JP2010148260A - Electric motor and electric power steering device including the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electric motor that achieves the size reduction, weight reduction, and cost reduction of a device by reducing the diameter of a flange faucet formed on the external surface side of a flange member while improving the strength of the flange faucet, and an electric power steering device including the same. <P>SOLUTION: The electric motor is configured such that an external casing is configured of a bottomed cylindrical motor case and a flange member mounted on an opening face of the motor case. The electric motor includes a resolver rotor fixedly provided to a motor shaft located further outside than the flange member, and a resolver stator arranged so as to face the resolver rotor. A part in the thickness direction of the resolver stator is fixed to the flange member so as to protrude from the external surface of the flange member. When the electric motor is mounted to a mounting target, a part of the resolver stator protruding from the external surface of the flange member is fitted to a flange faucet formed on a motor mounting face. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an electric motor having a resolver for detecting a magnetic pole position (rotation angle) of a rotor, and an electric power steering apparatus using the electric motor as a generation source of steering assist torque.

  In a general electric motor, a front bearing disposed on a flange member that covers an opening of the motor case and a bottom surface of the motor case in a bottomed cylindrical motor case in which a stator is attached along an inner peripheral surface A motor rotor and a motor shaft integrally coupled with the motor rotor are rotatably supported via a rear bearing disposed in the center.

  Further, this type of electric motor may be provided with a resolver for detecting the rotation angle of the motor rotor and the motor shaft. For example, Patent Document 1 discloses a conventional example. In the electric motor disclosed in Patent Document 1, the resolver rotor and the resolver stator are provided in the inlay portion of the flange member that closes the opening of the motor case in order to easily adjust the rise of the resolver signal and the induced voltage. A structure is employed in which the connection between the harness and the terminal block for connecting each coil of the stator is screwed from the outside within the flange of the flange member.

JP 2007-82285 A

  However, in the motor structure as disclosed in Patent Document 1, since the connection position of the terminal block and the harness terminal is arranged on the outer diameter side from the center of the electric motor, a structure in which the connection is made in the spigot portion of the flange member is provided. If it is going to adopt, the diameter of the spigot part must be enlarged, and as a result, there was a problem that a flange member and an electric motor will be enlarged.

  Further, when the connection structure between the terminal block and the harness terminal disclosed in Patent Document 1 is adopted, a tool for fastening a connection screw easily interferes with the flange member. Considering the workability of proper assembly, it was necessary to further increase the diameter of the spigot part.

  Further, when such an electric motor is used as a generation source of the electric power steering device, the motor mounting surface of the gear box to which the electric motor is mounted can be increased as the diameter of the spigot portion of the flange member increases. Required. As a result, it is necessary to increase the size of the gear box. As a result, the weight of the electric power steering device increases and the manufacturing cost increases.

  In general, the flange member of an electric motor is mainly formed by cutting cast aluminum, but considering the point of securing the coaxiality when attaching to the gear box or the like described above, dimensional tolerance is taken into consideration. Therefore, high-precision machining is required. In particular, in a brushless motor for an electric power steering apparatus, a resolver is used as a means for detecting the rotation angle (rotation position) of the rotor, and a structure in which a power harness or a sensor harness is provided on the flange member side and pulled out of the motor is employed. On the other hand, downsizing and weight reduction are required. In order to meet these requirements, in such a motor, the shape of the flange portion is complicated and thinned. As a result, the flange portion is easily deformed, and the inlay portion of the flange member is deformed after the motor is assembled. There was a problem of making it worse.

  This invention is made | formed in view of the said situation, The place made into the objective is reducing the diameter of the spigot part formed in the outer surface side of a flange member, and improving the intensity | strength of this spigot part. Accordingly, it is an object of the present invention to provide an electric motor and an electric power steering apparatus including the electric motor that are reduced in size, weight, and cost.

