JP2011160506A - Molded motor and electric vehicle with the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reliable molded motor, capable of achieving long life and long drive, by efficiently radiating heat generated during drive. <P>SOLUTION: The molded motor 20 is a motor for an electric vehicle 1 mounted while overlapping with a swing arm 5, namely a planar support member. The molded motor 20 includes a stator core 24 covered with a mold resin 21, a motor case 50 including the mold resin 21 and including openings 54 to 57 from which part of the mold resin 21 is exposed, and coupling units 58a to 58d for exposing at least part of the openings 54 to 57 to the outside of the swing arm 5 to couple the motor case 50 to the swing arm 5. Thus, even if the swing arm 5 covering the periphery of the molded motor 20 is coupled to the molded motor 20 by the coupling units 58a to 58d, the mold resin 21 is directly exposed to the fresh air. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a molded motor in which the entire outer periphery of a stator core having a coil portion is covered by integral molding of an insulating mold resin, and more particularly to a molded motor for an electric vehicle. Moreover, it is related with the electric vehicle carrying this mold motor.

  Conventionally, automobiles and motorcycles generally use an engine that obtains a driving force using gasoline or light oil as a driving source. However, recently, attention has been focused on the development of a vehicle using a motor that obtains a driving force using electric power as energy as a countermeasure for environmental protection.

  An example of a power unit of an electric motorcycle that is an electric vehicle using a motor as a drive source can be seen in Patent Document 1. The power unit of the electric scooter type vehicle described in Patent Document 1 is a direct drive type power unit in which an electric motor for driving is installed coaxially with the rear wheel, and has a left and right split structure composed of a case body and a case cover. An electric motor is included in the case.

JP-A-6-247374 (4th page, FIG. 2)

  Here, when using a motor, there exists a problem of the heat_generation | fever in the coil part. On the other hand, in the electric motorcycle described in Patent Document 1, the entire motor is completely covered by the case. As a result, the motor may not be able to dissipate heat efficiently. As a result, there is a possibility that the motor will be adversely affected and that the life of the motor may be shortened. Furthermore, it is necessary to limit the output of the motor to prevent a reduction in life, and even when it is desired to continue driving at the maximum output, for example, it is necessary to perform control that alternately performs maximum output driving and 50% output driving, etc. The problem that there is. In developing an electric vehicle, it is necessary to devise a design in consideration of efficiently dissipating the heat generated from the motor.

  The present invention has been made in view of the above points, and provides a highly reliable molded motor that can realize a long life and a long driving time by efficiently radiating heat generated during driving. For the purpose. It is another object of the present invention to provide a highly reliable electric vehicle including such a molded motor.

  In order to solve the above-described problems, the present invention is a mold motor that is attached in a state of being overlapped on a plate-like support member, and includes a stator core covered with a mold resin, the mold resin, and the mold resin. A motor case provided with a partially exposed opening; and a coupling portion that exposes at least a part of the opening to the outside from the support member to couple the motor case to the support member. It was decided.

  According to this configuration, even when a support member that covers and covers the periphery of the molded motor is attached to the molded motor, at least a part of the opening of the motor case is exposed to the outside from the support member. By forming a coupling portion that couples to the support member, the mold resin comes into direct contact with the outside air. Therefore, the heat of the motor is directly radiated from the mold resin exposed to the outside through the opening.

  In the molded motor having the above-described configuration, the rotation shaft is configured to be substantially horizontal, and at least a part of the opening is disposed below the rotation shaft.

  In the case of a molded motor for an electric vehicle, the motor is often supported by a swing arm or the like as a support member at a substantially central portion in the vertical direction and is suspended from above by a suspension as a suspension device. A relatively wide opening is formed under the case.

  Further, in the molded motor having the above-described configuration, a plurality of the coupling portions are provided, and at least one of the coupling portions in the vicinity of the connection portion that connects the lower end of the suspension device that suspends the molded motor at the upper portion of the motor case. It was decided to prepare one.

  According to this structure, the opening part of a comparatively wide area | region is formed under a motor case.

  In the present invention, the molded motor is mounted on an electric vehicle.

