JP2023167548A - Electric blower and vacuum cleaner - Google Patents

Abstract

To provide an electric blower and a vacuum cleaner, which are advantageous in performing unbalance adjustment with high accuracy and convenience.SOLUTION: An electric blower according to the present disclosure comprises: a frame; a shaft rotatably supported with respect to the frame; a rotor core mounted on the shaft; a stator core disposed around the rotor core and held on the frame; an impeller mounted on the shaft; and a straightening section for straightening an air flow sent out by rotation of the impeller. The straightening section is formed of a first straightening part and a second straightening part, which are mounted on the frame, the first straightening part corresponding to a half-circumferential portion in a circumferential direction around the shaft, and the second straightening part being a separate body from the first straightening part and corresponding to the remaining half-circumferential portion in the circumferential direction.SELECTED DRAWING: Figure 11

Description

The present disclosure relates to electric blowers and vacuum cleaners.

In recent years, there has been an increasing demand in the market for smaller and lighter vacuum cleaners, and with this, development of smaller and lighter electric blowers for use in vacuum cleaners has also progressed. Electric blowers that are smaller and lighter need to rotate at high speeds in order to obtain the same air volume as conventional electric blowers. In that case, the unbalance of the rotor and impeller increases the centrifugal force generated during rotation, which tends to increase the vibration of the electric blower. Generally, the rotor and impeller are assembled after correcting their respective unbalances, but there is a problem in that the unbalance becomes worse due to coaxial misalignment during assembly.

The electric blower described in Patent Document 1 has a top plate recess that is recessed downward on the top surface of the top plate of the motor housing that faces the bottom surface of the impeller in the axial direction. Adjusting the impeller imbalance.

JP2019-23434A

In the case of an electric blower, which has a large cogging torque due to the relationship between the magnetic poles and the stator core, the rotating impeller cannot be stopped at any rotational position. For this reason, the electric blower disclosed in Patent Document 1 has a problem in that it is difficult to match the position of the top plate recess with the location to be cut for unbalance adjustment, and unbalance adjustment cannot be performed.

The present disclosure has been made in order to solve the above-mentioned problems, and an object of the present disclosure is to provide an electric blower and a vacuum cleaner that are advantageous in performing unbalance adjustment with high precision and convenience.

An electric blower and a vacuum cleaner according to the present disclosure include a frame, a shaft rotatably supported with respect to the frame, a rotor core attached to the shaft, and a rotor core arranged around the rotor core and held by the frame. It includes a stator core, an impeller attached to the shaft, and a rectifier that adjusts the airflow sent out by the rotation of the impeller, and the rectifier has a first rectifier that corresponds to a half-circumferential portion in the circumferential direction around the shaft. The components and the first rectifying component are separate bodies, and the second rectifying component corresponding to the remaining half circumference in the circumferential direction is formed by being attached to the frame.
A vacuum cleaner according to the present disclosure is equipped with the electric blower described above.

According to the present disclosure, it is possible to provide an electric blower and a vacuum cleaner that are advantageous in performing unbalance adjustment with high precision and convenience.

1 is a perspective view showing the appearance of an electric blower according to Embodiment 1. FIG. 1 is a sectional view of the electric blower according to Embodiment 1, viewed from the side. 1 is an exploded perspective view of an electric blower according to Embodiment 1. FIG. 1 is a side view showing the appearance of a rotor assembly according to Embodiment 1. FIG. 1 is a perspective view showing the appearance of a stator assembly according to Embodiment 1. FIG. FIG. 2 is a perspective view of a state in which a plurality of stator assemblies according to the first embodiment are combined. 1 is a perspective view showing the appearance of a frame according to Embodiment 1. FIG. FIG. 3 is a cross-sectional view of the frame according to the first embodiment, viewed from the side. 1 is a perspective view showing the appearance of an impeller according to Embodiment 1. FIG. 1 is a perspective view showing the appearance of an impeller according to Embodiment 1. FIG. FIG. 2 is a perspective view showing the appearance of a first rectifying component and a second rectifying component that constitute the rectifying section according to the first embodiment. FIG. 2 is a perspective view of a combination of a first rectifying component and a second rectifying component that constitute the rectifying section according to the first embodiment. 1 is a perspective view showing the appearance of a bracket according to Embodiment 1. FIG. FIG. 3 is a flow diagram of an assembly process of the electric blower according to the first embodiment. FIG. 2 is a cross-sectional view schematically showing the electric blower when performing unbalance adjustment according to the first embodiment. 1 is a perspective view showing the appearance of a vacuum cleaner incorporating an electric blower according to Embodiment 1. FIG. FIG. 2 is an external view of the main body of the vacuum cleaner incorporating the electric blower according to Embodiment 1, viewed from the side. FIG. 2 is a sectional view of the main body of the vacuum cleaner incorporating the electric blower according to Embodiment 1, viewed from the side.

