JP2013027256A - Vehicle driving motor and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vehicle driving motor capable of installing a rotor on an inner diameter side of a stator to transport those in an integrated state, and being assembled to a vehicle without using a special assembling jig; and a manufacturing method of the motor.SOLUTION: A vehicle driving motor 1 is composed of a stator 10; and a rotor 20 installed on an inner diameter side so as to relatively rotate on the same axis as the stator 10. The vehicle driving motor 1 includes: a sheet-shaped shock absorber 40 interposed in a gap 30 between the stator 10 and the rotor 20 so as to surround an outer peripheral side surface 20a of the rotor 20; and a packing box 50 for integrating and packing the stator 10 and the rotor 20 while the shock absorber 40 is interposed in the gap 30. The packing box 50 is a member which is used only for transporting and storing the stator 10 and the rotor 20, and the shock absorber 40 is a member which is removed from the gap 30 after assembling the stator 10 and the rotor 20 to a vehicle.

Description

  The present invention relates to an electric motor for driving a vehicle comprising a stator and a rotor arranged to face the stator in a coaxially rotatable state and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, vehicles such as hybrid vehicles and electric vehicles are equipped with a motor (electric motor) including a cylindrical stator and a rotor installed on the inner diameter side of the stator as a drive source. In such a motor, a rotational driving force is generated in the rotor by a magnetic force generated between a coil formed by winding a winding around a stator core (tooth) of the stator and a permanent magnet installed in the rotor or on the outer peripheral surface thereof. It is like that.

  In a vehicle equipped with a motor as described above, if a malfunction such as deterioration or failure occurs due to long-term use, a motor service part or dealer may replace the motor parts. For this reason, stators and rotors that are components of motors are stocked as repair parts for vehicles at service centers and dealers around the world.

  The stator and rotor described above are manufactured at a parts manufacturing factory and then transported to a service center or a dealer repair shop. And it is stored in the said repair shop, and is assembled | attached to the transmission of a repair object vehicle as a replacement part. At this time, the stator of the motor is fixed to the transmission case side, and the rotor is splined to the rotating shaft side. Thus, the rotor is installed so as to be rotatable relative to the stator on the inner diameter side.

  However, since a strong magnetic force acts between the stator and the rotor, the stator and rotor as repair parts must be transported from the parts manufacturing factory to a service center or a dealer repair shop. If the rotor is transported in a state where the rotor is installed, there is a risk that problems such as breakage may occur due to inadvertent contact with them. Therefore, conventionally, the stator and the rotor have been separately packed and transported.

  However, when the stator and the motor are separately packed and transported as described above, the number of parts to be transported is increased and the external dimensions of the stator are increased. Therefore, it is desirable if the stator and the motor can be packed and transported integrally.

  As a technique for packing a conventional motor, there is a motor packing apparatus described in Patent Document 1. The packaging device described in Patent Document 1 is provided with a mounting base made of cushioning material such as foamed polystyrene at the bottom of a motor storage section partitioned by a partition plate in an exterior body formed of a cardboard box or the like, and the motor is placed on the mounting base. In this configuration, a presser frame is provided between the motor flange and the upper plate of the exterior body to restrict vertical and lateral movement. Further, a shaft hole for accommodating the end of the rotating shaft of the mounted motor is formed on the mounting table.

  Since the motor packed by the packing apparatus described in Patent Document 1 is a motor for household electrical appliances having a long dimension (axial length) in the longitudinal direction of the rotating shaft, a state where one end of the rotating shaft is inserted into the shaft hole of the mounting base Can be placed on the table and can be stably transported in that state. Further, since the stator and the rotor are configured to be housed and disposed inside the case, the rotor can be fixed so as not to move with respect to the stator simply by supporting a flange provided on the outer surface of the case. On the other hand, a vehicle driving motor mounted on a hybrid vehicle or the like is a flat motor having a short axial dimension (thickness dimension) with respect to a radial dimension, and a stator and a rotor are integrally formed. There is no housing case, and the rotor installed on the inner diameter side of the stator is not supported by other components. Therefore, the packaging device described in Patent Document 1 is not suitable for packaging for transporting a vehicle driving motor.

  In addition, as described above, after the stator and rotor are shipped from the parts manufacturing factory, they should be stored for several years as repair parts for vehicles at service centers and dealer repair shops. This is an assumed part. However, the stator is provided with a winding wound around the stator core, so that the end surface in the axial direction has a complicated shape with irregularities. For this reason, foreign substances such as dust may be mixed from the recesses on the end face of the stator during storage at a service center or dealer.

  Also, when assembling the above stator and rotor to a vehicle transmission at a service center or a dealer repair shop, the rotor is installed on the inner diameter side of the stator against the strong magnetic force acting between the stator and the rotor. There is a need. Since this operation is difficult to perform manually, the rotor is assembled to the inner diameter side of the stator using a dedicated assembly jig.

  However, since dedicated assembly jigs are expensive, there is a problem that costs are increased by installing the assembly jigs at repair shops in various places. Moreover, in order to accurately position and assemble the rotor so that the stator does not come into contact with the rotor, even if a dedicated assembly jig is used, a high level of skill is required. It takes time.

  As a prior art for facilitating the work of assembling a motor for driving a vehicle in a state in which the center axes of the stator and the rotor are aligned, Patent Document 2 discloses a rotating shaft at the time of assembling the motor. A configuration including a thin plate-like guide sleeve interposed in a gap between the rotor and the rotor is described. The technique described in Patent Document 2 secures a gap of a predetermined dimension between the stator and the rotor by fitting the guide sleeve to the outer peripheral side surface of the rotating shaft during assembly of the motor and fitting the rotor from above. Then, the rotor is assembled on the same axis as the stator by removing the guide sleeve. However, even if the guide sleeve as described above is used, the assembly of the stator and the rotor still requires a dedicated assembling jig, and it is easy to perform the assembly at the site such as a repair shop in various places. Not.