  According to this configuration, in the electric vehicle, the heat of the motor is directly radiated from the mold resin exposed to the outside through the opening of the motor case.

  An electric vehicle comprising the mold motor for driving a wheel and a swing arm for supporting the mold motor, wherein the swing arm covers and covers at least a part of the periphery of the mold motor. While supporting the mold motor, the mold motor is provided with a notch at a position corresponding to the mold motor, and the mold motor is provided with the opening that exposes a part of the mold resin from the notch. . In addition, as a mold resin, an insulating thing is preferable.

  In particular, in the case of a small electric vehicle such as a motorcycle, by disposing the wheels, the motor, and the braking mechanism on the same axis, they tend to approach each other and the heat dissipation action of the motor tends to decrease. The heat radiation effect is enhanced by using the opening.

  Further, in the electric vehicle having the above-described configuration, a connection portion that connects a lower end of a suspension device that suspends and supports the molded motor is formed at the rear portion of the swing arm.

  According to this structure, the opening part of a comparatively wide area | region is formed under the motor case of an electric vehicle.

  According to the configuration of the present invention, by efficiently radiating the heat generated during driving, it is possible to realize a long life and long driving, and to provide a highly reliable molded motor.

  In addition, by mounting such a molded motor on an electric vehicle, the vehicle life and travel distance can be extended and a highly reliable electric vehicle can be provided.

It is a left view which shows an example of the electric vehicle carrying the mold motor which concerns on embodiment of this invention. FIG. 2 is a left side view showing the vicinity of a rear wheel of the electric vehicle shown in FIG. 1. FIG. 3 is a top view around the rear wheel shown in FIG. 2. FIG. 3 is a left side view of the mold motor and swing arm shown in FIG. 2. It is a top view of the mold motor and swing arm shown in FIG. It is a bottom view of the mold motor and swing arm shown in FIG. It is a right view of the mold motor and swing arm shown in FIG. FIG. 2 is a vertical sectional front view of a rear wheel portion of the electric vehicle shown in FIG. 1. It is a perspective view which shows the state which decomposed | disassembled a part of mold motor and braking mechanism of FIG. It is a left view of the mold motor part shown in FIG. It is a vertical cross-sectional front view of the mold resin of the mold motor shown in FIG. It is a perspective view of the outer case of the mold motor shown in FIG.

  Hereinafter, embodiments of the present invention will be described with reference to FIGS. In the description, the front and rear, left and right directions and positions are based on the user sitting on the seat.

  First, the structure of an electric vehicle equipped with a molded motor according to an embodiment of the present invention will be described with reference to FIG. FIG. 1 is a left side view showing an example of an electric vehicle equipped with a molded motor.

  As shown in FIG. 1, the electric vehicle 1 is a motorcycle including a front wheel 2 and a rear wheel 3. The electric vehicle 1 includes a main frame 4 and a swing arm 5 as a main frame.

  The front end of the main frame 4 is bent upward, and the front wheel 2 and the handle 6 are supported by the front end so as to be steerable. On the rear end side of the main frame 4, a seat 7 on which a user sits and a battery housing portion 8 are provided at a substantially central portion in the front-rear direction of the electric vehicle 1. The battery accommodating portion 8 is provided below the seat 7 and can accommodate a battery (not shown) therein. The seat 7 also serves as a lid for the battery housing portion 8 and is attached to the battery housing portion 8 so as to be openable and closable. A luggage table 9 is provided behind the seat 7 of the main frame 4 and above the rear wheel 3.

  The swing arm 5 extends rearward from the lower part of the seat 7 and the battery accommodating part 8 at the rear part of the main frame 4. The rear wheel 3 is supported at the rear end of the swing arm 5. The swing arm 5 is provided only on the left side of the rear wheel 3, and supports the rear wheel 3 in a cantilever state (see FIG. 3). The rear wheel 3 is a drive wheel, and a mold motor 20 that drives the rear wheel 3 is provided between the rear wheel 3 and the swing arm 5. In other words, the swing arm 5 is a support member that supports the mold motor 20 and the rear wheel 3 with their rotation axes horizontal. In addition, a suspension unit 10 is provided as a suspension device that suspends the mold motor 20 and the rear wheel 3 from the upper part of the mold motor 20 of the swing arm 5 toward the upper luggage base 9.