Embodiments will be described below with reference to the drawings. Common or corresponding elements in each figure are denoted by the same reference numerals, and description thereof will be simplified or omitted. Note that when referring to angles in this disclosure, when there is a dominant angle and a recessive angle whose sum is 360°, this generally refers to the recessive angle, and there are acute angles and obtuse angles whose sum is 180°. In principle, it refers to an acute angle. Further, the configurations shown in the embodiments described below are examples of technical ideas according to the present disclosure, and can be combined with another known technology, or can be combined with multiple technologies described in the present disclosure. It is also possible to combine ideas. Further, it is also possible to omit or change a part of the configuration without departing from the gist of the present disclosure.

Embodiment 1.
FIG. 1 is a perspective view showing the appearance of an electric blower 1 according to the first embodiment. FIG. 2 is a sectional view of the electric blower 1 according to the first embodiment, viewed from the side. FIG. 3 is an exploded perspective view of the electric blower 1 according to the first embodiment. FIG. 4 is a side view showing the appearance of the rotor assembly 6 according to the first embodiment.

As shown in these figures, the electric blower 1 according to the first embodiment includes a frame 5, a rotor assembly 6, a stator assembly 7, an impeller 11 attached to the shaft 8 of the rotor assembly 6, It includes a rectifying section 3 that adjusts the airflow sent out by the rotation of the impeller 11.

As shown in FIG. 4, the rotor assembly 6 includes a shaft 8, a rotor core 9 attached to the shaft 8, an end cap 10, a first bearing 12a, a second bearing 12b, and a preload portion 13. Equipped with. In the present disclosure, a direction parallel to the rotational axis of the shaft 8 is referred to as an "axial direction," a direction orthogonal to the rotational axis of the shaft 8 is referred to as a "radial direction," and a circumferential direction around the rotational axis of the shaft 8 is referred to as a "radial direction." This will be explained as "circumferential direction".

Rotor core 9 has multiple magnetic poles. The rotor core 9 in this embodiment is a plastic magnet. The rotor core 9 is formed by injection molding or compression molding by kneading powder or finely pulverized magnetic material into a molding material such as resin or elastomer. The shaft 8 is made of stainless steel, for example. A rotor core 9 is attached to the outer periphery of the shaft 8. The shaft 8 is rotatably supported by a pair of bearings 12a and 12b, which will be described later. As a manufacturing method, for example, the shaft 8 is set in a molding die, and the rotor core 9 is molded so that the molding material of the plastic magnet is spread around the outer periphery of the shaft 8. Thereby, the rotor core 9 is formed integrally with the shaft 8. By forming it in this way, the assembly is more stable than the method of bonding and fixing the rotor core 9 formed separately to the shaft 8, and the reliability of the electric blower 1 can be improved and the life of the electric blower 1 can be extended.

The plastic magnets constituting the rotor core 9 are less likely to crack or chip than sintered magnets. If the outer diameter of the rotor core 9 is large, a large centrifugal force will act upon it when it rotates at high speed, which may lead to damage. Therefore, in order to keep the centrifugal force acting on the rotor core 9 small, it is desirable that the outer diameter of the rotor core 9 is as small as possible.

Note that in order to prevent scattering in the event that the rotor core 9 is damaged, a cylindrical sleeve may be attached to cover the outer periphery of the rotor core 9. The sleeve is made of a non-magnetic material, such as a composite material of carbon fiber and resin. Composite materials of carbon fiber and resin are lightweight, high strength, and have excellent heat resistance. The sleeve is inserted into the rotor core 9 with a loose fit, and an adhesive is injected into the gap between the sleeve and the rotor core 9. The sleeve is fixed to the rotor core 9 with the adhesive, and the gap between the sleeve and the rotor core 9 is filled with the adhesive, thereby serving to increase the strength of the rotor core 9 against damage.

