 28 via a magnet holding screw 82 screwed into the bottomed screw hole 80. Held in the department. As can be understood from FIG. 2, the secondary magnet 84 is close to the Hall ICs 24 a to 24 c in the second coupler 26.

  Here, the polarities of the main magnet 20 and the sub magnet 84 are schematically shown in FIG. FIG. 8 is an upper plan view shown from the second coupler 26 side.

  As shown in FIG. 8, in the brushless motor 10, the same polarity portions of the main magnet 20 and the submagnet 84 are similar to each other, and the phases thereof are the same. Therefore, it is not necessary to adjust the location of the sensor 90 that monitors the position of the polarity variation point in the sub magnet 84. Naturally, as schematically shown in FIG. 9, it is not necessary to provide an adjustment hole (such as a long hole) for adjusting the arrangement position of the sensor 90 from the outside.

  That is, according to the present embodiment, the two steps of providing the adjustment hole and adjusting the location where the sensor 90 is arranged are not necessary. Thereby, the manufacturing process of the brushless motor 10 is simplified, the production efficiency is improved, and the manufacturing cost can be reduced.

  The phases of the main magnet 20 and the sub magnet 84 can be matched using the magnetizing apparatus 100 shown in FIG. This magnetizing apparatus 100 includes a pedestal 104 provided with legs 102, an extrusion cylinder 106 installed so as to extend in parallel with the legs 102, and a magnetizing device positioned and fixed on the pedestal 104. Yoke 108. A terminal box 110 is disposed in the vicinity of the magnetizing yoke 108, and the magnetizing yoke 108 is magnetized / demagnetized in accordance with ON / OFF of a switch (not shown) provided therein.

  A through hole 112 is formed in the magnetizing yoke 108. The rod 114 constituting the extrusion cylinder 106 protrudes from the pedestal 104 so as to pass through the through hole 112. The inner diameter of the magnetizing yoke 108 is narrowed by a projecting narrow portion 116 projecting radially inward downward in FIG. On the other hand, a small-diameter portion 118 is formed at the upper end of the magnetizing yoke 108 by reducing the outer diameter.

  The first coupler 18 is further attached to the shaft 28 that holds the main magnet 20 via the magnet holder 66 and holds the auxiliary magnet 84 via the magnet holding screw 82. In this state, the shaft 28 is inserted into the through hole 112 of the magnetizing yoke 108 so that the sub magnet 84 is positioned downward.

  As shown in FIG. 10, when the first coupler 18 is seated on the end surface of the small diameter portion 118, the secondary magnet 84 is surrounded by the projecting narrow portion 116, and the main magnet 20 extends from above the projecting narrow portion 116 to the small diameter portion 118. It is surrounded by the part that reaches almost directly below. At this time, the distance between the main magnet 20 and the inner wall of the magnetizing yoke 108 and the distance between the sub magnet 84 and the inner wall of the magnetizing yoke 108 (projecting narrow portion 116) are substantially the same.

  Further, the magnetizing yoke 108 is magnetized as the switch of the terminal box 110 is turned on, and as a result, both the main magnet 20 and the sub magnet 84 are magnetized simultaneously. The distance between the main magnet 20 and the inner wall of the magnetizing yoke 108 is substantially the same as the distance between the sub magnet 84 and the inner wall of the magnetizing yoke 108 (projecting narrow portion 116). The magnet 84 is magnetized so as to develop substantially the same magnetic force.

  Further, in this case, the magnetizing yoke 108 is integrally formed from the projecting narrow portion 116 to the small diameter portion 118. Therefore, a magnetic field in the same direction is formed in the magnetizing yoke 108 from the protruding narrow portion 116 to the small diameter portion 118. For this reason, the main magnet 20 and the sub-magnet 84 have polarities of the same phase (see FIG. 8).

  In short, the main magnet 20 and the sub-magnet 84 can be magnetized simultaneously using the same magnetizing yoke 108, whereby the main magnet 20 and the sub-magnet 84 can be provided with the same phase polarity. Thereby, as described above, the two steps of providing the adjustment hole and adjusting the position where the sensor 90 is arranged are not necessary, and the production efficiency of the brushless motor 10 is improved. In addition, it is possible to reduce the manufacturing cost.