  Subsequently, the structure of the swing arm 5 of the electric vehicle 1 will be described with reference to FIGS. 2 to 7 in addition to FIG. 1. 2 is a left side view showing the periphery of the rear wheel of the electric vehicle, FIG. 3 is a top view of the periphery of the rear wheel shown in FIG. 2, FIG. 4 is a left side view of the mold motor and swing arm shown in FIG. FIG. 6 is a bottom view of the mold motor and the swing arm, and FIG. 7 is a right side view of the mold motor and the swing arm.

  As shown in FIG. 1, the swing arm 5 is attached to the main frame 4 below the seat 7 and the battery accommodating portion 8. As shown in FIGS. 1 and 2, the swing arm 5 includes a support shaft portion 5a extending horizontally at the front end portion thereof, with the rear rear wheel 3 side as a free end around the axis of the support shaft portion 5a, The rear wheel 3 side can swing up and down. The rear part of the swing arm 5 is positioned by the suspension unit 10.

  Moreover, as shown in FIGS. 2-7, the swing arm 5 is provided with the arm part 5b and the cover part 5c. The arm portion 5b has a hollow, substantially rectangular tube shape, and extends from the location of the support shaft portion 5a to the location of the rear wheel 3. A signal line 25 and a power line 26 (see FIG. 10) of the molded motor 20 are wired inside the arm portion 5b.

  The cover portion 5 c of the swing arm 5 is provided at a location corresponding to the mold motor 20. The cover portion 5c is formed such that the surface opposite to the rear wheel 3 side of the molded motor 20 (the left side surface side of the electric vehicle 1) and the outer peripheral surface are formed in a plate shape and overlapped with those surfaces of the molded motor 20 It is covered with. Moreover, the cover part 5c is provided with the notch part 5d which notched the part of the lower part and the rear part, and exposed the mold motor 20 outside.

  As shown in FIGS. 2, 4, and 7, the swing arm 5 is coupled to the mold motor 20 at the four coupling portions 58a to 58d provided around the mold motor 20 around the cover portion 5c. Yes. As shown in FIG. 7, the mold motor 20 is screwed to the swing arm 5 from the rear wheel 3 side (from the right side of the swing arm 5) at the front coupling portions 58a and 58b. In the outer coupling portion 58c and the upper coupling portion 58d, the mold motor 20 is screwed to the swing arm 5 from the opposite side to the rear wheel 3 side (from the left side of the swing arm 5). The suspension unit 10 has a lower end connected to the cover portion 5c of the swing arm 5 at a connection portion 5e immediately above the upper coupling portion 58d.

  As shown in FIGS. 6 and 7, the cover 5c of the swing arm 5 and the molded motor 20 are not in close contact with each other, and a gap S is provided between them. Thereby, the airflow at the time of driving | running | working can be taken in into the clearance gap S, and the heat radiation effect | action of the area | region covered with the swing arm 5 of the mold motor 20 is not impaired.

  Next, the structure of the rear wheel 3 of the electric vehicle 1 will be described with reference to FIGS. 8 and 9 in addition to FIG. FIG. 8 is a vertical sectional front view of the rear wheel portion of the electric vehicle, and FIG. 9 is a perspective view showing a part of the molded motor and the braking mechanism of FIG. In FIG. 9, the drawing of the rotor and the speed reduction mechanism inside the molded motor is omitted.

  As shown in FIG. 8, the rear arm 3 of the electric vehicle 1 has a swing arm 5, a mold motor 20, a speed reduction mechanism 30, a braking mechanism 40, and a rear part in order from the left side of the rear wheel 3, that is, the right side in FIG. A wheel 3 is provided. The mold motor 20, the braking mechanism 40, and the rear wheel 3 are arranged so as to be coaxial with each other.

  As shown in FIGS. 1 and 9, the mold motor 20 is a motor for an electric vehicle in which an annular stator core 24 (see FIG. 11) described later is covered with an insulating mold resin 21. The molded motor 20 is disposed close to the rear wheel 3 with the axis of the stator core 24 coinciding with the axle 3 a of the rear wheel 3.