The pair of bearings 12a and 12b are press-fitted onto the side of the shaft 8 on which the impeller 11 is attached. Therefore, the pair of bearings 12a and 12b are located between the rotor core 9 and the impeller 11. Of the pair of bearings 12a, 12b, the one located on the rotor core 9 side is referred to as a first bearing 12a, and the one located on the impeller 11 side is referred to as a second bearing 12b. A preload portion 13 is inserted between the first bearing 12a and the second bearing 12b with a gap between the shaft 8 and the shaft 8. The bearings 12a and 12b correspond to a bearing section.

The preload portion 13 is an elastic member, and is composed of, for example, a compression coil spring. The preload portion 13 applies preload in the direction in which the first bearing 12a and the second bearing 12b are separated. The first bearing 12a and the second bearing 12b are ball bearings. By applying preload by the preload portion 13, the behavior of the bearings 12a and 12b is stabilized, and the rotation of the electric blower 1 is stabilized, thereby extending the life of the electric blower 1. Note that the preload portion 13 is not limited to a compression coil spring, and any elastic body capable of applying a predetermined preload may be used, such as a wave washer.

FIG. 5 is a perspective view showing the appearance of the stator assembly 7 according to the first embodiment. FIG. 6 is a perspective view of a state in which a plurality of stator assemblies 7 according to the first embodiment are combined. As shown in FIG. 5, the stator assembly 7 includes a stator core 14 that drives the rotor core 9, insulators 15a and 15b, a coil 16, and a terminal 17. The stator assembly 7 has a configuration in which it is divided through a dividing surface along the radial direction. As shown in FIG. 6, when the four stator assemblies 7 are combined, a substantially circular space is formed when viewed from the axial direction.

The stator core 14 is arranged around the rotor core 9 and is formed by laminating electromagnetic steel plates. The insulators 15a and 15b are made of an electrically insulating resin material. An insulator 15a is attached to the rotor core 9 side of the stator core 14 (the opposite side of the impeller 11 in the direction along the axis 8). An insulator 15b is attached to the impeller 11 side of the stator core 14. The coil 16 is formed by winding an electric wire coated with enamel around the insulators 15a and 15b. Therefore, stator core 14 and coil 16 are configured to be electrically insulated. A terminal wire of the coil 16 is electrically connected to a terminal 17 attached to the insulator 15a. When current flows from the terminal 17 to the coil 16, a magnetic flux is generated in the stator assembly 7, and a force that rotates the rotor assembly 6 is exerted.

FIG. 7 is a perspective view showing the appearance of the frame 5 according to the first embodiment. FIG. 8 is a sectional view of the frame 5 according to the first embodiment, viewed from the side. The frame 5 forms part of the outer shell of the electric blower 1. The frame 5 has a cylindrical body 5a that is open at one end, and a cylindrical housing 5b having a smaller diameter than the body 5a. A housing 5b is formed on the side opposite to the open side of the body 5a, that is, on the impeller 11 side with respect to the body 5a. An annular flange portion 5c that projects radially inward is formed at the end of the housing 5b on the impeller 11 side. An opening 5d is provided at the center of the flange portion 5c.

The frame 5 is made of, for example, an aluminum alloy. Since aluminum alloy has a high thermal conductivity, heat generated by rotation of the bearings 12a, 12b, etc. is transmitted to the frame 5, so that heat can be efficiently radiated from the frame 5.

A stator assembly 7 and a portion of the rotor core 9 of the rotor assembly 6 are housed within the body 5a of the frame 5. A first bearing 12a, a preload portion 13, and a second bearing 12b of the rotor assembly 6 are housed within the housing 5b of the frame 5. The housing 5b holds a first bearing 12a and a second bearing 12b. The stator assembly 7 is attached to the body 5a so as to surround the rotor core 9. Therefore, the stator core 14 , which forms part of the stator assembly 7 , is held by the frame 5 . At this time, in order to match the magnetic centers of the stator core 14 and the rotor core 9, it is desirable that the axial center of the stator core 14 and the axial center of the rotor core 9 match.

