JP2010172090A - Mold motor and electric vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mold motor which is reduced in size and weight, and an electric vehicle. <P>SOLUTION: In the mold motor 5, a position detecting magnet 100 is attached to a first region 92B<SB>1</SB>which is exposed from a molding part 93 out of the second main surface 92B of a rotor plate 92. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a molded motor including a rotor molded with resin and an electric vehicle including the molded motor.

  Conventionally, lightweight and compact molded motors are widely used as driving sources for electric vehicles and washing machines.

  The molded motor includes an annular stator and a rotor that rotates inside the stator. The stator includes a plurality of teeth molded with a resin material. The rotor includes a plurality of magnets molded of a resin material and rotates around the axis of the stator. According to such a molded motor, since a plurality of constituent members can be combined into one, productivity can be improved.

  Here, for the purpose of accurately detecting the rotational position of the rotor, a method of attaching a position detection magnet to the rotor has been proposed (see Patent Document 1). Specifically, a position detection magnet having the same diameter as the rotor is connected to the rotor using a cylindrical support member.

JP 2006-320141 A

  However, in the method described in Patent Literature 1, since the cylindrical support member is used in addition to the large size of the position detection magnet, it is difficult to reduce the size and weight of the molded motor.

  The present invention has been made in view of the above-described situation, and an object thereof is to provide a molded motor and an electric vehicle that can be reduced in size and weight.

  A molded motor according to a feature of the present invention includes an annular stator, a rotor core having a plurality of rotor magnets, and a rotor plate disposed on a side surface of the rotor core. The rotor rotates inside the stator, and is attached to the rotor. A plurality of rotor cores and a rotor plate that are integrally molded with resin, and the rotor plate has a first region that is exposed from the resin. The position detecting magnet is attached to the first region.

  According to the molded motor according to the feature of the present invention, the position detection magnet can be easily attached to the rotor by exposing the first region from the resin. Accordingly, since a support member for attaching the position detection magnet to the rotor is unnecessary, the size and weight of the molded motor can be reduced.

  In the molded motor according to the feature of the present invention, the rotor plate has a first main surface on which the rotor core is disposed, and a second main surface provided on the opposite side of the first main surface. 2 may be formed on the main surface.

  In the molded motor according to the feature of the present invention, the second main surface has a first region and a second region that surrounds the first region and is coated with a resin. You may overhang toward the opposite side of the 1st principal surface rather than a field.

  In the molded motor according to the feature of the present invention, the plurality of rotor magnets are arranged in an annular shape on the first main surface, and the position detection magnet includes a plurality of position detection magnets on the projection plane substantially perpendicular to the axis of the rotor. It may be arranged inside the rotor magnet.

  An electric vehicle according to a feature of the present invention is an electric vehicle including a freely rotatable wheel and a molded motor that drives the wheel, the molded motor including an annular stator, a rotor core having a plurality of rotor magnets, A rotor plate disposed on a side surface of the rotor core, the rotor rotating inside the stator, and a position detection magnet attached to the rotor and used for position detection of the plurality of rotor magnets, The gist is that the rotor plate is integrally molded with resin, the rotor plate has a first region exposed from the resin, and the position detection magnet is attached to the first region.

  According to the present invention, it is possible to provide a molded motor and an electric vehicle that can be reduced in size and weight.

1 is a right side view of an electric motorcycle 1 according to an embodiment of the present invention. It is a perspective view of the mold motor 5 which concerns on embodiment of this invention. It is sectional drawing in the AA of FIG. FIG. 4 is an enlarged view of a portion B in FIG. 3. It is the perspective view which looked at the magnet 100 for position detection attached to the rotor 90 which concerns on embodiment of this invention from the non-output side. It is a figure which shows the state which removed the magnet 100 for position detection which concerns on embodiment of this invention from the rotor 90. FIG. It is the perspective view which looked at the rotor plate 92 which concerns on embodiment of this invention from the 2nd main surface 92B side. FIG. 6 is a diagram in which a plurality of rotor magnets 91 and position detection magnets 100 according to an embodiment of the present invention are projected on a projection plane substantially perpendicular to the axis S. It is a figure for demonstrating the manufacturing method of the rotor 90 which concerns on embodiment of this invention.

  Next, embodiments of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic and ratios of dimensions and the like are different from actual ones. Accordingly, specific dimensions and the like should be determined in consideration of the following description. Moreover, it is a matter of course that portions having different dimensional relationships and ratios are included between the drawings.