  The above-mentioned object of the present invention is to form an external housing by a bottomed cylindrical motor case having an open end and a flange member attached to the motor case so as to close the opening. A motor shaft that is rotatably supported in the motor case in an electric motor that is fixed to the mounting object in a state where the outer surface of the flange member is in contact with a motor mounting surface formed on the mounting object; A motor rotor fixed to the motor shaft in the motor case, a motor stator fixed to the inner peripheral surface of the motor case so as to face the motor rotor, and a motor shaft fixed to the outer side of the flange member. A resolver rotor provided, and a resolver stator disposed so as to face the resolver rotor, and the motor row And a resolver for detecting a rotation angle of the resolver stator, the resolver stator being fixed to the flange member so as to protrude from the outer surface of the flange member and attached to the attachment object. In this case, this is achieved by fitting a part of the resolver stator protruding from the outer surface of the flange member into an inlay portion formed on the motor mounting surface.

  Moreover, the said objective is effectively achieved because only a part of said resolver stator protrudes from the outer surface of the said flange member.

  Further, the object is that a sensor harness for transmitting a signal detected by the resolver passes through the outer casing from the resolver stator, and from the part between the motor case and the flange member, the outer casing. It is effectively achieved by being derived to the outside.

  Moreover, the said objective is effectively achieved because the cross-sectional shape of the both ends in the thickness direction of the said resolver stator is formed in substantially circle shape.

  Further, the object is that the resolver stator is fixed to the outer surface of the flange member via a screw, and the screw head is located at a portion of the motor mounting surface of the mounting object that interferes with the screw. This is effectively achieved by forming the screw escape recess formed so as not to contact.

  Further, the above object is achieved by an electric power steering apparatus provided with the above-described electric motor as a generation source of the steering assist force applied to the steering mechanism.

  Furthermore, the object is to reduce the rotational force of the electric motor and transmit it to the steering mechanism; and a gear box that houses the reduction mechanism and has a motor mounting surface to which the electric motor is fixed. This is effectively achieved by the electric power steering device provided.

  According to the electric motor and the electric power steering apparatus including the electric motor according to the present invention, the resolver including the resolver rotor and the resolver stator is disposed on the outer surface of the flange member attached so as to close the opening of the motor case. In addition, the resolver stator is fixed so that a part in the thickness direction protrudes from the outer surface of the flange member, and the protruding portion is fitted into an inlay recess formed on the motor mounting surface of the mounting object. It is a convex part. Thereby, since the diameter of the spigot convex part provided in the outer surface of a flange member can be reduced, and the size of an attachment target object can be reduced, the weight reduction and cost reduction of an apparatus can be promoted.

  Further, in the electric motor and the electric power steering device according to the present invention, when forming a flange member made of metal such as aluminum, it is not necessary to integrally form the spigot protrusion on the outer surface as in the prior art, so the cutting cost is reduced. In addition, the shape of the flange member can be simplified and sufficient strength can be ensured.

  Furthermore, in the electric motor and the electric power steering device according to the present invention, the outer diameter of the resolver stator formed with relatively high accuracy is used as the spigot protrusion when the spigot is fitted, so that, for example, the electric power steering When mounted on the motor mounting surface formed on the gearbox of the device, the degree of coaxiality between the speed reduction mechanism connected to the motor shaft and the bearing supporting the speed reduction mechanism is improved, and noise and torque unevenness are generated. Can be suppressed.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a front view showing an appearance of the electric motor according to the first embodiment of the present invention. 2 is a cross-sectional view of the electric motor along the line II-II in FIG. 1, and FIG. 3 is a cross-sectional view of the electric motor along the line III-III in FIG.

  In these drawings, the external housing of the electric motor 1 according to the present embodiment includes a motor case 2 that is formed in a substantially hollow cylindrical shape, and an opening on one end side (left side in FIG. 2) of the motor case 2. The motor case 2 and the flange member 3 are coupled to each other by screw fastening, press-fitting, adhesion, or the like. Bearings 4 and 5 are press-fitted and fixed to the bottom center recess 2a of the motor case 2 and the inner center recess 3a of the flange member 3 (in the case of the outer ring holding structure of the bearing housing, the inner diameter is set as a clearance). The motor shaft 6 is rotatably supported via 4 and 5. A motor rotor 7 is fixed to the motor shaft 6 in the motor case 2 so as to rotate integrally with the motor shaft 6. On the other hand, the motor case 2 facing the motor rotor 7 has a motor A stator 8 is fixed.