  After the magnetization of the main magnet 20 and the sub magnet 84 is completed, the switch is turned off, and the rod 114 of the push-out cylinder 106 moves forward. Accordingly, the shaft 28 is pressed, and the shaft 28 is taken out from the through hole 112 of the magnetizing yoke 108.

  As shown in FIG. 11, the second coupler 26 includes a disk portion 130 that closes the opening end portion of the casing 22, and a plug portion 132 that is integrated with a side peripheral wall of the disk portion 130. Among these, a circular concave portion 134 is formed in the disc portion 130, and the Hall ICs 24a to 24c are provided on the ceiling surface of the circular concave portion 134 in a state of being sealed in resin.

  Three screw seats 136 that are spaced apart from each other at substantially equal intervals protrude from the side wall of the disk portion 130, and screws 140 (see FIGS. 1 and 2) that are passed through the through holes 138 of the screw seat 136. The second coupler 26 is fitted into the casing 22 by being screwed into a screwing hole 142 provided on the end surface of the casing 22.

  In the plug portion 132, six terminal portions 146a to 146f extending integrally from the bus bar 144 (see FIG. 12A) and electrically connected to any of the Hall ICs 24a to 24c protrude. In other words, the lead terminals of the Hall ICs 24 a to 24 c are joined on the bus bar 144.

  Here, the 2nd coupler 26 is produced through the process shown to FIG. 12A-FIG. 12C. First, the bus bar 144 shown in FIG. 12A is prepared. The bus bar 144 extends from each of an arc portion 148 that is curved in an arc shape, six straight portions 150a to 150f that linearly extend from the end of the arc portion 148, and straight portions 150a to 150f. The terminal portions 146a to 146f are included. A mount portion 154 for joining the Hall ICs 24a to 24c to the capacitor 152 and the like is provided on the arc portion 148. In this case, the first support frame 156 is bridged so as to connect the mount portions 154 to each other. On the other hand, the straight portions 150a to 150f are integrally connected via a second support frame 158 extending in a direction orthogonal to the extending direction of the straight portions 150a to 150f.

  And tab part 160a, 160b is formed in the side surface in the linear part 150a, 150f of both ends, and protrudes outward. A through hole 162 is provided in each of the tab portions 160a and 160b.

  Next, lead terminals such as Hall ICs 24a to 24c or capacitors 152 sealed in an encapsulating resin material 163 such as an epoxy resin are joined to predetermined positions of the mount portion 154 in the bus bar 144. In this case, three Hall ICs 24 a to 24 c are installed on the mount portion 154.

  Next, the bus bar 144 is set in the mold apparatus. At this time, as shown in FIG. 12A, positioning pins 164a and 164b are passed through the through holes 162 of the tab portions 160a and 160b, respectively. As a result, the bus bar 144 is firmly positioned and fixed.

  In this state, molten resin (for example, polypropylene sulfide resin) is supplied to the mold apparatus. As described above, since the bus bar 144 is firmly positioned and fixed, it is avoided that the bus bar 144 is displaced due to the pressing force of the supplied melt. Therefore, the melt can be supplied only to a predetermined position of the bus bar 144.

  When the melt is cooled and solidified after a predetermined time has elapsed, as shown in FIG. 12B, the resin is interposed between the mount portions 154 and between the straight portions 150a to 150f. Next, the resin in the vicinity of the lead terminals in the Hall ICs 24a to 24c or the capacitor 152 is removed, and unnecessary portions such as the first support frame 156 and the second support frame 158 are cut from the bus bar 144 as shown in FIG. 12C. . Thereby, Hall IC24a-24c is mutually insulated.

  Further, the bus bar 144 is set in a mold apparatus different from the mold apparatus. Also at this time, as shown in FIG. 12C, the positioning pins 166a and 166b are respectively passed through the through holes 162 of the tab portions 160a and 160b, so that the bus bar 144 is firmly positioned and fixed.