(Schematic configuration of electric vehicle)
Hereinafter, an electric motorcycle 1 that is an electric vehicle to which a molded motor according to a first embodiment of the present invention is applied will be described with reference to the drawings. FIG. 1 is a right side view of the electric motorcycle 1.

  As shown in FIG. 1, the electric motorcycle 1 is a so-called underbone type electric motorcycle in which a body frame is disposed below. The electric motorcycle 1 includes a front wheel 2, a rear wheel 3, a swing arm 4, and a molded motor 5.

  The front wheel 2 is rotatably supported by a front fork. The rear wheel 3 is rotatably supported by the swing arm 4. The swing arm 4 is swingably attached to the vehicle body frame.

  The mold motor 5 is fixed to the swing arm 4. The driving force generated by the mold motor 5 is transmitted to the rear wheel 3 via a motor shaft 50 (see FIG. 2) provided at the approximate center of the mold motor 5. The mold motor 5 may be a geared motor with a built-in speed reducer. The configuration of the mold motor 5 will be described later.

(Mold motor configuration)
Hereinafter, the configuration of the molded motor according to the present embodiment will be described with reference to the drawings. In the following, the “output side” is the side of the molded motor 5 where the motor shaft 50 is connected to the rear wheel 3, and the “non-output side” is the opposite side of the molded motor 5 to the output side. It is.

  FIG. 2 is a perspective view of the molded motor 5. As shown in FIG. 2, the molded motor 5 includes a motor shaft 50, a stator 51, a first motor case 52, and a second motor case 53.

  The motor shaft 50 is provided approximately at the center of the molded motor 5. The motor shaft 50 is inserted through the first motor case 52. As the motor shaft 50 rotates about the axis S, the rear wheel 3 is driven.

  The stator 51 is formed in an annular shape around the axis S. The stator 51 is formed by molding a plurality of teeth arranged on a circle centering on the axis S and a coil wound around each of the plurality of teeth with a resin mold portion (not shown). A cylindrical inner space P is formed inside the annular stator 51. The internal structure of the molded motor 5 will be described later.

  The first motor case 52 covers the output side of the stator 51 (inner space P). The motor shaft 50 is inserted through the first motor case 52. The first motor case 52 is screwed to the swing arm 4.

  The second motor case 53 covers the non-output side of the stator 51 (inner space P). The inner space P is sealed by screwing the first motor case 52 and the second motor case 53 together.

(Internal structure of molded motor)
Hereinafter, the internal structure of the molded motor 5 will be described with reference to the drawings. 3 is a cross-sectional view taken along line AA in FIG.

  As shown in FIG. 3, the molded motor 5 includes a gear case 70, a reduction gear 80, a rotor 90, a position detection magnet 100, and a position detection element mount PCB 110 (Printed Circuit Board) in the internal space P.

  The gear case 70 is formed in a dome shape and is connected to the first motor case 52. A reduction gear 80 is stored between the gear case 70 and the first motor case 52.

  The reduction device 80 transmits the rotation transmitted from the rotor 90 via the gear shaft 54 to the motor shaft 50 by reducing the rotation at a predetermined reduction ratio.

  The rotor 90 is disposed between the gear case 70 and the second motor case 53. The rotor 90 is formed in an annular shape and rotates about the axis S. The rotation of the rotor 90 is transmitted to the speed reducer 80 via a gear shaft 54 inserted through the center of the rotor 90.

  Here, the rotor 90 includes a plurality of rotor magnets 91, a rotor plate 92, a mold part 93, and a rotor core 94 having the plurality of rotor magnets 91. Each of the plurality of rotor magnets 91 is inserted into the rotor core 94. The plurality of rotor magnets 91 are arranged along a circumference centered on the axis S and arranged to face the stator 51. The rotor core 94 is disposed on a side surface (a first main surface 92A described later) of the rotor plate 92. Similarly, the plurality of rotor magnets 91 are disposed on the side surface of the rotor plate 92. The mold part 93 molds the plurality of rotor magnets 91, the rotor plate 92, and the rotor core 94.

  The stator 51 is formed by molding a plurality of teeth arranged on a circle centering on the axis S and a coil wound around each tooth via an insulating member with a resin material.

  The position detection magnet 100 is a magnetic member used for position detection of the plurality of rotor magnets 91. The position detection magnet 100 is attached to the non-output side of the rotor 90. The attachment state of the position detection magnet 100 will be described later. When a plastic magnet is used as the position detection magnet 100, the dimensional accuracy can be improved as compared with the case where a sintered magnet is used.