Japanese Utility Model Publication No. 61-56285 Japanese Patent No. 4059276

  The present invention has been made in view of the above-mentioned points, and the object of the present invention is that the stator and the rotor can be transported in an integrated state, and can be assembled on the vehicle side without using a dedicated assembling jig. An object is to provide a motor for driving a vehicle and a method for manufacturing the same.

  In order to solve the above-mentioned problems, the present invention provides an electric motor for driving a vehicle comprising a stator (10) and a rotor (20) arranged coaxially relative to the stator (10) so as to be relatively rotatable. (1), comprising a sheet-like cushioning material (40) interposed in a gap (30) between the stator (10) and the rotor (20), wherein the cushioning material (40) A member used only during transportation and storage of the stator (10) and the rotor (20), and after the stator (10) and the rotor (20) are assembled to the vehicle-side parts (60, 100), It is a member removed from the gap (30) when the electric motor (1) is in an operable state. In this case, a packing member (50) for packing the stator (10) and the rotor (20) in an integrated state with the cushioning material (40) interposed in the gap (30) is further provided. May be. The electric motor (1) may be a flat electric motor having a shorter axial dimension than an outer diameter.

  According to the electric motor for driving a vehicle according to the present invention, by providing the buffer material in the gap between the stator and the rotor, the rotor can be packed and transported in an integrated state on the inner diameter side of the stator. Thereby, compared with the case where it packs and conveys a stator and a rotor separately, the number of packing of the components to convey can be decreased and the external dimension of a packing can be restrained small. Therefore, the conveyance efficiency of the stator and the rotor is improved. Further, by conveying the stator and the rotor integrally, it is possible to prevent damage due to an impact at the time of conveyance.

  In addition, according to the present invention, since the rotor is previously installed on the inner diameter side of the stator and these are integrated and packed and transported, the step of installing the rotor on the inner diameter side of the stator is performed by manufacturing the stator and the rotor. This can be done at the parts manufacturing plant. This eliminates the need to perform the work of installing the rotor on the inner diameter side of the stator when assembling the stator and rotor on the vehicle side at a service center or a dealer repair shop. Therefore, it is not necessary to provide a rotor assembly jig at repair shops in various places. Therefore, the cost can be kept low. Also, by performing the process of installing the rotor on the inner diameter side of the stator as part of the manufacturing process at the parts manufacturing factory, the performance and quality of the motor can be improved, and the work for repairing the vehicle can be performed. The time and effort required can be reduced.

  In the above-mentioned electric motor for driving a vehicle, the cushioning material (40) installed in the gap (30) is installed in a state where at least a part of the end side (40a) protrudes from the gap (30). It is good to be. According to this configuration, the cushioning material can be extracted from the gap simply by pulling the end of the cushioning material protruding from the gap. Therefore, when the stator and the rotor are assembled to a vehicle-side part such as a transmission case, the cushioning material can be easily and quickly removed.

  Moreover, in the electric motor for driving the vehicle, the cushioning material (40-2) is made of a flexible material, and the cushioning material (40-2) extending from the gap (30). The extending portion (40-2c) including the end side (40a) of the rotor has a shape that gradually increases in diameter as it moves away from the axial end surfaces (10a, 20a) of the stator (10) and the rotor (20). The extension part (40-2c) is preferably folded back so as to cover the end face (10a) in the axial direction of the stator (10).

  According to this configuration, the end surface of the stator can be protected by covering the end surface of the stator with the extending portion of the buffer material extending from the end surface of the stator. Thereby, even when the stator and the rotor are stored for a long time, it is possible to prevent foreign matters such as dust from entering from the end face of the stator. Accordingly, when the stator and the rotor are assembled to the vehicle as repair parts, it is not necessary to remove dust and other foreign matters, and the assembly work can be performed immediately.

  Further, the end surfaces (10a, 20a) on the side from which the cushioning material (40) projects in the axial direction of the stator (10) and the rotor (20) or the opposite end surfaces (10b, 20b) are arranged on the end surfaces (10a, 20a). 20a or 10b, 20b) may be attached to holding members (45, 65) that contact and hold the same. According to this configuration, since the end surfaces of the stator and the rotor are held by the holding member, the influence of the bending stress generated between the stator and the rotor due to the weight of the rotor when the stator is lifted can be reduced. Can do. Therefore, it is possible to prevent problems such as deformation in the stator and the rotor, and the position of the rotor with respect to the stator from shifting.

  Furthermore, in this case, the holding member (65) is a member constituting a part of the vehicle-side parts (60, 100), and the stator (10) and the rotor (20) are formed of the holding member ( 65) may be assembled to the vehicle-side parts (60, 100) via 65). According to this configuration, by attaching the holding member to the vehicle-side component, the stator of the electric motor and the electric motor can be assembled on the vehicle side, so that the assembling of the electric motor can be simplified.

  Alternatively, in the above-described electric motor for driving a vehicle, the packing member (50) has an accommodating portion (51) that accommodates the stator (10) and the rotor (20) in an integrated state, and the accommodating portion (51). At least the bottom (51b) is formed of a material having a buffering action, and the end surface (10b, 20b) may be placed on the bottom (51b) of the housing (51).

  According to this configuration, the end surfaces of the stator and the rotor are placed on the bottom portion of the housing portion by housing the stator and the rotor in the housing portion of the packing member, so that the end surfaces are held in contact with the bottom portion. become. Thereby, even if some vibrations and impacts are applied during the transportation of the stator and rotor packed in the packing member, it is possible to avoid problems such as tilting of the rotor in the axial direction relative to the stator.

  In addition, a method of manufacturing an electric motor for driving a vehicle according to the present invention includes a vehicle including a stator (10) and a rotor (20) disposed opposite to the stator (10) so as to be coaxially and relatively rotatable. A method for manufacturing an electric motor (1) for driving, comprising a step of installing a rotor (20) and a stator (10) so as to face each other in a radial direction and integrating them, a stator (10) and a rotor ( 20), a step of inserting the sheet-like cushioning material (40) into the gap (30), a step of packing the stator (10) and the rotor (20) in an integrated state, and a packed stator ( 10) and the step of conveying the rotor (20), the step of assembling the stator (10) and the rotor (20) to the vehicle-side components (60, 100) in an integrated state, the stator (10) and the rotor (20 Between) And performing the steps of the operable state electric motor (1) for driving the vehicle and remove the buffer material (40) from the gap (30), the in this order.

