JP2014045550A - Drive unit and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the flexibility of terminal arrangement.SOLUTION: A drive unit includes: a rotor which is supported so as to freely rotate around a predetermined axial direction; a stator core which is provided at the radially out side of the rotor and is used for rotating the rotor; a coil wound around the stator core; and a terminal which is attached to a non rotation portion excluding the rotor after the coil is joined and receives electric power supply from the exterior.

Description

  The present invention relates to a drive unit and a method for manufacturing the drive unit.

  The electric motor of Patent Document 1 includes a stator core, a winding wound around the stator core a plurality of times, a resin insulator that insulates between the stator core and the winding, and a terminal.

JP 2011-10398 A

  However, in the configuration of Patent Document 1, the terminal and the winding are connected after the terminal is attached to the stator core (insulator). Since the connection between the terminal and the winding involves joining such as welding, the terminal cannot be arranged unless it is a place where the joining can be performed, and the place where the terminal is arranged is restricted. In addition, it is necessary to provide a space for bonding in the insulator, which is a factor of increasing the size of the apparatus.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a drive unit that can improve the degree of freedom of terminal arrangement.

  The drive unit according to claim 1, a rotor supported rotatably around a predetermined axial direction, a stator core provided on a radially outer side of the rotor, for rotating the rotor, and wound around the stator core And a terminal which is attached to a non-rotating portion excluding the rotor and to which electric power from the outside is supplied after the winding is joined.

  According to this drive unit, after the winding wound around the stator core is joined to the terminal, the joined terminal is attached to the non-rotating portion excluding the rotor.

  As described above, since the terminal is joined (for example, welding) before being attached to the non-rotating portion and is not joined at the attachment place, the place where the joining cannot be performed can be set as the attachment place. For this reason, the freedom degree of the place which attaches a terminal improves.

  Further, according to the drive unit of the first aspect, it is not necessary to provide a joining space in the non-rotating portion to which the terminal is attached, which leads to downsizing of the device.

  A drive unit according to a second aspect is the drive unit according to the first aspect, wherein the terminal is arranged to face one end surface in the axial direction of the rotor.

  According to this drive unit, the terminals can be arranged by effectively utilizing the dead space on the one axial end surface side of the rotor. As described above, the terminals are arranged by effectively using the dead space, which leads to downsizing of the apparatus.

  A drive unit according to a third aspect is the drive unit according to the first aspect, wherein the terminal is disposed on the radially outer side of the stator core.

  According to this drive unit, the terminals can be arranged by effectively utilizing the dead space on the radially outer side of the stator core. As described above, the terminals are arranged by effectively using the dead space, which leads to downsizing of the apparatus.

  The drive unit according to claim 4 is the drive unit according to any one of claims 1 to 3, wherein the drive unit is connected to the terminal to supply electric power from the outside to the terminal, and the axial direction of the rotor The electric wire arrange | positioned along the orthogonal direction is provided.

  According to this drive unit, since the electric wire for supplying electric power from the outside to the terminal is disposed along the direction orthogonal to the axial direction of the rotor, the axial length of the drive unit can be suppressed. Thereby, it leads to size reduction of an apparatus.

  The drive unit according to claim 5 is the drive unit according to claim 4, wherein the connection end of the electric wire to the terminal and the connection end of the winding to the terminal are shafts of the rotor. It is arrange | positioned on the same plane orthogonal to a direction.

  According to this drive unit, since the connection end to the terminal in the electric wire and the connection end to the terminal in the winding are arranged on the same plane orthogonal to the axial direction of the rotor, the shaft of the drive unit The direction length can be suppressed. Thereby, it leads to size reduction of an apparatus.

  The method for manufacturing a drive unit according to claim 6 includes a rotor that is rotatably supported around a predetermined axial direction, a stator core that is provided radially outside the rotor and that rotates the rotor, and the stator core In a method of manufacturing a drive unit comprising: a winding wound around the terminal; and a terminal connected to the winding and supplied with electric power from the outside, after the winding is joined to the terminal, the terminal Is attached to the non-rotating part except the rotor.

  According to this drive unit manufacturing method, after the winding wound around the stator core is joined to the terminal, the joined terminal is attached to the non-rotating portion excluding the rotor.