  The motor stator 8 is composed of a stator core 8a constituted by any one of an integral, divided and sintered core, an insulator 8b inserted into the stator core 8a, and a coil 8c wound around the insulator 8b. . Since the electric motor 1 according to the present embodiment is a three-phase motor, the number of stator cores 8a of the motor stator 8 is 3n (a multiple of 3), and the 3n stator cores 8a are respectively connected to the yoke portions. It is integrated by press fitting or welding every (back yoke). In addition, the structure which integrates the stator core 8a is not limited to this, For example, what connected the stator core 8a or what integrated by welding the connection part may be used. A terminal block 10 into which a current supply bus bar terminal 9 is inserted or insert-molded is disposed at one end side (left side in FIG. 2) of the motor stator 8 having such a configuration. The bus bar terminal 9 and each phase coil 8c are electrically connected by fusing, resistance welding or the like. The front end portion of the bus bar terminal 9 connected to the terminal block 10 passes through a grommet portion 11 a interposed in a part between the motor case 2 and the flange member 3 and is led out of the electric motor 1. . The stator core 8a is fixed to the inside of the motor case 2 by press fitting, bonding, shrink fitting or the like. Here, the stator cores 8a are described as being integrated in order to improve workability. However, the present invention is not limited to this, and there is no particular problem even if the stator cores 8a are not integrated. . The electric motor 1 is configured to supply a drive current via the bus bar terminal 9, but a power harness or the like may be applied instead of the bus bar terminal 9.

  On the other hand, the motor rotor 7 is composed of a rotor core press-fitted into the motor shaft 6 or integrally formed with the motor shaft 6. A plurality of magnets are arranged at equal intervals on the outer peripheral surface of the rotor core (in the rotor core in the case of an embedded magnet type) via an adhesive or a holding member. Cover (nonmagnetic SUS material, aluminum, heat shrinkable tube, etc.) is provided.

  A rotor (hereinafter referred to as a resolver rotor) 13 of a resolver 12 for detecting a rotation angle (rotation position) is fixed to one end side (left side in FIG. 2) of the motor shaft 6 located outside the flange member 3 by press-fitting or the like. The motor shaft 6 and the motor rotor 7 which are objects are rotated together. On the other hand, an outer central concave portion 3b having a larger diameter than the inner central concave portion 3a is formed outside the inner central concave portion 3a of the flange member 3 in which the bearing 5 is disposed. A stator (hereinafter referred to as a resolver stator) 14 of a substantially hollow cylindrical resolver 12 is fixed to the outer central recess 3b by fastening with screws 15 or caulking, and is disposed so as to face the resolver rotor 13. A sensor harness 16 for transmitting signals relating to the rotation angles of the motor shaft 6 and the motor rotor 7 detected by the resolver 12 to the outside passes from the resolver stator 14 through the external housing, and the motor case 2, the flange member 3, and the like. Is led out to the outside of the electric motor 1 through a grommet portion 11b interposed in a part of the gap.

  4A is a side perspective view and FIG. 4B is a top perspective view showing an appearance of a resolver stator attached to the electric motor. In the figure, the resolver stator 14 has a substantially hollow cylindrical shape formed by pressing and laminating thin electromagnetic steel plates, and a plurality of resolver stators 14 are formed so as to protrude from the outer peripheral portion 14a toward the inner diameter direction. Teeth 14b is erected at equal intervals. A coil 14c such as an excitation winding or a detection winding is wound around each tooth 14b via an insulator so that an induced voltage is generated in the detection winding by applying an excitation voltage to the excitation winding. It has become. When the resolver rotor 13 rotates in this state, the gap permeance between the resolver rotor 13 and the resolver stator 14 changes according to the rotation angle, and accordingly, the amplitude of the induced voltage generated in the detection winding is modulated. . Based on the amplitude modulation of the induced voltage, rotation angle detection of the motor shaft 6 and the motor rotor 7 by the resolver 12 is executed.