  Another method of manufacturing a motor for driving a vehicle according to the present invention is such that the stator (10) is opposed to the inner diameter side of the stator (10) in a state of being rotatable relative to the stator (10) on the same axis. A method for manufacturing an electric motor (1) for driving a vehicle comprising a rotor (20) to be arranged, the step of surrounding an outer peripheral side surface of the rotor (20) with a sheet-like cushioning material (40), and a cushioning material (40 ) Is inserted into the inner diameter side of the stator (10) so that the cushioning material (40) is interposed in the gap (30) between the rotor (20) and the stator (10). The step of integrating the stator (10) and the rotor (20), the step of packing the stator (10) and the rotor (20) in an integrated state, and conveying the packed stator (10) and rotor (20) And stator (10) The step of assembling the rotor (20) in the vehicle-side component (60, 100) in an integrated state, and removing the cushioning material (40) from the gap (30) between the stator (10) and the rotor (20) The step of making the vehicle drive motor (1) operable is performed in this order.

  According to the method for manufacturing an electric motor for driving a vehicle according to the present invention, a cushioning material is provided in the gap between the stator and the rotor, so that the rotor is installed on the inner diameter side of the stator and these are integrated and packed. And can be transported. Thereby, compared with the case where it packs and conveys a stator and a rotor separately, the number of packing of the components to convey can be decreased and the external dimension of a packing can be restrained small. Therefore, the conveyance efficiency of the stator and the rotor is improved. Further, by conveying the stator and the rotor integrally, it is possible to prevent damage due to an impact at the time of conveyance.

  Further, according to the method for manufacturing an electric motor for driving a vehicle according to the present invention, a rotor can be installed on the inner diameter side of the stator, and these can be packed and transported in an integrated state. The step of installing the rotor can be performed at a parts manufacturing factory when the stator and the rotor are manufactured. This eliminates the need to install the rotor on the inner diameter side of the stator when assembling the stator and rotor to the vehicle side at a repair center of a service center or dealer. No need to deploy tools. Therefore, the cost can be kept low. Also, by performing the process of installing the rotor on the inner diameter side of the stator in a batch at the parts manufacturing factory, the performance and quality of the electric motor can be improved, and the effort required for the work at the site where the vehicle is repaired And can save time.

  Moreover, in said manufacturing method concerning this invention, the buffer material (40) is comprised with the material which has flexibility, and the extension part of the buffer material (40-2) extended from a gap (30) (40-2c) has a shape that gradually increases in diameter as it moves away from the axial end face (10a) of the stator (10), and the stator (10) and the rotor (20) are packed in an integrated state. Before, the extension part (40-2c) of the cushioning material (40-2) is folded outward so that at least the axial end face (40a) of the stator (10) is formed by the extension part (40-2c). It is good to have the process of covering.

According to this, the end surface of the stator can be protected by the buffer material by folding back the extending portion of the buffer material extending from the end surface of the stator so as to cover the end surface of the stator. Thereby, even when the stator and the rotor are stored for a long time, it is possible to prevent foreign matters such as dust from entering from the end face of the stator. Accordingly, when the stator and the rotor are assembled to the vehicle as repair parts, it is not necessary to remove dust and other foreign matters, and the assembly work can be performed immediately.
In addition, the code | symbol in said parenthesis shows the code | symbol of the component in embodiment mentioned later as an example of this invention.

  According to the electric motor for driving a vehicle and the manufacturing method thereof according to the present invention, a rotor can be installed on the inner diameter side of the stator, and these can be packed and transported in an integrated state. Assembly on the vehicle side can be performed without using tools.

1 is a perspective view showing a vehicle driving motor according to a first embodiment of the present invention. It is a figure which shows the stator and rotor of a motor, (a) is a schematic sectional drawing which looked at them from the axial direction, (b) is a figure which shows the XX arrow cross section of (a). It is a figure which shows the procedure which attaches a shock absorbing material to the gap between a stator and a rotor. (A) is the elements on larger scale which show the example of composition of the lower end side of a shock absorbing material, (b) is a perspective view showing the motor provided with the shock absorbing material of other composition, (c) is under the stator and rotor It is a figure which shows the holding member attached to the end surface. It is a perspective view which shows the box for packing which accommodates a stator and a rotor. It is a disassembled perspective view for demonstrating the procedure which attaches a stator and a rotor to a transmission. It is a flowchart which shows the procedure (1st pattern) of the manufacturing method of a motor. It is a flowchart which shows the procedure (2nd pattern) of the manufacturing method of a motor. It is a figure which shows the motor for a vehicle drive concerning 2nd Embodiment of this invention, (a) is a perspective view which shows the state before turning back the shock absorbing material which protrudes from a gap, (b) is the buffer which protrudes from a gap. It is a perspective view which shows the state which turned up the material and covered the end surface of the stator. It is a perspective view which shows the motor for vehicle driving concerning 3rd Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[First Embodiment]
FIG. 1 is a perspective view showing an electric motor (hereinafter referred to as “motor”) 1 for driving a vehicle according to a first embodiment of the present invention. FIG. 2 is a view showing the stator 10 and the rotor 20 of the motor 1. FIG. 2A is a schematic sectional view of the stator 10 and the rotor 20 viewed from the axial direction, and FIG. It is a figure which shows a XX arrow cross section. In the following description, the term “up” or “down” refers to the upper or lower direction of the motor 1 with the axial direction directed in the vertical direction as shown in FIG.