  As described above, since the terminal is joined (for example, welding) before being attached to the non-rotating portion and is not joined at the attachment place, the place where the joining cannot be performed can be set as the attachment place. For this reason, the freedom degree of the place which attaches a terminal improves.

  Further, it is not necessary to provide a joining space in the non-rotating portion to which the terminal is attached, which leads to downsizing of the device.

FIG. 3 is a side sectional view of the drive unit according to the first embodiment (a sectional view taken along line AA in FIG. 2). It is the figure which looked at the drive unit shown by FIG. 1 in the axial direction. FIG. 2 is a side sectional view showing a state before the terminal is fixed to the mounting portion in the drive unit shown in FIG. 1. It is a sectional side view (BB sectional view of FIG. 2) of the drive unit shown by FIG. It is a sectional side view of the drive unit concerning a 2nd embodiment. It is the figure which looked at the drive unit which concerns on 3rd Embodiment in the axial direction. It is a sectional side view of the drive unit concerning a 3rd embodiment. It is the figure which looked at the drive unit which concerns on 4th Embodiment in the axial direction. It is a sectional side view of the drive unit concerning a 4th embodiment. It is a perspective view which shows the example which applied the drive unit which concerns on embodiment to an electric bicycle. It is a perspective view which shows the example which applied the drive unit which concerns on embodiment to an electric bicycle.

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

(First embodiment)
First, the drive unit 10 according to the first embodiment will be described. 1 to 4 show the configuration of the drive unit 10 according to the first embodiment. In each figure, the arrow A direction indicates the axial direction of the drive unit 10 (hereinafter sometimes simply referred to as “axial direction”), the arrow A1 direction indicates the axial direction outside of the drive unit 10, and the arrow A2 direction. Indicates the axially inner side of the drive unit 10. With the axial center S (see FIG. 1) of the drive unit 10 (the stator core 182 described later) as a boundary, the axial direction away from the axial center S is the axial outer side, and the axial direction approaching the axial center S is the axial inner side It is. In each figure, the arrow B direction indicates the radial direction of the drive unit 10 (hereinafter sometimes simply referred to as “radial direction”), the arrow B1 direction indicates the radially outer side of the drive unit 10, and the arrow B2 direction Indicates the radially inner side of the drive unit 10 (the same applies to FIGS. 5 to 9 showing drive units 200 to 400 according to second to fourth embodiments described later).

  As shown in FIG. 1, the drive unit 10 according to the first embodiment includes a rotor 16, a stator 18, a motor housing 20, and an output shaft 34 (see FIG. 2) as main components. .

  The rotor 16 is supported by a pair of bearings (not shown) as rotor support portions provided in the motor housing 20 so as to be rotatable around the axial direction of the output shaft 34. The stator 18 is formed in an annular shape and is provided outside the rotor 16 in the radial direction.

  The stator 18 and the rotor 16 constitute a brushless motor. In the brushless motor having the rotor 16 and the stator 18, when a rotating magnetic field is generated in the stator 18, an attractive / repulsive force acts between the rotor 16 and the stator 18, and the output shaft 34 is rotated together with the rotor 16. It has become so.

  Specifically, the stator 18 includes a plurality of stator cores (iron cores) 182 provided on the outer side in the radial direction of the rotor 16 along the circumferential direction of the rotor 16 (rotational direction (arrow C direction in FIG. 2)), and an insulating member. A winding portion 188 in which a winding 186 is wound around each stator core 182 via a plurality of turns 184, a metal terminal 189 to which an end portion 186A of each winding 186 is connected and power from the outside is supplied; , And is configured.

  As shown in FIG. 1, each winding portion 188 specifically extends from the winding portion main body 188 </ b> B as a portion wound around each stator core 182 via the insulating member 184 and the winding portion main body 188 </ b> B. And an extension 188C having an end 186A.

  Each insulating member 184 has a function of insulating between the stator core 182 and the winding portion 188 (winding portion main body 188B), and is made of, for example, resin. Specifically, each insulating member 184 includes a covering portion 184A that covers the surface of the stator core 182 and a plurality of protruding portions 184B that protrude outward in the axial direction from the covering portion 184A. .