  At substantially the center of the resolver stator 14 in the stacking direction, flange portions 14d and 14d formed so as to protrude in the outer diameter direction from the outer peripheral surface are disposed in a positional relationship facing each other. A long hole 14e for the screw 15 is bored in the flange portion 14d along the outer peripheral direction of the resolver stator 14, so that the mounting phase of the resolver stator 14 with respect to the flange member 3 can be adjusted. The flange portions 14d and 14d may be formed so as to be flush with the end surface of the outer peripheral portion 14a of the resolver stator 14 attached to the flange member 3. In this case, the outer central concave portion of the flange member 3 is formed. The formation of 3b becomes unnecessary. Furthermore, the side surface of the outer peripheral portion 14a of the resolver stator 14 is not limited to a circumferential curved surface, and for example, a plurality of uneven shapes applied as inlays to the circumferential curved surface may be formed.

  As shown in FIGS. 2 and 3, the resolver stator 14 attached to the flange member 3 has a part in the stacking direction (on the opposite side of the attachment surface to the flange member 3) from the outer surface 3 c of the flange member 3. It is fixed to protrude. A part of the resolver stator 14 that protrudes from the outer surface 3c of the flange member 3 is an inlay convex portion that is fitted into an inlay concave portion formed on a motor mounting surface of an attachment target of the electric motor 1 described later. . As described above, the outer peripheral portion 14a of the resolver stator 14 serving as the inlay convex portion is formed with high precision by laminating the pressed thin steel sheets, so that it is formed in the inlay recess of the attachment object. It has sufficient accuracy to be used as an inlay convex portion to be fitted. In the electric motor 1 according to this embodiment, the flange portion 3 protruding in the radial direction is formed in a state where the inlay convex portion formed by a part of the resolver stator 14 is fitted in the inlay concave portion of the attachment target. The bolts are inserted into the two bolt holes 3d, 3d and fastened to be fixed to the motor mounting surface.

  FIG. 5 is a mechanism diagram illustrating a schematic configuration of an electric power steering apparatus including the electric motor according to the embodiment of the present invention. In the figure, the steering mechanism of the electric power steering device 20 includes a steering shaft 22 that rotates in response to a steering operation of a steering wheel 21 attached to the tip, and a universal joint 23 on the other end side of the steering shaft 22. 24, a rack and pinion mechanism 25 that converts the rotational motion of the steering shaft 22 into a linear motion of the rack shaft, and a tie rod 26 that transmits the motion of the rack shaft of the rack and pinion mechanism 25 to the steering wheel. It is composed of

  In addition, the column portion of the electric power steering apparatus 20 includes a torque sensor 27 that detects a steering torque input to the steering shaft 22 via the steering wheel 21 and a steering coupled to the steering shaft 22 via the speed reduction mechanism 28. An auxiliary electric motor 1 is provided.

  The driving of the electric motor 1 is controlled by a control unit (ECU) 29 equipped with a control circuit and the like. The control unit 29 is supplied with electric power from a battery (power source) 30 and receives an ignition key signal from an ignition key 31. The control unit 29 calculates the steering assist command value I based on the steering torque value T detected by the torque sensor 27 and the vehicle speed V detected by the vehicle speed sensor 32, and the calculated steering assist command value. The drive current supplied to the electric motor 1 is controlled according to I.

  The electric power steering device 20 described above is a column assist type in which the electric motor 1 is disposed in the column portion, but is not limited to this, for example, the electric motor 1 is disposed in the pinion portion of the rack and pinion mechanism. It may be a pinion assist type, or a rack assist type in which the electric motor 1 is disposed in the rack portion.