  The motor 1 including the stator 10 and the rotor 20 illustrated in FIGS. 1 and 2 is manufactured in a parts manufacturing factory and transported to service centers and dealers in various places. The motor 1 includes a stator 10, a rotor 20 installed on the inner diameter side of the stator 10, and a buffer for transportation and storage interposed in a minute gap (gap) 30 formed between the stator 10 and the rotor 20. The material 40 is provided. The cushioning material 40 is a member for preventing the rotor 20 installed on the inner diameter side of the stator 10 from colliding with the stator 10 during transportation. The cushioning material 40 is a member attached to the motor 1 in the transportation stage and storage stage of the motor 1. When the motor 1 is assembled in a transmission 100 of a vehicle to be described later, the motor 1 is ready for operation. Is something to remove.

  The motor 1 shown in FIGS. 1 and 2 is used in a hybrid vehicle having an engine and a motor as drive sources, though not shown in detail, so as to share an axis with the crankshaft and transmission of the engine. Installed. The stator 10 is fixed to the side of a transmission case (see FIG. 6) mounted on the vehicle, and the rotor 20 that can rotate relative to the stator 10 is splined to the transmission rotation shaft (see FIG. 6) connected to the crankshaft of the engine. Installed by mating. The motor 1 assists in driving the engine by supplying electric power from the battery. It is also possible to run the vehicle with only the driving force of the motor 1 without using the engine. Furthermore, when the vehicle decelerates, the rotation of the wheels is transmitted to operate as a generator, and a part of the kinetic energy is regenerated into electric power.

  Unlike a general motor, the motor 1 of the present embodiment is a flat type (thin type) motor in which the axial length dimension (thickness dimension) is smaller than the radial dimension of the stator 10. As shown in FIG. 1, the stator 10 includes a stator core 12 that protrudes inward in the radial direction. A plurality of the stator cores 12 are arranged along the circumferential direction, and the entire stator 10 is formed in a circular ring shape. A stator coil (winding) 15 is wound around each stator core 12 via an insulating insulator (not shown). In FIG. 2, the stator coil 15 wound around the stator core 12 is not shown. A circular opening 11 is provided inside the inner diameter end of each stator core 12, and a rotor 20 is installed in the opening 11.

  The rotor 20 has a circumferential outer peripheral side surface, and is provided with a shaft hole 22 for inserting and fixing the rotation shaft at the center. And as shown in FIG. 2, the permanent magnet 25 is embedded in the inside. The motor 1 of the present embodiment is an interior permanent magnet (IPM) type motor in which a permanent magnet 25 is embedded in an iron core of a rotor 20.

  The cushioning material 40 inserted into the gap 30 between the stator 10 and the rotor 20 is a thin plate-like member formed in a circular ring shape surrounding the outer peripheral side surface of the rotor 20. The material constituting the buffer material 40 is a material that can transmit the magnetic force of the permanent magnet 25 embedded in the rotor 20 to the stator 10 side, and is damaged by the stator 10 and the rotor 20 that are attracted to each other by the magnetic force between them. It is necessary that the material has a shock absorbing property that does not cause the above problem. A specific example of the material of the buffer material 40 that satisfies such requirements is an elastic material formed by foaming a synthetic resin material such as polyurethane into a sponge shape. In addition to the synthetic resin material, a thin plate member made of metal such as copper may be used.

  Next, the process of assembling the motor 1 having the above configuration into the state shown in FIG. 1 will be described. FIG. 3 is a diagram for explaining a procedure for inserting the cushioning material 40 into the gap 30 between the stator 10 and the rotor 20. In a component manufacturing factory that manufactures the motor 1, the stator 10 and the rotor 20 are manufactured, and then the rotor 20 is installed in the opening 11 on the inner diameter side of the stator 10, as shown in FIG. At this time, since a strong magnetic force acts between the stator 10 and the rotor 20, in order to install the rotor 20 on the inner diameter side of the stator 10, the rotor 20 is installed under the condition that the magnetic force acts. The rotor 20 is supported at the center of the opening 11 of the stator 10 (concentrically with the stator 10) by a dedicated assembly jig that can be used. Thereby, the rotor 20 is supported so that the gap 30 between the stator 10 on the outer peripheral side of the rotor 20 has the same width dimension on the entire circumference. In this state, as shown in FIG. 3, the cushioning material 40 is inserted into the gap 30 between the stator 10 and the rotor 20. The cushioning material 40 is inserted so that the end side (lower end side) 40 b is inserted into the gap 30 from one end side (upper end side) of the motor 1 in the axial direction. Thus, the cushioning material 40 is inserted into the gap 30 between the stator 10 and the rotor 20 as shown in FIG.

  When the support of the rotor 20 by the assembling jig is released in this state, the rotor 20 is attracted to one of the openings 11 by the magnetic force with the stator 10 as shown in FIG. The stator 10 is fixed by suction through the buffer material 40. In FIG. 2, the width dimension of the gap 30 between the stator 10 and the rotor 20 is illustrated with a larger width dimension than actual for the sake of explanation. As described above, the motor 1 of the present embodiment is transported and stored in a state where the cushioning material 40 is inserted into the gap 30 between the stator 10 and the rotor 20 and the stator 10 and the rotor 20 are attracted by magnetic force. It has become.

  Further, as shown in FIG. 1, the cushioning material 40 inserted into the gap 30 between the stator 10 and the rotor 20 has an end side (upper end side) 40 a opposite to the insertion side on the stator 10 and the rotor 20. It is installed in a state protruding slightly upward from the end faces 10a, 20a. As a result, as will be described later, when the motor 1 is assembled to the transmission 100 (see FIG. 6), the cushioning material 40 can be easily and quickly extracted from the gap 30.

  FIG. 4A is a partially enlarged cross-sectional view illustrating a configuration example of the lower end side 40b of the cushioning material 40. FIG. Since the width of the gap 30 between the stator 10 and the rotor 20 is very small, about several millimeters at most, when the cushioning material 40 is inserted into the gap 30 in the above procedure, the cushioning material 40 can be inserted smoothly. There is a risk of not. Therefore, as shown in FIG. 4A, it is preferable to provide a chamfered portion 41 that is chamfered so that the lower end side (end side on the insertion side) 40 b of the cushioning material 40 has a tapered cross section. By providing such a chamfered portion 41, the cushioning material 40 can be smoothly inserted into the gap 30 between the stator 10 and the rotor 20.