  Specifically, the winding portion main body 188B of each winding portion 188 is formed by winding the winding portion 186 around the covering portion 184A a plurality of times between the plurality of overhang portions 184B of the insulating member 184.

  The extending portion 188C of each winding portion 188 extends along the radial direction (direction perpendicular to the axial direction) to the radially inner side (arrow B2 side) with respect to the stator core 182 (winding portion main body 188B). Specifically, the end portion 186A of the extending portion 188C is disposed such that its axial direction (length direction) is along the radial direction (direction orthogonal to the axial direction).

  Each terminal 189 has a plate-like main body portion 189A disposed along the radial direction inside the stator core 182 (winding portion main body 188B of the winding portion 188), and an extension portion 188C connected to the main body portion 189A. An end connection portion 189D connected to the end portion 186A of the main body 189A, and an external connection portion 189C (see FIGS. 2 and 4) connected to the main body 189A and connected to the electric wire 190 for supplying power from the outside. ing.

  As shown in FIG. 1, the main body 189A is specifically formed in a plate shape having a thickness in the axial direction (arrow A direction) and a length in the radial direction (arrow B direction). . The main body 189A is formed with an insertion hole 189E into which a fixing part 41B of the mounting part 41 described later is inserted, and a fitting hole 189F into which a convex part 41A of the mounting part 41 described later is fitted. The fitting hole 189F is disposed on the radially outer side (arrow B1 side) with respect to the insertion hole 189E.

  As shown in FIG. 2, the end connection portion 189D and the external connection portion 189C are arranged along the radial direction in the radially outer portion of the main body portion 189A with respect to the fitting hole 189F. Further, the external connection portion 189C is arranged on one side in the circumferential direction of the rotor 16 (direction of arrow C in FIG. 2) in the main body portion 189A, and the end connection portion 189D is the other in the circumferential direction of the rotor 16 in the main body portion 189A Arranged on the side.

  As shown in FIG. 1, the end connection portion 189D is sandwiched between the end portion 186A of the extension portion 188C and the main body portion 189A from the outside in the axial direction, and is subjected to resistance welding (an example of a joining method). Thus, the end portion 186A is joined. That is, the radially outer portion and the end connecting portion 189D of the main body portion 189A and the end portion 186A of the extending portion 188C are overlapped and joined in the axial direction.

  The external connection portion 189C is joined to the electric wire 190 by sandwiching the electric wire 190 from the outer side in the axial direction between the main body portion 189A and resistance welding. Similar to the extending portion 188C of the winding portion 188, the electric wire 190 is disposed along the radial direction (direction perpendicular to the axial direction) from the radially outer side to the inner side of the drive unit 100.

  Specific examples of resistance welding include spot welding and projection welding. Moreover, as a joining method, for example, fusing or the like may be used, and a joining method other than resistance welding may be used.

  The external connection portion 189C as the connection end portion to the terminal 189 in the electric wire 190 and the end connection portion 189D as the connection end portion to the terminal 189 in the extending portion 188C of the winding portion 188 are the same orthogonal to the axial direction. It arrange | positions on a plane (refer FIG.2 and FIG.4).

  Further, in the drive unit 10, a part of the resin motor housing 20 constitutes an attachment portion 41 to which the terminal 189 is attached. That is, the attachment portion 41 constitutes a part of the non-rotating portion in the drive unit 10. The non-rotating portion is a portion excluding the rotating portion (the rotor 16 and the output shaft 34) in the drive unit 10.

  The attachment portion 41 is disposed on the radially inner side of the stator core 182 (the winding portion main body 188B of the winding portion 188) and on the outer side in the axial direction of the rotor 16. That is, the attachment portion 41 (terminal 189) is disposed so as to face the axial end surface 16A of the rotor 16.

  The mounting portion 41 is formed with a convex portion 41A that is fitted in the fitting hole 189F and is convex outward in the axial direction, and a fixing portion 41B that is provided on the radial inner side of the convex portion 41A and fixes the terminal 189. ing. Specifically, the fixing portion 41B includes a protruding portion 41C that is inserted into the insertion hole 189E of the terminal 189 and protrudes outward in the axial direction, and a flange portion that protrudes outward in the radial direction of the protruding portion 41C at the distal end portion of the protruding portion 41C. 41D.

  Here, the terminal 189 is fixed to the mounting portion 41 by the fixing portion 41B as follows.