  The position detection element mount PCB 110 has a function of detecting the position of the position detection magnet 100. The position detection element mount PCB 110 is attached to the counter-output side of the stator 51.

(Mounting position detection magnet)
Hereinafter, the attachment state of the position detection magnet 100 will be described with reference to the drawings. FIG. 4 is an enlarged view of a portion B in FIG. FIG. 5 is a perspective view of the position detection magnet 100 attached to the rotor 90 as viewed from the non-output side. FIG. 6 is a diagram illustrating a state in which the position detection magnet 100 is removed from the rotor 90.

  As shown in FIG. 4, the rotor plate 92 has a first main surface 92A provided on the output side and a second main surface 92B provided on the opposite side of the first main surface 92A. The first main surface 92A faces the speed reducer 80. A rotor core 94 and a plurality of rotor magnets 91 are disposed on the first main surface 92A.

  As shown in FIGS. 5 and 6, the position detection magnet 100 is attached to the second main surface 92 </ b> B of the rotor plate 92. Specifically, the locking portion Ta formed on the surface facing the second main surface 92B of the position detection magnet 100 is locked in the locking hole Tb formed in the second main surface 92B of the rotor plate 92. To do. Further, the attachment hole Sa formed in the position detection magnet 100 is screwed to the attachment hole Sb formed in the second main surface 92B of the rotor plate 92.

  The position detecting magnet 100 is formed by molding a kneaded material of a magnetic material and a resin with a mold. Therefore, as shown in FIG. 6, magnetic poles (N pole and S pole) are directly magnetized on the surface of the position detection magnet 100. The number of poles of the position detection magnet 100 is the same as the number of poles of the plurality of rotor magnets 91.

FIG. 7 is a perspective view of the rotor plate 92 as viewed from the second main surface 92B side. As shown in FIG. 7, the second main surface 92B includes a first region 92B ₁ and the second region 92B _2.

The first region 92B ₁ is a region exposed from the mold portion 93 of the second main surface 92B. The position detection magnet 100 is attached to the first region 92B _1. The second region 92B ₂ surrounds the first region 92B _1. The second region 92B ₂ is covered by a molded portion 93 of the second main surface 92B. As shown in FIGS. 4 and 7, the first region 92B ₁ is formed to protrude toward the opposite side of the first main surface 92A than the second region 92B _2. In other words, the first region 92B ₁ is formed to protrude toward the opposite-to-output side of the second region 92B _2.

  FIG. 8 is a diagram in which a plurality of rotor magnets 91 and position detection magnets 100 are projected onto a projection plane that is substantially perpendicular to the axis S of the stator 51.

  As shown in FIG. 8, the plurality of rotor magnets 91 are arranged in an annular shape along the circumferential direction with the axis S as the center. The position detection magnet 100 is disposed inside the plurality of rotor magnets 91.

(Function and effect)
In the molded motor 5 according to the embodiment, the position detection magnet 100 is attached to the first region 92B ₁ that is exposed from the mold portion 93 of the second main surface 92B of the rotor plate 92.

Thus, by exposing the first region 92 </ b> B ₁ from the mold portion 93, the position detection magnet 100 can be easily attached to the rotor 90. Therefore, since a support member for attaching the position detection magnet 100 to the rotor 90 is not required, the mold motor can be reduced in size and weight.

  Further, since the position detection magnet 100 can be directly attached to the rotor plate 92, the attachment strength of the position detection magnet 100 can be improved as compared with the case where the position detection magnet 100 is attached to the mold part 93. Therefore, the position detection error under the usage environment of the mold motor 5 can be reduced.

  Here, normally, the inside of the plurality of rotor magnets 91 is used as a space in which the speed reducer 80 and the like are arranged. Therefore, it is difficult to dispose the position detection element mount PCB 110 on the first main surface 92A side of the rotor plate 92. On the other hand, when the position detection element mount PCB 110 is arranged on the second main surface 92B side of the rotor plate 92 and the position detection magnet 100 is arranged on the first main surface 92A side, the position of the gear case 70 made of iron or the like is increased. Since a magnetic circuit is formed between the detection magnet 100 and the position detection error may increase. Therefore, in this embodiment, the position detection magnet 100 is attached to the second main surface 92B of the rotor plate 92. Therefore, a position detection error due to the position detection element mount PCB 110 can be reduced.