9 and 10 are perspective views showing the appearance of the impeller 11 according to the first embodiment. FIG. 11 is a perspective view showing the appearance of the first rectifying component 3X and the second rectifying component 3Y that constitute the rectifying section 3 according to the first embodiment. FIG. 12 is a perspective view of a combination of the first rectifier component 3X and the second rectifier component 3Y that constitute the rectifier 3 according to the first embodiment. FIG. 13 is a perspective view showing the appearance of the bracket 4 according to the first embodiment.

The impeller 11 is fixed to the end of the shaft 8 on the opposite side to the rotor core 9 side. The impeller 11 generates negative pressure by rotating. The impeller 11 includes a disc-shaped disk portion 11a and an impeller portion 11b having a plurality of blades. In the illustrated example, the disk portion 11a and the impeller portion 11b are integrally molded.

As shown in FIG. 2, the rectifier 3 is attached to the frame 5 so as to surround the outer periphery of the housing 5b. As shown in FIG. 12, in the flow straightening section 3, a row of blades 3a arranged in a circumferential manner is formed at a position outside the outer diameter of the impeller 11. Each blade of the blade row 3a is inclined along the rotation direction of the impeller 11. The blade row 3 a rectifies the air flow generated by the rotation of the impeller 11 and sends it out of the electric blower 1 .

The bracket 4 forms part of the outer shell of the electric blower 1. As shown in FIG. 2, the bracket 4 is attached to the frame 5 so as to surround the outer periphery of the housing 5b. The cover 2 is attached to cover the impeller 11 and surround the rectifier 3 and one end of the bracket 4. The cover 2 is fixed to the bracket 4. The cover 2 is provided with an intake port 2a for sucking air from the electric blower 1. When the impeller 11 rotates, air is sucked into the cover 2 through the intake port 2a. This sucked air passes through the blade row 3a of the rectifier 3 and the inside of the bracket 4, and is sent out of the electric blower 1 from the exhaust port 4b.

In this embodiment, the impeller 11, cover 2, rectifier 3, and bracket 4 are all made of resin material. By forming these from a resin material, the weight of the electric blower 1 can be reduced. Note that a metal cylindrical member may be provided on the inner peripheral portion of the impeller 11. The cylindrical member is integrally molded with the impeller 11, for example.

Next, the characteristic configuration of the electric blower 1 in this embodiment will be explained. As shown in FIG. 11, the rectifier 3 in this embodiment includes a first rectifier component 3X and a second rectifier component 3Y that is separate from the first rectifier component 3X. The first rectifying component 3X corresponds to a half circumferential portion of the rectifying portion 3 in the circumferential direction. The second rectifying component 3Y corresponds to the remaining half circumferential portion of the rectifying portion 3 in the circumferential direction. The first rectifier component 3X and the second rectifier component 3Y are attached to the frame 5, thereby forming the rectifier section 3.

Each of the first rectifying component 3X and the second rectifying component 3Y has a semicircular outer shape. As shown in FIG. 12, when the first rectifying component 3X and the second rectifying component 3Y are combined, a rectifying section 3 having a ring shape is configured.

As shown in FIG. 2, each of the first rectifying component 3X and the second rectifying component 3Y is attached between the impeller 11 and the bracket 4 so as to surround the outer periphery of the housing 5b.

Unlike this embodiment, when the rectifying section 3 is in the form of an integral ring that is not divided into two, in order to insert the housing 5b into the central opening of the rectifying section 3, the impeller 11 is moved to the shaft 8. It is necessary to attach the rectifier 3 to the outer periphery of the housing 5b in a step before fixing it to the end of the housing 5b. On the other hand, in the present embodiment, even in the process after the rotor assembly 6, stator assembly 7, and impeller 11 are integrally assembled to the frame 5, the first rectifying component 3X and the second rectifying component 3Y can be attached to the outer periphery of the housing 5b. Thereby, in a state in which the rotor assembly 6, stator assembly 7, and impeller 11 are integrated, unbalance measurement and unbalance adjustment can be performed without the rectifier 3 by the method described later.