  As shown in FIG. 3, the fixing portion 41B has a cylindrical shape before the terminal 189 is fixed, and has a shape (state) in which the flange portion 41D is not formed. Further, the extending portion 188 </ b> C extends from the winding portion main body 188 </ b> B outward in the axial direction before fixing the terminal 189.

  Then, as shown in FIG. 3, with the extension portion 188C extending outward in the axial direction from the winding portion main body 188B, the end portion 186A of the extension portion 188C is connected to the main body portion by the end portion connection portion 189D. The end connection portion 189D and the end portion 186A are resistance-welded by being sandwiched between 189A. Further, the external connection portion 189C and the electric wire 190 are resistance-welded with the electric wire 190 sandwiched between the external connection portion 189C and the main body portion 189A.

  Next, the base portion of the extending portion 188C is inserted so that the columnar fixing portion 41B is inserted into the insertion hole 189E of the terminal 189 and the convex portion 41A is inserted into the insertion hole 189F of the terminal 189. Is bent radially inward (arrow B2 side). Accordingly, the body portion 189A is positioned with respect to the attachment portion 41 by inserting the convex portion 41A into the insertion hole 189F and inserting the columnar fixing portion 41B into the insertion hole 189E.

  Then, the columnar fixing portion 41B is formed in a flange shape (saddle shape) projecting outward in the radial direction by applying pressure (heating by caulking) while heating from the outside in the axial direction. Thereby, it becomes the fixing | fixed part 41B which has the protrusion part 41C and the flange part 41D. Thus, the terminal 189 is fixed by the fixing portion 41B.

  Thus, in this embodiment, after the end 186A of the extending part 188C is resistance-welded to the terminal 189, the terminal 189 is attached to the attaching part 41 as a non-rotating part. Manufactured. It should be noted that there is no trace of resistance welding in the attachment portion 41, no space for resistance welding is provided in the attachment portion 41, and the resistance welded portion of the terminal 189 is sandwiched between the attachment portion 41. Thus, in the manufactured drive unit 10, it is understood that the terminal 189 is attached to the attachment portion 41 after the end portion 186 </ b> A of the extension portion 188 </ b> C is resistance welded to the terminal 189.

(Operational effects of the first embodiment)
Next, the function and effect of the first embodiment will be described.

  According to the drive unit 10 according to the first embodiment, after the end portion 186A of the winding 186 wound around the stator core 182 is resistance-welded to the terminal 189, the resistance-welded terminal 189 is not rotated. It attaches with respect to the attaching part 41 as a part.

  As described above, the terminal 189 is subjected to resistance welding before being attached to the attachment portion 41, and resistance welding is not performed at the attachment portion 41, so that the place where resistance welding cannot be performed can be the attachment portion 41. For this reason, the freedom degree of the place which attaches the terminal 189 improves.

  Moreover, according to the drive unit 10, it is not necessary to provide the space for resistance welding in the attaching part 41 to which the terminal 189 is attached, and it leads to size reduction of an apparatus.

  Further, according to the drive unit 10, since the terminal 189 (mounting portion 41) is disposed to face the axial end surface 16 </ b> A of the rotor 16, the dead space on the axial end surface 16 </ b> A side of the rotor 16 is effectively used. Thus, the terminal 189 can be disposed. As described above, the terminal 189 is arranged by effectively using the dead space, which leads to downsizing of the apparatus.

  Moreover, according to the drive unit 10, since the electric wire 190 which supplies the electric power from the outside to a terminal is arrange | positioned along the direction orthogonal to the axial direction of the rotor 19, the axial direction length of the drive unit 10 is suppressed. Can do. Thereby, it leads to size reduction of an apparatus.

  Moreover, according to the drive unit 10, since the external connection part 189C and the end part connection part 189D are arrange | positioned on the same plane orthogonal to an axial direction, the axial direction length of the drive unit 10 can be suppressed. . Thereby, it leads to size reduction of an apparatus.

(Second Embodiment)
Next, the drive unit 200 according to the second embodiment will be described. FIG. 5 shows the configuration of the drive unit 200 according to the second embodiment. Here, a different part from the structure of the drive unit 10 which concerns on 1st Embodiment mentioned above is demonstrated, and description is abbreviate | omitted suitably about the same part. In addition, the same code | symbol is attached | subjected to the part which has the same function as the structure of the drive unit 100. FIG.