  As shown in FIG. 8, a rotor 22 that is a motor rotor is provided inside the mold resin 21. The rotor 22 is arranged with its axis aligned with the axis of the stator core 24, and is fixed to a motor shaft 23 that is rotatably provided. Therefore, the rotor 22 is rotated by driving the mold motor 20, and the power is transmitted to the motor shaft 23.

  The speed reduction mechanism 30 is disposed at a location between the motor shaft 23 and the axle 3a. The speed reduction mechanism 30 is composed of, for example, a planetary gear mechanism.

  The braking mechanism 40 is a so-called drum-type brake disposed in the vicinity of the wheel 3b of the rear wheel 3, and includes a brake shoe 41, a spring 42, a brake arm 43, and a brake cover 44 as shown in FIGS. ing. The brake shoe 41 is disposed inside the wheel 3b. When the brake mechanism 40 is not used, the brake shoe 41 is separated radially inward from the wheel 3b by the action of the spring 42. The brake shoe 41 is spread outward in the radial direction with respect to the axle 3 a against the elastic force of the spring 42 by the rotation of the brake arm 43. The brake shoe 41 generates a frictional resistance between the wheel 3a and a drum (not shown) that rotates integrally with the wheel 3a, and brakes the rotation of the wheel 3a, that is, the rear wheel 3.

  In addition, a brake cover 44 is attached as a lid to a portion of the wheel 3b where the brake shoe 41 is disposed, and is covered so that dust and the like do not enter inside (see FIG. 8). The brake cover 44 has a function of holding brake members such as a brake shoe 41, a spring 42, and a brake arm 43 in addition to a dustproof function for the brake mechanism 40.

  Next, a detailed configuration of the molded motor 20 will be described with reference to FIGS. 10 to 12 in addition to FIGS. 2, 4, and 7 to 9. 10 is a left side view of the mold motor unit, FIG. 11 is a front view of a vertical section of the mold resin of the mold motor, and FIG. 12 is a perspective view of the outer case of the mold motor.

  The mold motor 20 includes a stator core 24, a motor case 50, a signal line 25, and a power line 26 in addition to the mold resin 21, rotor 22, and motor shaft 23 described above.

  The stator core 24 has an annular shape, and as shown in FIG. 11, a coil portion 24a is disposed on the radially inner side. The periphery of the stator core 24 including the coil portion 24a is covered with an insulating mold resin 21. The mold resin 21 is made of a thermosetting resin containing glass fiber, for example. A concave portion 21 a that is recessed from the rear wheel 3 side is formed in the mold resin 21 at a location radially inward from the coil portion 24 a of the stator core 24. The recess 21a has a cylindrical shape, and the rotor 22 is disposed here (see FIG. 8).

  The motor case 50 is made of a metal such as an aluminum alloy and is provided so as to enclose and hold the mold resin 21. The motor case 50 includes two plate-like case members arranged so as to sandwich the mold resin 21 inside, that is, an inner case 51 shown in FIG. 9 and an outer case 52 shown in FIG. As shown in FIG. 8, the inner case 51 is disposed on the rear wheel 3 side, and the outer case 52 is disposed on the cover portion 5c side of the swing arm 5 opposite to the rear wheel 3 side.

  As shown in FIG. 9, the inner case 51 has a tongue-like front connection piece 51a and a rear connection piece 51b at its ends, and the outer case 52 has a tongue-like front connection piece 52a and a rear side at its ends. Each of the connecting pieces 52b is provided. As shown in FIG. 10, the front side connecting piece 51a and the rear side connecting piece 51b, and the front side connecting piece 52a and the rear side connecting piece 52b sandwich the straight line L1 that passes through the axial center of the mold motor 20 and extends in the radial direction. It is arrange | positioned at the substantially opposing location, ie, the front side and the rear side of the mold motor 20, respectively. As shown in FIG. 9, the inner case 51 and the outer case 52 are formed by connecting the corresponding connecting pieces, that is, the front connecting piece 51a and the front connecting piece 52a, and the rear connecting piece 51b and the rear connecting piece. 52b is connected to each other by three bolts 53 with the mold resin 21 interposed therebetween.