  In this state, a melt of resin (for example, polypropylene sulfide resin) is supplied to the mold apparatus. Of course, in this case as well, it is avoided that the bus bar 144 pressed by the melt is displaced. This is because the bus bar 144 is firmly positioned and fixed as described above.

  Then, if the melt is cooled and solidified, a housing including a disk portion 130 in which a bus bar 144 is sealed with resin, a plug portion 132 surrounding the terminal portions 146a to 146f, and the like is formed. The second coupler 26 shown is obtained.

  In this way, elements such as Hall ICs 24a to 24c are first joined to the bus bar 144, and then primary molding for closing the hole of the bus bar 144 and secondary molding for providing the disk portion 130 and the plug portion 132 are performed. By doing so, the second coupler 26 in which each element is positioned and fixed with high precision can be produced. In this embodiment, since the bus bar 144 is positioned and fixed using the positioning pins 164a, 164b, 166a, and 166b in both the primary molding and the secondary molding, the positional accuracy of the element is further improved. Can do.

  In the second coupler 26, a convex portion 168 is formed in the vicinity of the plug portion 132 of the disc portion 130. The convex portion 168 is inserted into a concave portion (not shown) provided on the end surface of the casing 22, whereby the second coupler 26 is positioned and fixed more firmly.

  Note that reference numerals 170, 172, and 174 in FIG. 2 indicate O-rings as sealing materials.

  The brushless motor 10 according to the present embodiment configured as described above operates as follows.

  The brushless motor 10 is attached to the internal combustion engine such that the holder base 12 faces the cylinder head. At this time, screws (not shown) are passed through through holes 44a to 44c (see FIG. 1) provided in the wide portion 42 of the holder base 12, and each of the screws is screwed into a screw hole of the cylinder head. And the tooth part 78 (refer FIG. 2) of the shaft 28 is meshed | engaged with the tooth | gear part of the rotating shaft which is provided in the internal combustion engine (not shown).

  When the internal combustion engine is operated while the automobile is running, the internal combustion engine vibrates. As a result, vibration is also applied to the brushless motor 10.

  As described above, the screw 40 is screwed so that the head portion faces the cylinder head. The screw holes 36a to 36c are closed by the cylinder head. For this reason, even if the screw 40 is loosened due to the addition of vibration over a long period of time, the screw 40 does not fall off the holder base 12.

  In other words, the connection between the holder base 12 and the casing 22 is reliably maintained over a long period of time. That is, the operational reliability of the brushless motor 10 over a long period is ensured.

  Further, since the head of the screw 40 faces the cylinder head side, it is not necessary to project the screw seat on the casing 22 side. For this reason, it is avoided that the dimension of the width direction of the casing 22 increases.

  Furthermore, as shown in FIG. 6, the conducting wire 60 of the electromagnetic coil 14 is locked to the claw portion 58 in the vicinity of the connector 16 of the first coupler 18 in a state where tension is applied. For this reason, even if the internal combustion engine vibrates, it is difficult for the lead wire 60 to be detached from the connector 16.

  In addition, since chamfering is applied to the corner of the surface of the connector 16 facing the conductor 60 (see FIG. 7), the stress acting on the conductor 60 is small. For this reason, it is avoided that the conducting wire 60 breaks from the contact point with the corner of the connector 16 as a starting point.

  In addition to the fact that the phases of the same polarity parts of the main magnet 20 and the sub-magnet 84 coincide with each other and the Hall ICs 24a to 24c are accurately placed at predetermined positions of the second coupler 26 as described above, Since the second coupler 26 is firmly positioned and fixed by inserting the convex portion in the vicinity of the plug portion 132 of the two coupler 26 into the concave portion of the end face of the casing 22, the operational reliability of the brushless motor 10 is ensured over a long period of time. The

  As described above, according to the present embodiment, it is possible to configure the brushless motor 10 that is small and excellent in reliability. Further, since the brushless motor 10 is downsized, there is an advantage that the degree of freedom of layout of the internal combustion engine is expanded.

  Moreover, since the magnet holder 66 is a hollow body, the driving force for rotating the shaft 28 can be reduced. As a result, power for operating the brushless motor 10 can be saved.