  In the drive unit 10 according to the first embodiment, the terminal 189 and the mounting portion 41 are disposed so as to face the axial end surface 16A of the rotor 16. On the other hand, in the drive unit 200 according to the second embodiment, as shown in FIG. 5, the terminal 189 and the attachment portion 41 are disposed on the radially outer side of the stator core 182.

  The attachment portion 41 in the second embodiment constitutes a part of the non-rotating portion of the drive unit 200, similarly to the attachment portion 41 in the drive unit 10.

  Also in the second embodiment, as in the first embodiment, the terminal 189 is fixed to the attachment portion 41 by the fixing portion 41B. That is, first, in a state where the extending portion 188C is extended outward in the axial direction from the winding portion main body 188B, the end portion 186A of the extending portion 188C is interposed between the main body portion 189A and the end connecting portion 189D. The end connection portion 189D and the end portion 186A are resistance-welded (see FIG. 3). Further, the external connection portion 189C and the electric wire 190 are resistance-welded with the electric wire 190 sandwiched between the external connection portion 189C and the main body portion 189A.

  Next, the base portion of the extending portion 188C is inserted so that the columnar fixing portion 41B is inserted into the insertion hole 189E of the terminal 189 and the convex portion 41A is inserted into the insertion hole 189F of the terminal 189. Is bent outward in the radial direction (arrow B1 side). Accordingly, the main body 189A is positioned with respect to the attachment portion 41 by inserting the convex portion 41A into the insertion hole 189F and inserting the columnar fixing portion 41B into the insertion hole 189E.

  Then, the columnar fixing portion 41B is formed in a flange shape (saddle shape) projecting outward in the radial direction by applying pressure (heating by caulking) while heating from the outside in the axial direction. Thereby, it becomes the fixing | fixed part 41B which has the protrusion part 41C and the flange part 41D. Thus, the terminal 189 is fixed by the fixing portion 41B. Thereby, after the terminal 189 is resistance-welded to the end 186A of the extending part 188C, the drive unit 200 attached to the attaching part 41 as a non-rotating part is obtained.

  According to the drive unit 200 according to the second embodiment, since the terminal 189 (attachment portion 41) is disposed on the radially outer side of the stator core 182, the terminal space is effectively utilized in the dead space on the radially outer side of the stator core 182. 189 can be arranged. As described above, the terminal 189 is arranged by effectively using the dead space, which leads to downsizing of the apparatus.

(Third embodiment)
Next, the drive unit 300 according to the third embodiment will be described. 6 and 7 illustrate the configuration of the drive unit 300 according to the third embodiment. Here, a different part from the structure of the drive unit 10 which concerns on 1st Embodiment mentioned above is demonstrated, and description is abbreviate | omitted suitably about the same part. In addition, the same code | symbol is attached | subjected to the part which has the same function as the structure of the drive unit 100. FIG.

  In the drive unit 10 according to the first embodiment, the electric wire 190 is drawn out from the external connection portion 189C to the outside in the radial direction. On the other hand, in the drive unit 300 according to the third embodiment, as shown in FIGS. 6 and 7, the electric wire 190 is drawn from the external connection portion 189 </ b> C inward in the radial direction. That is, the electric wire 190 is drawn from the external connection portion 189C on the opposite side to the direction in which the extension portion 188C is drawn from the end connection portion 189D.

  The electric wire 190 drawn out from the external connection portion 189C to the inside in the radial direction is drawn out to the outside in the radial direction of the drive unit 300 beyond the axial center portion of the drive unit 300.

  Also in the drive unit 300, since the electric wire 190 is disposed along a direction orthogonal to the axial direction of the rotor 19, the axial length of the drive unit 300 can be suppressed. Thereby, it leads to size reduction of an apparatus.

(Fourth embodiment)
Next, the drive unit 400 which concerns on 4th Embodiment is demonstrated. 8 and 9 show the configuration of the drive unit 400 according to the fourth embodiment. Here, a different part from the structure of the drive unit 10 which concerns on 1st Embodiment mentioned above is demonstrated, and description is abbreviate | omitted suitably about the same part. In addition, the same code | symbol is attached | subjected to the part which has the same function as the structure of the drive unit 100. FIG.