  Further, as shown in FIGS. 8 and 10 to 12, the motor case 50 includes four openings that are independent from each other, a first opening 54, a second opening 55, a third opening 56, and A fourth opening 57 is provided (in the following description, they may be collectively referred to as “openings 54 to 57”). As shown in FIG. 10, the first opening 54 and the second opening 55, and the third opening 56 and the fourth opening 57 pass a straight line L <b> 2 that passes through the axial center of the mold motor 20 and extends in the radial direction. They are arranged at positions substantially opposite to each other, that is, above and below the mold motor 20, respectively. Each of these four openings 54 to 57 exposes part of the mold resin 21 to the outside of the motor case 50.

  The first opening 54 is disposed on the upper side of the outer case 52, and the second opening 55 is disposed on the lower side of the outer case 52, and the openings penetrate between the inner side and the outer side of the outer case 52 itself. It is formed in the form of The outer case 52 is provided with a frame portion 52 c on the radially outer side of the first opening 54, and a frame portion 52 d is provided on the radially outer side of the second opening 55.

  The third opening 56 is disposed on the upper side of the motor case 50, and has a notch provided on the upper outer edge of the inner case 51 and a notch provided on the upper outer edge on the inner case 51 side from the frame portion 52 c of the outer case 52. Are formed in the shape of a window penetrating between the inner side and the outer side of the motor case 50. Similarly, the fourth opening 57 is disposed on the lower side of the motor case 50, a notch provided on the lower outer edge of the inner case 51, and the lower outer edge on the inner case 51 side from the frame portion 52 d of the outer case 52. It is formed in the shape of a window that is combined with a notch provided in the portion and penetrates between the inside and outside of the motor case 50.

  Due to the configuration of the openings 54 to 57, in the motor case 50, the front connection piece 51a and the front connection piece 52a are longer in the circumferential direction than the rear connection piece 51b and the rear connection piece 52b. In addition, regarding the three bolts 53 that connect the inner case 51 and the outer case 52 described above, two bolts 53 are provided at both ends in the circumferential direction at the front connection piece 51a and the front connection piece 52a that are longer in the circumferential direction. However, one piece is provided at the rear end portion in the place of the rear side connecting piece 51b and the rear side connecting piece 52b which are shorter in the circumferential direction (see FIGS. 9 and 10).

  Further, the signal line 25 and the power line 26 of the mold motor 20 extend forward along the swing arm 5 from the region of the front portion of the outer case 52 that remains after the openings 54 to 57 are provided.

  Further, as shown in FIGS. 7, 9, and 10, the motor case 50 is provided with four coupling portions 58 a to 58 d around the motor case 50. As shown in FIGS. 7 and 9, front coupling portions 58a and 58b are provided on the front side of the motor case 50, and as shown in FIGS. 7 and 10, the side surface opposite to the rear wheel 3 side of the motor case 50 is provided. The outer coupling portion 58c is disposed at the upper portion, and the upper coupling portion 58d is disposed at the upper portion. Each coupling portion 58a to 58d is provided with a screw hole 59 for screwing using a bolt and a female screw portion, and as shown in FIGS. 2, 4, and 7, the swing arm 5 is attached by screwing. Thus, the entire mold motor 20 is supported.

  The coupling portions 58a to 58d are provided such that a part of the openings 54 to 57 is exposed to the outside from the cutout portion 5d of the cover portion 5c of the swing arm 5. That is, as shown in FIG. 4, the notch portion 5d is located below and behind the path from the portion corresponding to the lower front coupling portion 58b in the cover portion 5c to the upper coupling portion 58d via the outer coupling portion 58c. It has been removed. Accordingly, as shown in FIG. 4 with reference to FIG. 10, almost the entire area of the second opening 55 and the fourth opening 57 of the mold motor 20, and a part of the first opening 54 and the third opening 56. Is exposed to the outside from the swing arm 5.

  In this way, even when the swing arm 5 that covers and covers the periphery of the mold motor 20 is attached to the mold motor 20, at least a part of the openings 54 to 57 of the motor case 50 is formed from the swing arm 5. By forming the coupling portions 58a to 58d that are exposed to the outside and couple the motor case 50 to the swing arm 5, the mold resin 21 comes into direct contact with the outside air. Therefore, the heat of the motor is directly radiated from the mold resin 21 exposed to the outside through the openings 54 to 57.