  FIG. 6 is a main part sectional view showing a state in which the electric motor according to the first embodiment is attached to the gear box of the electric power steering apparatus. In the figure, the electric motor 1 described above is in a state in which the outer surface 3c of the flange member 3 is in contact with the motor mounting surface 35a of the gear box 35 in which the worm 33 and the worm wheel 34 constituting the speed reduction mechanism 28 are accommodated. The bolt 17 inserted into the bolt hole 3d of the flange member 3 is fixed by being fastened to the screw hole 35d formed in the motor mounting surface 35a, and the inlay convex portion by the resolver stator 14 of the electric motor 1 is A shape corresponding to the convex portion (that is, the same dimension as the outer diameter of the resolver stator 14) is fitted into an inlay concave portion (hollow opening) 35b formed on the motor mounting surface 35a. The worm 33 is rotatably supported via bearings 36 and 37 disposed at both ends, and a worm wheel 34 that meshes with the worm 33 is an output shaft (not shown) of the steering shaft 22 in the gear box 35. ). The motor shaft 6 and the worm 33 are engaged with a spline shaft portion 6a formed at the distal end portion of the motor shaft 6 in a spline hole 33a formed at the base end portion (right side in FIG. 6) of the worm 33, Transmission of rotational force by the electric motor 1 is freely coupled. A screw escape recess 35c is formed at a portion of the motor mounting surface 35a that interferes with the screw 15 when the electric motor 1 is mounted so that the head of the screw 15 does not come into contact.

  In this case, the coupling between the motor shaft 6 and the worm 33 is a spline coupling, but the present invention is not limited to this. For example, a coupling by an elastic coupling or the like may be used. Further, in FIG. 6, the inlay convex portion formed by the resolver stator 14 is fitted in a state of being in direct contact with the inlay concave portion 35 b formed on the motor mounting surface 35 a, but for example, an O-ring or the like is interposed in this contact portion. You may make it fit in the made state.

  As described above, in the electric motor 1 and the electric power steering apparatus 20 according to the present embodiment, the resolver rotor 13 and the resolver stator 14 are disposed on the outer surface 3c of the flange member 3 attached so as to close the opening of the motor case 2. And the resolver stator 14 is fixed so that a part in the thickness direction of the resolver stator 14 protrudes from the outer surface 3c of the flange member 3, and a part of the protruded resolver stator 14 is attached to the mounting object. It is a spigot convex part fitted by the spigot concave part 35b formed in the motor mounting surface 35a of the gear box 35 which is. Thereby, since the diameter of the spigot protrusion provided on the outer surface 3c of the flange member 3 can be reduced and the gear box 35 can be reduced in size, the electric motor 1 and the gear box 35 can be reduced in weight and cost. be able to.

  Further, in the electric motor 1 according to the present embodiment, when the flange member 3 made of metal such as aluminum is formed, it is not necessary to integrally form the spigot protrusion on the outer surface 3c as in the prior art, so that the cutting cost, etc. In addition, the strength of the flange member 3 can be improved.

  Furthermore, in the electric motor 1 according to the present embodiment, the spigot protrusion when the outer peripheral portion 14a of the resolver stator 14 formed with relatively high precision by pressing and laminating thin electromagnetic steel plates or the like is subjected to spigot fitting. The worm 33 connected to the motor shaft 6 and the bearing supporting the worm 33 when mounted on the motor mounting surface 35a formed on the gear box 35 of the electric power steering apparatus 20 The coaxiality with 36 and 37 is improved, and the occurrence of noise and torque unevenness can be suppressed.

  FIG. 7 is a front view showing the appearance of the electric motor according to the second embodiment of the present invention, and FIG. 8 is a cross-sectional view of the electric motor along the line VIII-VIII in FIG. Moreover, FIG. 9 is principal part sectional drawing which shows the state with which the electric motor based on 2nd Embodiment was attached to the gear box. In these drawings, the same members as those in the first embodiment described above are denoted by the same reference numerals, and the description thereof is omitted.

  As shown in FIGS. 7 to 9, in the electric motor 1A and the electric power steering apparatus 20A according to the present embodiment, the fastening structure of the bolt 17 for fixing the electric motor 1A to the gear box 35A that is an attachment object is as follows. This is different from the first embodiment described above. That is, in this embodiment, the screw hole 3Ae is formed on the inner peripheral side from the outer diameter of the outer surface 3Ac of the flange member 3A, and the bolt hole 35Ae through which the bolt 17 is inserted into the motor mounting surface 35Aa of the gear box 35A. It has been drilled. Then, the bolt 17 is inserted into the bolt hole 35Ae from the side opposite to the motor mounting surface (left side in FIG. 9), and the bolt 17 is fastened to the screw hole 3Ae of the flange member 3A, whereby the electric motor 1A is fixed to the gear box 35A. It has come to be.