  In addition, since the magnet holder 66 is a hollow body and has a low weight, the shaft 28 in a stopped state can be rotated in a short time. On the other hand, since the magnet holder 66 is low in weight, inertia when the rotation of the shaft 28 is stopped, that is, so-called inertia is reduced. In other words, the rotation of the shaft 28 can be stopped in a short time.

  That is, according to the present embodiment, it is possible to configure the brushless motor 10 with low power consumption and good response speed.

  In the above-described embodiment, the brushless motor 10 mounted on an automobile is described as an example. However, the application of the brushless motor 10 is not particularly limited thereto.

1 is a schematic overall perspective view of a brushless motor according to an embodiment. It is a side longitudinal cross-sectional view of the brushless motor of FIG. It is a back surface block diagram of the brushless motor of FIG. It is a schematic whole top view of the 1st coupler which comprises the brushless motor of FIG. It is a schematic whole top view which shows the terminal and connector which comprise the 1st coupler of FIG. FIG. 6 is a main part enlarged configuration explanatory view showing an enlarged vicinity of the connector of FIGS. 4 and 5. It is principal part expansion structure explanatory drawing which expands and shows the connector vicinity of FIG.4 and FIG.5 from another viewpoint. FIG. 2 is an upper plan explanatory view schematically showing polar phases of a main magnet and a sub magnet constituting the brushless motor of FIG. 1. FIG. 2 is a schematic upper plan explanatory view of the brushless motor of FIG. 1. 1 is an overall schematic partial cross-sectional front view of a magnetizing apparatus for magnetizing a main magnet and a sub magnet. FIG. It is a schematic whole top view of the 2nd coupler which comprises the brushless motor of FIG. FIG. 12A to FIG. 12C are flow explanatory diagrams showing a schematic manufacturing process of the second coupler.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Brushless motor 12 ... Holder base 14 ... Electromagnetic coil 16 ... Connector 18 ... 1st coupler 20 ... Main magnet 22 ... Casing 24a-24c ... Hall IC
26 ... 2nd coupler 28 ... Shaft 36a-36c ... Screw hole 40 ... Screw 46 ... Ring part 48 ... Plug part 50 ... Mold material 54a-54c ... Terminal part 56a-56d ... Terminal 58 ... Claw part 60 ... Conductor 62 ... Bridge part pair 64 ... guide member 66 ... magnet holder 78 ... tooth part 82 ... magnet holding screw 84 ... secondary magnet 90 ... sensor 144 ... bus bar 146a to 146f ... terminal part 156 ... first support frame 158 ... second support frame 160a, 160b ... tab portion 162 ... through holes 164a, 164b, 166a, 166b ... positioning pins

Claims (5)

A brushless motor having a coupler provided with a magnetic pole position detection element for detecting the position of a magnetic pole of a magnet held on a shaft,
The coupler has a bus bar coated with resin,
The magnetic pole position detection element has a terminal part joined to the bus bar and is covered with a resin separate from the resin.   2. The brushless motor according to claim 1, wherein a positioning through-hole for inserting a positioning member for positioning and fixing the bus bar when the two types of the resin are provided on the bus bar is provided. motor.   3. The brushless motor according to claim 1, wherein an engaging portion is provided on the coupler, an engaged portion is provided on a member connected to the coupler, and the engaging portion is engaged with the engaged portion. A brushless motor characterized by that. A method of manufacturing a brushless motor having a coupler provided with a magnetic pole position detection element for detecting the position of a magnetic pole of a magnet held on a shaft,
The step of coating the magnetic pole position detection element with resin, the step of bonding the magnetic pole position detection element coated with resin to the bus bar, the step of coating the bus bar with resin, and molding the housing of the coupler from resin A method of manufacturing a brushless motor, comprising: manufacturing the coupler through a process.   5. The manufacturing method according to claim 4, wherein the bus bar is provided with a positioning through-hole, and each of the step of covering the bus bar with resin and the step of molding the coupler housing from resin. A method for manufacturing a brushless motor, wherein a positioning member is inserted into the through hole for positioning and the bus bar is positioned and fixed.

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