  Further, the mold motor 20 is configured with the motor shaft 23 that is a rotating shaft substantially horizontal, and at least a part of the openings 54 to 57 is disposed below the motor shaft 23. A relatively wide area of the second opening 55 is formed. Similarly, a plurality of connecting portions between the molded motor 20 and the swing arm 5 are provided, and an upper connecting portion 58d is provided in the upper portion of the motor case 50 and in the vicinity of the connecting portion 5e connecting the lower end of the suspension unit 10. Therefore, a relatively wide area of the second opening 55 is formed below the motor case 50.

  According to the above configuration, by efficiently radiating the heat generated during driving, a long life and long driving can be realized, and the highly reliable mold motor 20 can be provided.

  In addition, the rear wheels, the motor, and the braking mechanism are arranged on the same axis so that they are close to each other and the heat dissipation effect of the motor tends to be reduced. However, the above-described molded motor 20 is mounted on the electric vehicle 1. Thus, it is possible to enhance the heat dissipation effect using the openings 54 to 57. As a result, the vehicle life and the travel distance are extended, and the highly reliable electric vehicle 1 can be provided.

  Although the embodiments of the present invention have been described above, the scope of the present invention is not limited to these embodiments, and various modifications can be made without departing from the spirit of the invention.

  For example, in the embodiment of the present invention, the motorcycle 1 shown in FIG. 1 is described as an example of the electric vehicle 1 on which the molded motor is mounted. However, the electric vehicle to be mounted is not limited to the motorcycle. An automatic tricycle or an automatic four-wheeled vehicle may be used.

  Further, the shape, the number, and the arrangement of the opening portions 54 to 57 and the coupling portions 58a to 58d of the mold motor 20 and the cutout portion 5d of the swing arm 5 are not limited to the configuration described in the above embodiment, but are different. It does not matter as the shape, number and arrangement. For example, regarding the notch portion 5d, two notch portions may be provided on the cover portion 5c of the swing arm 5, and the notch portion 5d may be provided not only on the lower portion but also on the upper portion.

  The present invention can be used for all types of molded motors.

DESCRIPTION OF SYMBOLS 1 Electric vehicle 2 Front wheel 3 Rear wheel 3a Axle 5 Swing arm (support member)
10 Suspension unit (suspension device)
5c Cover part 5d Notch part 20 Mold motor 21 Mold resin 23 Motor shaft (rotating shaft)
24 Stator Core 40 Braking Mechanism 50 Motor Case 51 Inner Case 52 Outer Case 54 First Opening 55 Second Opening 56 Third Opening 57 Fourth Opening 58a, 58b Front Coupling 58c Outer Coupling 58d Upper Coupling

Claims (6)

A mold motor attached in a state of being stacked on a plate-like support member,
A stator core coated with mold resin;
A motor case enclosing the mold resin and provided with an opening from which a part of the mold resin is exposed;
A coupling portion for exposing at least a part of the opening to the outside from the support member and coupling the motor case to the support member;
A molded motor comprising:   The mold motor according to claim 1, wherein the rotating shaft is substantially horizontal, and at least a part of the opening is disposed below the rotating shaft.   A plurality of the coupling portions are provided, and at least one of the coupling portions is provided in the vicinity of a connection portion that is connected to a lower end of a suspension device that suspends a molded motor, and is an upper portion of the motor case. Item 3. A molded motor according to Item 2.   An electric vehicle comprising the molded motor according to any one of claims 1 to 3. An electric vehicle including the mold motor for driving a wheel and a swing arm that supports the mold motor,
The swing arm is provided with a notch at a location corresponding to the mold motor while supporting the mold motor while covering and covering at least a part of the periphery of the mold motor,
The electric vehicle according to claim 4, wherein the mold motor includes the opening that exposes a part of the mold resin to the outside from the notch.   The electric vehicle according to claim 5, wherein a connecting portion that connects a lower end of a suspension device that suspends and supports the molded motor is formed at a rear portion of the swing arm.

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