In addition, the first region 92B ₁ to which the position detection magnet 100 is attached protrudes beyond the second region 92B ₂ covered by the mold part 93. Here, as shown in FIG. 9, the plurality of rotor magnets 91 and the rotor plate 92 are arranged after the rotor plate 92 and the plurality of rotor magnets 91 are sequentially arranged on the lower mold 120A. Molding is performed by injecting a resin material between the mold 120B. Therefore, by the first region 92B ₁ overhang than the second region 92B _2, it is possible to form the first region 92B ₁ that is not covered by the resin material in the molding process in a simple manner.

  Further, the position detection magnet 100 is disposed inside the plurality of rotor magnets 91 on the projection plane substantially perpendicular to the axis S. Thus, since the position detection magnet 100 is miniaturized, the manufacturing cost of the molded motor 5 can be reduced.

  The position detecting magnet 100 has a locking portion Ta that protrudes toward the rotor plate 92, and the rotor plate 92 has a locking hole Tb that locks the locking portion Ta. Therefore, it is possible to improve the position accuracy when the position detection magnet 100 is attached, and to suppress the displacement in the environment where the position detection magnet 100 is used.

(Other embodiments)
Although the present invention has been described by using the above-described embodiments, it should not be understood that the description and drawings constituting a part of this disclosure limit the present invention. From this disclosure, various alternative embodiments, examples and operational techniques will be apparent to those skilled in the art.

  For example, in the above embodiment, the case where the molded motor 5 is applied to the electric motorcycle 1 has been described. However, the present invention is not limited to this. For example, the mold motor 5 can be applied to a blower or a washing machine.

  In the above embodiment, the position detection magnet 100 is screwed to the rotor plate 92, but the present invention is not limited to this. For example, the position detection magnet 100, the rotor plate 92, and the plurality of rotor magnets 91 may be entirely molded of a resin material.

 Thus, it should be understood that the present invention includes various embodiments and the like not described herein. Therefore, the present invention is limited only by the invention specifying matters in the scope of claims reasonable from this disclosure.

  DESCRIPTION OF SYMBOLS 1 ... Electric motorcycle, 2 ... Front wheel, 3 ... Rear wheel, 4 ... Swing arm, 5 ... Molded motor, 50 ... Motor shaft, 51 ... Stator, 52 ... 1st motor case, 53 ... 2nd motor case, 54 ... Gear Shaft, 70 ... gear case, 80 ... reduction gear, 90 ... rotor, 91 ... rotor magnet, 92 ... rotor plate, 92A ... first main surface, 92B ... second main surface, 92B1 ... first region, 92B2 ... second region , 93 ... Mold part, 94 ... Rotor core, 100 ... Position detection magnet, 110 ... Position detection element mount PCB, 120A ... Lower mold, 120B ... Upper mold

Claims (5)

An annular stator;
A rotor core having a plurality of rotor magnets, and a rotor plate disposed on a side surface of the rotor core, the rotor rotating inside the stator;
A position detection magnet attached to the rotor and used for position detection of the plurality of rotor magnets;
The plurality of rotor cores and the rotor plate are integrally molded with resin,
The rotor plate has a first region exposed from the resin;
The position detecting magnet is attached to the first region. The rotor plate has a first main surface on which the rotor core is disposed, and a second main surface provided on the opposite side of the first main surface,
The molded motor according to claim 1, wherein the first region is formed on the second main surface. The second main surface has the first region, and a second region surrounding the first region and covered with the resin,
3. The molded motor according to claim 2, wherein the first region projects toward the opposite side of the first main surface from the second region. The plurality of rotor magnets are annularly arranged on the first main surface,
4. The molded motor according to claim 2, wherein the position detection magnet is disposed inside the plurality of rotor magnets on a projection plane substantially perpendicular to the axis of the rotor. 5. Wheels that can be driven to rotate,
An electric vehicle comprising a molded motor for driving the wheels,
The mold motor is
An annular stator;
A rotor core having a plurality of rotor magnets, and a rotor plate disposed on a side surface of the rotor core, the rotor rotating inside the stator;
A position detection magnet attached to the rotor and used for position detection of the plurality of rotor magnets;
The plurality of rotor cores and the rotor plate are integrally molded with resin,
The rotor plate has a first region exposed from the resin;
The electric vehicle according to claim 1, wherein the position detection magnet is attached to the first region.

Images