In this embodiment, the end surface of the second bearing 12b on the impeller 11 side abuts the flange portion 5c of the impeller 11 side end of the housing 5b in the axial direction. As a result, even if the fixing force between the pair of bearings 12a, 12b and the housing 5b is lost, the rotor assembly 6 including the shaft 8, the rotor core 9, and the pair of bearings 12a, 12b can be rotated by the impeller 11. Since the electric blower 1 does not move toward the impeller 11 due to the suction force caused by the generated negative pressure, damage to the electric blower 1 can be more reliably suppressed.

As shown in FIG. 11, the first rectifying component 3X includes a fitting claw 3x. The second rectifying component 3Y includes a fitting hole 3y. As shown in FIG. 12, by fitting the fitting claw 3x and the fitting hole 3y together, a ring-shaped rectifying section 3 in which the two are integrated is formed. As described above, in the present embodiment, the fitting claw 3x, which is the fitting part provided on the first rectifying component 3X, and the fitting claw 3x, which is the fitting part provided in the second rectifying component 3Y, By fitting, the first rectifying component 3X and the second rectifying component 3Y can be integrated. Therefore, after the unbalance measurement and unbalance adjustment are completed, the step of attaching the first rectifying component 3X and the second rectifying component 3Y to the outer periphery of the housing 5b to form the rectifying part 3 can be carried out more easily and more reliably. It becomes possible to do so. In the illustrated example, two sets of fitting claws 3x and fitting holes 3y are provided, for example, on the outer peripheral sides of the first rectifying component 3X and the second rectifying component 3Y.

Unlike this embodiment, when fixing the rectifier 3 using screws, for example, it is conceivable to insert the screws in the axial direction and fasten them together with the bracket 4 to the frame 5. In this case, if the impeller 11 is fixed to the shaft 8 before the rectifier 3, the screws for fixing the rectifier 3 cannot be inserted, so the assembly order of the impeller 11 and the rectifier 3 is changed. You will be restricted. In contrast, in the present embodiment, even when the impeller 11 is fixed to the shaft 8, the first rectifying component 3X and the second rectifying component 3Y are installed in the axial gap between the impeller 11 and the bracket 4, respectively. Assembly is possible by inserting from the radial direction. That is, it becomes possible to assemble the rectifying section 3 in a process after the impeller 11 is shaved to correct the imbalance.

As shown in FIG. 13, the bracket 4 in this embodiment is a ring-shaped integral part without a dividing surface. That is, the bracket 4 is a ring-shaped component that is not divided into a plurality of parts in the circumferential direction. The bracket 4 includes a fitting portion 4a on its outer periphery. The fitting part 4a corresponds to a fixing part for fixing the cover 2. The fitting portion 4a protrudes from the outer peripheral surface of the bracket 4. In this embodiment, the bracket 4 is provided with a plurality of fitting portions 4a at different positions in the circumferential direction.

As shown in FIGS. 1 and 3, the cover 2 has an engaging portion 2b that engages with a fitting portion 4a of the bracket 4. As shown in FIGS. The engaging portion 2b protrudes from the outer peripheral portion of the cover 2 in the axial direction. The engaging portion 2b has a frame-like shape into which the fitting portion 4a can be inserted. In this embodiment, the cover 2 is provided with a plurality of engaging portions 2b corresponding to the plurality of fitting portions 4a. As shown in FIG. 1, the cover 2 is fixed by the engaging portion 2b engaging with the fitting portion 4a of the bracket 4.

The bracket 4 is fixed to the outer periphery of the housing 5b with its central axis aligned with the central axis of the shaft 8. Therefore, the fitting part 4a is located on the circumference of the shaft 8 and the same center. Therefore, the central axis of the cover 2 attached to the fitting part 4a of the bracket 4 coincides with the central axis of the shaft 8, and also coincides with the central axis of the impeller 11 fixed to the shaft 8. If the center axis of the cover 2 and the center axis of the impeller 11 are fixed with a misalignment, problems such as the blowing efficiency of the electric blower 1 will decrease or the impeller 11 will come into contact with the cover 2 may occur. There are concerns. If the bracket 4 were configured to be divided into a plurality of parts in the circumferential direction via a dividing surface along the radial direction, like the straightening part 3, the fitting part 4a would be separated due to molding variations or assembly variations. The position of the shaft 8 tends to deviate from the position on the circumference that is co-centered with the central axis of the shaft 8. In contrast, in the present embodiment, only the rectifying section 3 is divided and the bracket 4 is a ring-shaped integral part, so that the mounting position of the cover 2 is difficult to change. Therefore, it is possible to provide an electric blower 1 that is more stable and has high air blowing efficiency.