  In addition to inserting the cushioning material 40 into the gap 30 after installing the rotor 20 on the inner diameter side of the stator 10 as described above, when the rotor 20 is assembled on the inner diameter side of the stator 10, It is also possible to attach the cushioning material 40 to the side surface 20 c and install the rotor 20 and the cushioning material 40 together on the inner diameter side of the stator 10. Even in such a case, it is preferable to provide a chamfered portion 41 at the lower end side 40b of the cushioning material 40 so that the tip cross-section has an acute angle. Thereby, it is possible to prevent the lower end side 40 b of the cushioning material 40 from being caught by the tip of the stator core 12 arranged on the inner peripheral surface of the stator 10.

  FIG. 4B is a diagram illustrating another configuration example of the cushioning material 40. The cushioning material 40 may be a member divided into a plurality of plate members as shown in FIG. 4B in addition to the circular annular member as shown in FIGS. In this case, each plate material of the buffer material 40 is a rectangular flat plate-like member, and is inserted into the gap 30 so as to be arranged along the outer peripheral side surface of the rotor 20. Also in this case, the upper end side 40a of the cushioning material 40 is installed in a state of slightly protruding upward from the upper end surfaces 10a, 20a of the stator 10 and the rotor 20.

  Further, as shown in FIG. 2, in the motor 1 in a state where the rotor 20 is installed on the inner diameter side of the stator 10, the stator 10 and the rotor 20 are separated from each other by the magnetic force acting between them. The inner peripheral side surface 10c is in contact with only one contact portion 31 in the circumferential direction. Therefore, when the stator 10 of the motor 1 with the axial direction directed up and down is lifted in that state, a bending stress in the axial direction is generated between the stator 10 and the rotor 20 due to the weight of the rotor 20. If this bending stress becomes prominent, there is a risk that an excessive load will act on the stator 10 and the rotor 20 to cause a problem such as deformation of the parts, or that the motor 1 cannot be smoothly assembled to the transmission case 60. is there.

  Therefore, when the influence of the bending stress generated between the stator 10 and the rotor 20 as described above is large and may affect the assembly of the motor 1, as shown in FIG. In addition, a flat plate material (holding member) 45 may be attached to the lower end surfaces 10 b and 20 b of the rotor 20, and the lower end surfaces 10 b and 20 b of the stator 10 and the rotor 20 may be held by the plate material 45. The plate member 45 is a member used only when the stator 10 and the rotor 20 are transported and stored, and is removed when the stator 10 and the rotor 20 are assembled to the transmission 100 of the vehicle. Further, as will be described later, when the lower end surfaces 10b and 20b of the stator 10 and the rotor 20 can be held by the bottom surface 51b (see FIG. 5) of the accommodating portion 51 of the packing box 50, the plate material 45 may not be provided.

  FIG. 5 is a diagram illustrating a configuration example of a packing box (packing material) 50 used when the motor 1 is transported. In the motor 1 assembled in the above procedure, the rotor 20 is installed on the inner diameter side of the stator 10 and these are integrated. The packaging box 50 has a rectangular parallelepiped shape as a whole, and is made of a material formed by foaming a synthetic resin material such as polyurethane to form a sponge. On the upper surface 50 a of the packaging box 50, a concave accommodating portion 51 that accommodates each motor 1 is formed. The accommodating part 51 is a cylindrical bottomed concave part along the outer shape of the stator 10, and a plurality of the accommodating parts 51 are formed on the upper surface 50 a of the packing box 50.

  The motor 1 is accommodated in the accommodating part 51 of the packaging box 50 as shown in FIG. The plurality of motors 1 are transported to the destination while being accommodated in the packing box 50. At this time, the motor 1 housed in the housing portion 51 is in a state where the lower end surface 10b of the stator 10 is placed on the bottom surface (bottom portion) 51b of the housing portion 51 and is in contact with the bottom surface 51b. The lower end surface 10 b and the lower end surface 20 b of the rotor 20 are held by the bottom surface 51 b of the accommodating portion 51. Thereby, even if some vibrations or impacts are applied to the motor 1 in the packing box 50 during transportation, problems such as the inclination of the rotor 20 in the axial direction with respect to the stator 10 can be avoided. Further, since the bottom surface 51b of the accommodating portion 51 holds (backs up) the lower end surface 10b of the stator 10 and the lower end surface 20b of the rotor 20, bending in the axial direction that occurs between the stator 10 and the rotor 20 is performed. The influence of stress can be reduced.

  Next, the procedure of the process of assembling the motor 1 having the above configuration to the transmission of the vehicle will be described. FIG. 6 is a diagram for explaining a procedure for assembling the stator 10 and the rotor 20 in the transmission case 60, and is an exploded perspective view showing a configuration example of the motor 1 and its periphery in the transmission 100. In order to assemble the motor 1 in which the stator 10 and the rotor 20 are integrated as described above to the transmission 100, first, the transmission case 60 is set so that the axial direction is vertical as shown in FIG. Install it facing upward. In this state, the operator holds the stator 10 of the motor 1 with both hands, and lowers it to the inside of the transmission case 60 with its axial direction directed vertically. At this time, the cushioning material 40 inserted in the gap 30 between the stator 10 and the rotor 20 is not removed yet and is left installed. In this state, the rotation shaft 101 of the transmission 100 is spline-fitted into the shaft hole 22 of the rotor 20 to fix the rotor 20 to the rotation shaft 101 and align the knock position of the stator 10, thereby fixing the stator 10 to the transmission case 60. To fix. Thus, the stator 10 and the rotor 20 of the motor 1 are assembled to the transmission 100. Thereafter, the cushioning material 40 inserted in the gap 30 between the stator 10 and the rotor 20 is removed. For this purpose, the upper end side 40 a of the buffer material 40 protruding from the upper end surfaces 10 a and 20 a of the stator 10 and the rotor 20 is pulled up, and the buffer material 40 is extracted from the gap 30. As described above, the motor 1 including the stator 10 and the rotor 20 is assembled in the transmission case 60. Thereafter, the side cover 65 is put on the motor 1 and attached to the mating surface 61 of the transmission case 60.