  Therefore, according to the electric motor 1A and the electric power steering apparatus 20A according to the present embodiment, the bolt hole 3c through which the bolt 17 is inserted as well as the same operation and effect as the first embodiment described above can be obtained. Since the portion protruding in the radial direction of the flange member 3A in which the bolt hole 3c is formed is not necessary, the size of the flange member 3A in the radial direction can be reduced.

  As mentioned above, although embodiment of this invention was described concretely, this invention is not limited to this, In the range which does not deviate from the meaning, it can change suitably.

It is a front view showing the appearance of the electric motor concerning a 1st embodiment of the present invention. It is sectional drawing of the electric motor along the II-II line | wire in FIG. It is sectional drawing of the electric motor along the III-III line in FIG. It is the (a) side perspective view and (b) top perspective view which show the appearance of the resolver stator attached to an electric motor. It is a mechanism figure showing a schematic structure of an electric power steering device provided with an electric motor concerning an embodiment of the present invention. It is principal part sectional drawing which shows the state with which the electric motor which concerns on 1st Embodiment was attached to the gear box of the electric power steering apparatus. It is a front view which shows the external appearance of the electric motor which concerns on 2nd Embodiment of this invention. It is sectional drawing of the electric motor along the VIII-VIII line in FIG. It is principal part sectional drawing which shows the state with which the electric motor which concerns on 2nd Embodiment was attached to the gear box of the electric power steering apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Electric motor 2 ... Motor case 3 ... Flange member 3c ... Outer surface 4, 5 ... Bearing 6 ... Motor shaft 7 ... Motor rotor (rotor core)
8 ... Motor stator 12 ... Resolver 13 ... Resolver rotor 14 ... Resolver stator (inlay convex part)
14a ... Outer peripheral part 15 ... Screw 16 ... Sensor harness 20 ... Electric power steering device 28 ... Deceleration mechanism 33 ... Worm 34 ... Worm wheel 35 ... Gear box (Mounting) Object)
35a ... Motor mounting surface 35b ... Inlay recess (hollow opening)
35c ... Screw escape recess

Claims (7)

An outer casing is configured by a bottomed cylindrical motor case having an open end and a flange member attached to the motor case so as to close the opening, and the outer surface of the flange member is attached. An electric motor that is fixed to the mounting object in a state of being in contact with a motor mounting surface formed on the object,
A motor shaft rotatably supported in the motor case;
A motor rotor fixed to the motor shaft in the motor case;
A motor stator fixed to the inner peripheral surface of the motor case so as to face the motor rotor;
A resolver rotor fixed to the motor shaft outside the flange member, and a resolver stator disposed so as to face the resolver rotor, and a resolver for detecting a rotation angle of the motor rotor,
The resolver stator is fixed to the flange member such that a part of its thickness direction protrudes from the outer surface of the flange member, and
A part of the resolver stator that protrudes from the outer surface of the flange member when fitted to the attachment object is fitted in an indented recess formed in the motor attachment surface.   The electric motor according to claim 1, wherein only a part of the resolver stator protrudes from an outer surface of the flange member.   A sensor harness for transmitting a signal detected by the resolver passes through the outer casing from the resolver stator and is led out of the outer casing from a part between the motor case and the flange member. The electric motor according to claim 1 or 2.   The electric motor according to any one of claims 1 to 3, wherein a cross-sectional shape of both ends in the thickness direction of the resolver stator is formed in a substantially circular shape. The resolver stator is fixed to the outer surface of the flange member via a screw; and
5. A screw escape recess formed so that a head portion of the screw does not come into contact with a portion of the attachment target that interferes with the screw on the motor mounting surface. The electric motor described.   An electric power steering apparatus comprising the electric motor according to any one of claims 1 to 5 as a generation source of a steering assist force applied to a steering mechanism. A deceleration mechanism that decelerates and transmits the rotational force of the electric motor to the steering mechanism;
The electric power steering apparatus according to claim 6, further comprising a gear box that houses the speed reduction mechanism and has a motor mounting surface to which the electric motor is fixed.

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