As shown in FIGS. 2 and 4, an end cap 10 that is a ring-shaped member is provided at the end of the rotor core 9 on the opposite side to the impeller 11 side in the axial direction. The end cap 10 corresponds to an unbalance correcting section for correcting rotational unbalance. The end cap 10 is fixed to the shaft 8 by, for example, press fitting. In this embodiment, the imbalance is corrected by cutting the end cap 10. Unlike this embodiment, when correcting the unbalance of the rotor assembly 6 alone, end caps 10 are attached to both sides of the rotor core 9 in the axial direction, and each end cap 10 is shaved. There are ways to adjust the balance. In contrast, in this embodiment, the unbalance measurement is performed with the rotor assembly 6 and impeller 11 integrated, as will be described later. The imbalance can be corrected by cutting the end cap 10 fixed to the end of the rotor assembly 6 opposite to the impeller 11 and the impeller 11, respectively. That is, the end cap 10 is not required at the end of the rotor core 9 on the impeller 11 side. Therefore, the rotor assembly 6 can be made smaller and lighter. Furthermore, since the distance between the rotor core 9 and the first bearing 12a and second bearing 12b can be shortened, the radial load applied to the first bearing 12a and second bearing 12b during rotation can be reduced. This makes it possible to extend the life of the bearings 12a and 12b.

The end cap 10 is made of a non-magnetic metal material such as brass. By using the end cap 10 made of a metal material with high specific gravity, the unbalance can be greatly improved even with a small amount of cutting, so that the unbalance correction work becomes easy. Furthermore, when the end cap 10 is made of a magnetic material, an unnecessary passage of magnetic flux is created, which may adversely affect the magnetic circuit when the rotor assembly 6 is rotated. In order to reliably prevent such adverse effects, it is desirable that the end cap 10 be formed of a non-magnetic material so as not to affect the magnetic circuit.

As shown in FIG. 7, a protrusion 5e projecting radially outward is formed on the outer circumference of the housing 5b. The protrusions 5e are provided at two positions 180° apart from each other in the circumferential direction at the end of the outer circumference of the housing 5b on the impeller 11 side.

As shown in FIGS. 11 and 12, a notch 3b, which is a concave portion recessed inward in the radial direction, is provided on the end surface of the inner peripheral portion of each of the first rectifying component 3X and the second rectifying component 3Y on the impeller 11 side. is formed. As shown in FIG. 2, when attaching the first rectifying component 3X and the second rectifying component 3Y to the outer periphery of the housing 5b, the projections 5e and the notches 3b are aligned and fixed so that they fit together. be done. By fitting and fixing the projection 5e and the notch 3b, it is possible to restrict movement of the rectifier 3 in the rotational direction and the axial direction with respect to the housing 5b.

Next, a method of assembling the electric blower 1 and a method of adjusting the imbalance according to the present embodiment will be explained. FIG. 14 is a flowchart of the assembly process of the electric blower 1 according to the present embodiment. FIG. 15 is a cross-sectional view schematically showing the electric blower 1 when unbalance adjustment is performed.

In step S1 of FIG. 14, the stator assembly 7 is fixed to the body 5a of the frame 5. As a means for fixing the stator assembly 7 to the body portion 5a, for example, shrink fitting is used. In that case, the body 5a is first heated to expand its diameter through thermal expansion, and the stator assembly 7 is inserted from the opening side of the frame 5, and then the diameter of the body 5a is reduced by cooling to form an interference fit. be done.

In step S2, the rotor assembly 6 is fixed to the housing 5b of the frame 5. For example, an adhesive is used to fix the rotor assembly 6. In that case, an adhesive is applied to the outer circumferential surface of the first bearing 12a and the outer circumferential surface of the second bearing 12b, and the rotor assembly 6 is inserted into the housing 5b from the open side of the frame 5. When inserting the rotor assembly 6, the end surface of the second bearing 12b on the impeller 11 side abuts against the flange portion 5c. This eliminates the need to separately prepare a positioning means during assembly, which not only improves ease of assembly but also suppresses dimensional variations in assembly positions.