  Here, the procedure of the method for manufacturing the stator 10 and the rotor 20 of the motor 1 according to the present embodiment is organized based on the flowcharts shown in FIGS. In the procedure (first pattern) of the manufacturing method of the motor 1 shown in FIG. 7, a process of installing the rotor 20 on the inner diameter side of the stator 10 and integrating them (first process: step ST1-1), and the stator 10 The step of inserting the sheet-like cushioning material 40 into the gap 30 between the rotor 20 and the rotor 20 (second step: step ST1-2) and the step of packing the stator 10 and the rotor 20 in an integrated state (third step) : Step ST1-3), a step of transporting the packed stator 10 and rotor 20 (fourth step: Step ST1-4), and a step of assembling the stator 10 and the rotor 20 into the vehicle transmission 100 in an integrated state ( Fifth step: Step ST1-5), a state in which the shock absorber 40 is removed from the gap 30 between the stator 10 and the rotor 20, and the motor 1 can be operated. That step (sixth step: Step ST1-6) has a to perform in this order.

  Further, in another procedure (second pattern) of the method for manufacturing the motor 1 shown in FIG. 8, a step of enclosing the outer peripheral side surface of the rotor 20 with the sheet-like cushioning material 40 (first step: step ST2-1), and buffering By inserting the rotor 20 surrounded by the material 40 into the inner diameter side of the stator 10, the stator 10 and the rotor 20 are integrated with the buffer material 40 interposed in the gap 30 between the rotor 20 and the stator 10. Step (second step: step ST2-2), step of packing the stator 10 and the rotor 20 in an integrated state (third step: step ST2-3), and step of transporting the packed stator 10 and the rotor 20 (Fourth step: Step ST2-4) and a step of assembling the stator 10 and the rotor 20 into the vehicle transmission 100 in an integrated state (Fifth step: Step ST2-5) And the process (6th process: step ST2-6) which removes the buffer material 40 from the gap 30 between the stator 10 and the rotor 20, and makes the motor 1 for driving a vehicle operable | operated is performed in this order. It is like that.

  In the first to third steps (steps ST1-1 to 1-3 and steps ST2-1 to 2-3), the stator 10 and the rotor 20 are manufactured at a parts manufacturing factory that is a conveyance source of the motor 1. The fifth step and the sixth step (steps ST1-5, 1-6, steps ST2-5, 2-6) are repairs of the service center or dealer that is the transport destination of the motor 1. It is a process performed in a factory.

  As described above, according to the motor 1 and the manufacturing method thereof according to the present embodiment, the rotor 20 is provided on the inner diameter side of the stator 10 by providing the buffer material 40 in the gap 30 between the stator 10 and the rotor 20. It can be packed and transported in an integrated state. Thereby, compared with the case where the stator 10 and the rotor 20 are packed and conveyed separately, the number of parts to be conveyed can be reduced, and the outer dimensions of the packing can be kept small. Therefore, the conveyance efficiency of the stator 10 and the rotor 20 is improved. Further, by conveying the stator 10 and the rotor 20 in an integrated manner, it is possible to prevent damage due to impact during transportation.

  Further, in the motor 1 and the manufacturing method thereof according to the present embodiment, since the rotor 20 is installed on the inner diameter side of the stator 10 and can be packed and transported integrally, the influence of the magnetic force of the rotor 20 during transport is minimized. Can be suppressed.

  Further, in the motor 1 and the manufacturing method thereof according to the present embodiment, the step of installing the rotor 20 on the inner diameter side of the stator 10 can be performed at a parts manufacturing factory when the motor 1 is manufactured. This eliminates the need to perform the work of installing the rotor 20 on the inner diameter side of the stator 10 at a repair center of a service center or a dealer, so that it is not necessary to provide dedicated assembly jigs at repair shops in various places. Therefore, the cost can be kept low. In addition, the performance and quality of the motor 1 can be improved by performing the process of installing the rotor 20 on the inner diameter side of the stator 10 at a part manufacturing factory, and the work at the site where the vehicle is repaired. Can reduce the time and effort required.

  Moreover, in said motor 1, only the edge 40a of the shock absorbing material 40 is pulled by protruding the edge 40a of the shock absorbing material 40 attached to the gap 30 between the stator 10 and the rotor 20 from the gap 30. Thus, the buffer material 40 can be extracted from the gap 30. Therefore, when the stator 10 and the rotor 20 are assembled to the transmission 100 of the vehicle, the cushioning material 40 can be easily and quickly removed.

  Moreover, in this embodiment, the packaging box 50 which has the accommodating part 51 which accommodates the stator 10 and the rotor 20 is provided, and the bottom face 51b of the accommodating part 51 is formed with the material which has a buffering effect, and the stator 10 and rotor The lower end surfaces 10 b and 20 b of 20 are placed on the bottom surface 51 b of the accommodating portion 51.

  According to this configuration, since the stator 10 and the rotor 20 are housed in the housing portion 51 of the packing box 50, the lower end surfaces 10 b and 20 b of the stator 10 and the rotor 20 are placed on the bottom surface 51 b of the housing portion 51. The lower end surfaces 10b and 20b are held in contact with the bottom surface 51b. Therefore, even if some vibration or impact is applied to the stator 10 and the rotor 20 in the packing box 50 during transportation, it is possible to avoid problems such as the tilt of the rotor 20 in the axial direction with respect to the stator 10. .

[Second Embodiment]
Next, a second embodiment of the present invention will be described. In the description of the second embodiment and the corresponding drawings, the same or corresponding components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted below. In addition, matters other than those described below are the same as those in the first embodiment. This is the same in other embodiments. FIG. 9 is a perspective view showing a motor 1-2 according to the second embodiment of the present invention. The shock absorber 40-2 attached to the motor 1-2 of the present embodiment has a larger axial length than the shock absorber 40 attached to the motor 1 of the first embodiment. The extension portions 40-2c of the buffer material 40-2 extending upward from the upper end surfaces 10a, 20a of the stator 10 and the rotor 20 are separated from the stator 10 and the upper end surfaces 10a, 20a of the rotor 20 (the buffer material 40- 2 is formed in a divergent shape (trumpet shape) that gradually increases in diameter (as it approaches the upper end side 40-2a).