  In the drive unit 10 according to the first embodiment, the electric wire 190 is drawn out from the external connection portion 189C to the outside in the radial direction. On the other hand, in the drive unit 400 according to the fourth embodiment, as shown in FIGS. 8 and 9, the electric wire 190 is drawn out in the radial direction from the external connection portion 189 </ b> C. That is, the electric wire 190 is drawn from the external connection portion 189C on the opposite side to the direction in which the extension portion 188C is drawn from the end connection portion 189D.

  The electric wire 190 drawn out inward in the radial direction from the external connection portion 189C is bent outward in the axial direction at the intermediate portion and drawn out in the axial direction of the drive unit 400.

  Also in the drive unit 400, the portion between the connection end 190A connected to the external connection portion 189C in the electric wire 190 and the bent portion 190B is arranged along the direction orthogonal to the axial direction of the rotor 19, In this portion, the axial length of the drive unit 400 can be suppressed. Thereby, it leads to size reduction of an apparatus.

(Application examples of drive units 10, 200, 300, 400)
The aforementioned drive units 10, 200, 300, and 400 (hereinafter referred to as 10 to 400) can be applied as a power source of an electric bicycle, for example, as shown in FIGS.

  In the example shown in FIG. 10, the drive units 10 to 400 are provided at the tip of the fork 502 of the electric bicycle, and the wheels 504 of the electric bicycle are fixed to the output shaft 34 of the drive units 10 to 400. In this configuration, the fork 502 is disposed on one side in the axial direction of the wheel 504, and the one side in the axial direction of the wheel 504 is rotatably supported by the output shaft 34. The electric wires 190 of the drive units 10 to 400 are arranged along the fork 502. The drive units 10 to 400 are configured such that the output shaft 34 protrudes to one side in the axial direction, and the rotational force is output from the one side in the axial direction of the drive units 10 to 400 by the output shaft 34.

  In the example shown in FIG. 11, drive units 10 to 400 are provided on the hub 506 of the wheel 504 of the electric bicycle. The drive units 10 to 400 are configured such that the output shaft 34 projects to both sides in the axial direction, and the rotational force is output from both sides in the axial direction of the drive units 10 to 400 by the output shaft 34. The forks 502 are disposed on both sides in the axial direction of the wheels 504, and the forks 502 are fixed to the pair of output shafts 34 of the drive units 10 to 400, respectively. The electric wires 190 of the drive units 10 to 400 are arranged along the fork 502.

  The drive units 10 to 400 are not limited to use as a power source for an electric bicycle, and may be used as other power sources.

  Although one embodiment of the present invention has been described above, the present invention is not limited to the above, and other various modifications can be made without departing from the spirit of the present invention. It is.

10, 200, 300, 400 ... drive unit, 16 ... rotor, 182 ... stator core, 186 ... winding, 189 ... terminal

Claims (6)

A rotor supported rotatably around a predetermined axial direction;
A stator core provided on the radially outer side of the rotor for rotating the rotor;
Windings wound around the stator core;
After the winding is joined, it is attached to a non-rotating part excluding the rotor, and a terminal to which electric power is supplied from the outside,
Drive unit equipped with.   The drive unit according to claim 1, wherein the terminal is disposed to face one end surface in the axial direction of the rotor.   The drive unit according to claim 1, wherein the terminal is disposed on a radially outer side of the stator core.   The drive unit according to claim 1, further comprising an electric wire connected to the terminal to supply electric power from the outside to the terminal and arranged along a direction orthogonal to the axial direction of the rotor. .   The drive unit according to claim 4, wherein a connection end portion of the electric wire to the terminal and a connection end portion of the winding to the terminal are arranged on the same plane orthogonal to the axial direction of the rotor. . A rotor supported rotatably around a predetermined axial direction;
A stator core provided on the radially outer side of the rotor for rotating the rotor;
Windings wound around the stator core;
A terminal connected to the winding and supplied with power from the outside;
In a manufacturing method of a drive unit comprising:
After the said coil | winding is joined to the said terminal, this terminal is attached to the non-rotating part except the said rotor, The manufacturing method of the drive unit.

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