In step S3, the bracket 4 is fixed to the outer periphery of the housing 5b. As shown in FIG. 3, the bracket 4 is fixed to the frame 5 from the axial direction by screws 18. As shown in FIG. 2, the bottom of the bracket 4 is provided with a protrusion 4c for positioning. The convex portion 4c is inserted into a positioning hole 5f provided in the closed end face of the body portion 5a of the frame 5. This improves ease of assembly.

In step S4, the impeller 11 is fixed to the end of the shaft 8. The impeller 11 is fastened to the end of the shaft 8 opposite to the rotor core 9 side with a nut 19 . Note that the method of fixing the impeller 11 is not limited to fastening with a nut, and means such as adhesion or press-fitting may be used.

In step S5, unbalance measurement is performed. Here, the amount of unbalance of the rotor-impeller assembly 20 in which the rotor assembly 6 and the impeller 11 are integrated is measured. At this time, since the rotor-impeller assembly 20 and the stator assembly 7 are in a combined state, the rotor-impeller assembly 20 can be rotated by the magnetic flux generated by passing current through the stator assembly 7. . By marking the outer periphery of the disk portion 11a of the impeller 11 or the surface of the disk portion 11a on the impeller portion 11b side in advance, the rotation speed can be detected by a sensor. The rotor-impeller assembly 20 is rotated at a constant speed, and vibrations during rotation are measured by a sensor from outside the body 5a of the frame 5. The measured vibration acceleration is converted into the amount of unbalance of the rotor-impeller assembly 20, and the unbalance adjustment position and adjustment amount are determined based on the marking position of the impeller 11.

In step S6, unbalance adjustment is performed. The unbalance adjustment is performed by cutting both axial ends of the rotor-impeller assembly 20, that is, the end cap 10 and the impeller 11, respectively.

As shown in FIG. 15, the end cap 10 is cut by inserting a cutting tool 50 in the axial direction from the opening side of the frame 5 toward the end surface of the end cap 10. At this time, the end cap 10 is located at the end of the rotor assembly 6, and since there is no part that covers the end surface of the end cap 10 when viewed from the opening side of the frame 5, the cutting tool 50 can be easily inserted. be able to. The unbalance of the rotor-impeller assembly 20 is corrected by cutting a round hole shape with a cutting tool 50 on the end face of the end cap 10 on the side where the unbalance is biased.

The impeller 11 is cut by inserting a cutting tool 50 between the impeller 11 and the bracket 4 from the outside in the radial direction. A cutting tool 50 is used to cut the surface of the disk portion 11a of the impeller 11 on the side opposite to the impeller portion 11b at a position where there is an imbalance due to imbalance. At this time, since there is a gap over the entire circumference between the impeller 11 and the bracket 4, it becomes easy to cut in any direction. This makes it possible to perform unbalance adjustment with high precision and convenience. Further, by setting the surface to be cut to be the surface of the disk portion 11a opposite to the impeller portion 11b, it is possible to avoid turbulence in the airflow when the impeller 11 rotates. Furthermore, by cutting the outer peripheral side of the disk portion 11a, the unbalance can be significantly improved even with a small amount of cutting.

Unlike this embodiment, in the case of a method in which the rotor assembly 6 and the impeller 11 are individually corrected for unbalance and then combined after correcting the unbalance, due to coaxial misalignment between the impeller 11 and the shaft 8, etc. This imbalance may worsen. In addition, the rotation of the rotor assembly 6 may also be affected by a coaxial misalignment between the rotor assembly 6 and the stator assembly 7, that is, by a bias in the magnetic balance due to a bias in the gap between the rotor core 9 and the stator core 14. In contrast, in this embodiment, the above-mentioned influence is eliminated by measuring and adjusting the unbalance while the rotor assembly 6, stator assembly 7, and impeller 11 are integrated. The electric blower 1 can be suppressed and have a small unbalance.