  9A, the gap 30 between the stator 10 and the rotor 20 extends upward from the gap 30 in a state where the lower end side 40-2b side of the cushioning material 40-2 is inserted. The extended portion 40-2c of the cushioning material 40-2 is folded outward. As a result, as shown in FIG. 9B, the upper end surface 10 a of the stator 10 is covered with the extended portion 40-2 c of the buffer material 40-2 extending from the gap 30. The packaging box shown in FIG. 5 is a motor 1-2 in which the stator 10 and the rotor 20 are integrated in a state where the upper end surface 10a of the stator 10 is covered with the extending portion 40-2c of the cushioning material 40-2 as described above. It accommodates in 50 accommodating parts 51.

  Thus, in the motor 1-2 of this embodiment, the extension part 40-2c of the buffer material 40-2 is formed in a divergent shape, and the upper end surface 10a of the stator 10 is turned to the buffer material 40 by folding the portion outward. -2 to protect. Thereby, it is possible to prevent the foreign matter from adhering to and entering the stator coil 15 exposed on the upper end surface 10a of the stator 10 and the gap, and to prevent the upper end surface 10a and the outer peripheral side surface of the stator 10 from being scratched. .

  In addition, the length dimension of the extension part 40-2c extended from the gap 30 in the buffer material 40-2 covers at least the upper end surface 10a of the stator 10 in a state where the extension part 40-2c is folded back. However, it is more preferable if the dimensions can cover the upper end surface 10a and the outer peripheral side surface 10d of the stator 10. Further, the cushioning material 40-2 of the present embodiment is made of a flexible material such as a sponge made of a synthetic resin material so that the extending portion 40-2c can be easily folded back. Further, in the motor 1-2 of the present embodiment, when the rotor 20 is assembled to the inner diameter side of the stator 10, the outer peripheral side surface of the rotor 20 is previously enclosed on the lower end side 40-2b side of the cushioning material 40-2, and these The rotor 20 and the buffer material 40-2 may be installed on the inner diameter side of the stator 10 together.

  In the procedure of the manufacturing method of the motor 1-2 provided with the buffer material 40-2 according to the present embodiment, although not shown, the procedure of the manufacturing method of the motor 1 according to the first embodiment shown in FIGS. In FIG. 5, before the step of packing the stator 10 and the rotor 20 in an integrated state (third step: steps ST1-3 and 2-3), the extended portion 40-2c of the cushioning material 40-2 is folded outward. Thus, a process of covering the upper end surface 10a of the stator 10 with the extending portion 40-2c is performed.

[Third Embodiment]
Next, a third embodiment of the present invention will be described. FIG. 10 is a perspective view showing a vehicle driving motor according to the third embodiment of the present invention. In the present embodiment, the side cover 65 of the transmission 100 is attached in advance to the upper end surfaces 10a, 20a of the stator 10 and the rotor 20 when the motor is manufactured, and the stator 10 and the rotor 20 are packed and transported in that state. ing. In this case, the buffer material 40 installed in the gap 30 between the stator 10 and the rotor 20 is a rectangular flat plate member divided into a plurality of plate materials as shown in FIG. And each board | plate material of the buffer material 40 is inserted in the gap 30 so that it may arrange in the circumferential direction along the outer peripheral side surface of the rotor 20, and the upper end side 40a of the buffer material 40 is the upper end surface of the stator 10 and the rotor 20 It is installed in a state of slightly protruding upward from 10a, 20a. And the side cover 65 is attached to the upper end surfaces 10a and 20a side of the stator 10 and the rotor 20 so that the upper end side 40a side of the shock absorbing material 40 may be covered.

  Further, as shown in FIG. 10, in the present embodiment, a plurality of slits 66 are formed in the side cover 65 as a structure for extracting the cushioning material 40 after the stator 10 and the rotor 20 are assembled to the transmission 100. . Each slit 66 has a configuration in which through-holes corresponding to the respective plate members of the cushioning material 40 are arranged circumferentially around the center of the side cover 65.

  The motor according to the present embodiment is assembled in a parts manufacturing factory until the side cover 65 is attached to the upper end surfaces 10a and 20a of the stator 10 and the rotor 20, and is packed in that state and transported to various repair shops. Moreover, it is stored in that state. After that, when the side cover 65 is fastened to the transmission case 60 by fastening bolts, the stator 10 and the rotor 20 are assembled into the transmission case 60 via the side cover 65 when assembled to the transmission 100 of the vehicle at a repair shop. It is supposed to be. After the stator 10 and the rotor 20 are assembled in the transmission case 60 in this way, the cushioning material 40 is removed from the gap 30 between the stator 10 and the rotor 20 by removing the cushioning material 40 from the slit 66 of the side cover 65. Can do.

  In the motor of the present embodiment, the side cover 65 contacts and holds the stator 10 and the upper end surfaces 10a and 20a of the rotor 20, and the side cover 65 functions as a holding member according to the present invention. . Therefore, the bending stress generated between the stator 10 and the rotor 20 due to the weight of the rotor 20 when the stator 10 is lifted by holding the stator 10 and the upper end surfaces 10a, 20a of the rotor 20 by the side cover 65. Can alleviate the effects. Therefore, it is possible to prevent problems such as deformation of the stator 10 and the rotor 20 during transportation and the displacement of the position of the rotor 20 with respect to the stator 10.

  Further, in the present embodiment, the stator 10 and the rotor 20 can be assembled in the transmission case 60 by attaching the side cover 65 to the transmission case 60. Therefore, the assembling process of the stator 10 and the rotor 20 at a repair shop or the like. Simplification can be achieved.

  In FIG. 10, as a configuration for removing the buffer material 40 from the gap 30 after the side cover 65 is attached to the transmission case 60, the case where the slit 66 is provided in the side cover 65 is shown. In addition to this configuration, the transmission case 60 may be provided with a cut portion cut into a slit shape or the like from the mating surface 61 with respect to the side cover 65. It is. In this case, after attaching the side cover 65 to the transmission case 60, a hand or a tool is inserted into the cut portion, and the cushioning material 40 in the transmission case 60 is extracted. In the case where the above-described cut portion is provided, the cushioning material 40 is preferably not a plate material divided into a plurality of pieces but a single belt-like member arranged in an annular shape along the outer peripheral surface of the rotor 20. . Accordingly, it is possible to reliably remove the cushioning material 40 from the gap 30 only by pulling one end of the cushioning material 40 with a hand or tool inserted from the notch.

  Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the technical idea described in the claims and the specification and drawings. Deformation is possible. For example, the motors 1 and 1-2 of the above embodiment are interior permanent magnet (IPM) type motors in which the permanent magnets 25 are embedded in the iron core of the rotor 20. The motor to which the invention is applied may be a surface permanent magnet (SPM) type motor in which a magnet is attached to the outer peripheral side surface of the rotor 20.

  In the above embodiment, as the electric motor according to the present invention, a so-called inner rotor type motor in which a rotor is arranged on the inner diameter side of the stator is shown. A so-called outer rotor type motor in which a rotor is disposed on the outer diameter side of the stator may be used.

DESCRIPTION OF SYMBOLS 1 Motor 10 Stator 10a Upper end surface 10b Lower end surface 10c Inner peripheral surface 10d Outer peripheral side surface 11 Opening part 12 Stator core 15 Stator coil 20 Rotor 20b Lower end surface 20c Outer peripheral side surface 22 Shaft hole 25 Permanent magnet 30 Gap 40 Buffer material 40a Upper end side 40b Lower end side 41 Chamfer 45 Plate material (holding member)
50 Box for packing (packing material)
50a Upper surface 51 Housing portion 51b Bottom surface (bottom)
60 Transmission case 65 Side cover 100 Transmission 101 Rotating shaft

Claims (11)

An electric motor for driving a vehicle comprising a stator and a rotor arranged opposite to the stator so as to be rotatable relative to the stator on the same axis,
A sheet-like cushioning material interposed in the gap between the stator and the rotor;
The cushioning material is a member used only during transportation and storage of the stator and the rotor, and when the stator and the rotor are assembled to parts on the vehicle side, when the electric motor is made operable. A motor for driving a vehicle, the member being a member to be removed from the gap. A packing member for packing the stator and the rotor in an integrated state with the cushioning material interposed in the gap;
The electric motor for driving a vehicle according to claim 1, wherein the packing member is a member used only during transportation and storage of the stator and the rotor. The electric motor for driving a vehicle according to claim 1 or 2, wherein the cushioning material installed in the gap is installed in a state in which at least a part of an end thereof protrudes from the gap. The cushioning material is made of a flexible material,
The extending portion including the end side of the cushioning material extending from the gap has a shape that gradually increases in diameter as the distance from the axial end surface of the stator and the rotor increases.
The electric motor for driving a vehicle according to claim 3, wherein the extension portion is folded back so as to cover an end face of the stator in the axial direction. A holding member that contacts and holds the end surface is attached to an end surface of the stator and the rotor in the axial direction on the side where the cushioning material protrudes or an end surface on the opposite side. The electric motor for driving a vehicle according to claim 3 or 4. The holding member is a member constituting a part of the vehicle-side component,
The motor for driving a vehicle according to claim 5, wherein the stator and the rotor are assembled to the vehicle-side component via the holding member. The packing member has an accommodating portion for accommodating the stator and the rotor in an integrated state,
The accommodating portion is formed of a material having a buffering action at least at the bottom thereof,
5. The vehicle according to claim 3, wherein an end surface of the stator and the rotor in an axial direction opposite to a side from which the cushioning material is protruded is placed on a bottom portion of the housing portion. Electric motor for driving. The electric motor for driving a vehicle according to any one of claims 1 to 7, wherein the electric motor is a flat electric motor having a shorter axial dimension than an outer diameter. A method for manufacturing an electric motor for driving a vehicle comprising a stator and a rotor arranged opposite to the stator so as to be rotatable relative to the stator coaxially,
Installing the rotor and the stator so as to face each other in the radial direction and integrating them;
Inserting a sheet-like cushioning material into the gap between the stator and the rotor;
Packing the stator and the rotor in an integrated state;
Transporting the packed stator and rotor;
Assembling the stator and the rotor into a vehicle-side component in an integrated state;
Removing the cushioning material from the gap between the stator and the rotor to enable the vehicle driving motor to operate;
In this order. A method for manufacturing an electric motor for driving a vehicle. A method of manufacturing an electric motor for driving a vehicle comprising a stator and a rotor arranged to face the inner diameter side of the stator so as to be relatively coaxially rotatable with respect to the stator,
Enclosing the outer peripheral side surface of the rotor with a sheet-like cushioning material;
Inserting the rotor surrounded by the buffer material into the inner diameter side of the stator, and integrating the stator and the rotor in a state where the buffer material is interposed in the gap between the rotor and the stator; ,
Packing the stator and the rotor in an integrated state;
Transporting the packed stator and rotor;
Assembling the stator and the rotor into a vehicle-side component in an integrated state;
Removing the cushioning material from the gap between the stator and the rotor to enable the vehicle driving motor to operate;
In this order. A method for manufacturing an electric motor for driving a vehicle. The cushioning material is made of a flexible material,
The extending portion of the cushioning material extending from the gap has a shape that gradually increases in diameter with increasing distance from the axial end surface of the stator,
Before the step of packing the stator and the rotor in an integrated state,
The vehicle driving device according to claim 9, further comprising a step of covering at least the axial end surface of the stator with the extending portion by folding the extending portion of the cushioning material outward. Method of manufacturing the electric motor.

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