In step S7, the rectifier 3 is fixed to the outer periphery of the housing 5b. In this case, each of the semicircular first rectifier component 3X and second rectifier component 3Y constituting the rectifier section 3 is attached so as to surround the outer periphery of the housing 5b between the impeller 11 and the bracket 4. By aligning and fixing the protrusion 5e provided on the outer periphery of the housing 5b with the notch 3b of the first rectifier component 3X and the notch 3b of the second rectifier component 3Y, the rectifier 3 is fixed relative to the housing 5b. movement in the rotational direction and axial direction can be restricted. In addition, when fixing the rectifier 3, adhesive may be applied to the contact surface between the first rectifier component 3X and the bracket 4, and the contact surface between the second rectifier component 3Y and the bracket 4 for adhesive fixation. . In that case, the configuration is not limited to the configuration in which the protrusion 5e is provided on the outer circumference of the housing 5b, and for example, a positioning protrusion or the like may be provided on the bracket 4.

In step S8, the cover 2 is fixed to the bracket 4. In this embodiment, the cover 2 is fixed by fitting between the fitting portion 4a of the bracket 4 and the engaging portion 2b. In that case, an arbitrary number of fitting claws are provided on the bracket 4 as fitting portions 4a at equal intervals in the circumferential direction. The cover 2 is provided with an engaging part 2b having a fitting hole at a position corresponding to the fitting claw of the fitting part 4a. Note that the method of fixing the cover 2 and the bracket 4 is not limited to nail fitting, and means such as adhesive may also be used. In that case, the bracket 4 has a shape with no irregularities on its outer periphery, and is configured to be a loose fit on the inner periphery side of the cover 2. Then, by pouring a low-viscosity adhesive into the gap between the inner periphery of the cover 2 and the outer periphery of the bracket 4, both are fixed.

In step S9, the substrate 30 is fixed to the stator assembly 7. After the substrate 30 is fixed to the insulator 15a with screws, it is electrically connected to the terminals 17 by soldering.

(Configuration of vacuum cleaner)
Hereinafter, the configuration of a vacuum cleaner 100 incorporating the electric blower 1 according to the first embodiment will be described with reference to FIGS. 16 to 18. FIG. 16 is a perspective view showing the appearance of a vacuum cleaner 100 incorporating the electric blower 1 according to the first embodiment. FIG. 17 is an external view of the main body of the vacuum cleaner 100 incorporating the electric blower 1 according to the first embodiment, viewed from the side. FIG. 18 is a cross-sectional view of the main body of the vacuum cleaner 100 incorporating the electric blower 1 according to the first embodiment, as viewed from the side direction.

As shown in FIG. 16, the vacuum cleaner 100 includes a main body 101, a dust collecting section 102, an extension pipe 103, and a suction tool 104. The main body 101 is provided with a handle 101b that is a part that the user grips when handling the vacuum cleaner 100. Further, the main body 101 is provided with an operation section 101c including a switch (not shown) for driving the electric blower 1 when the vacuum cleaner 100 is operated.

The extension pipe 103 is for connecting the main body 101 and the suction tool 104 in a ventilable manner. The extension tube 103 is connected to the main body tube portion 101a of the main body 101 shown in FIG. A suction tool 104 is connected to an end of the extension tube 103 opposite to the end connected to the main body tube portion 101a. Although not shown, the main body 101 and the suction tool 104 can be connected without using the extension pipe 103.

The suction tool 104 sucks air containing dust from a surface to be cleaned, such as a floor. The suction tool 104 is provided with an opening (not shown) on a surface facing a surface to be cleaned such as a floor. This opening is an opening for sucking air containing dust.

As shown in FIG. 18, the dust collection section 102 has a dust collection chamber 102a. The dust collection chamber 102a is for storing dust. A separation section 114 is provided within the dust collection chamber 102a. The separation unit 114 is for separating dust by swirling air containing dust. The separated dust is stored in the dust collection chamber 102a. The vacuum cleaner 100 is a cyclone vacuum cleaner.

Inside the main body 101, the electric blower 1 according to the first embodiment and a secondary battery 111 that supplies power for driving the electric blower 1 are housed. The vacuum cleaner 100 is a cordless vacuum cleaner in which an electric blower 1 is driven by a secondary battery 111.

In the vacuum cleaner 100, the electric blower 1 generates suction air that sucks air containing dust. The electric blower 1 is, so to speak, the heart of the vacuum cleaner 100. The air intake port 2a of the electric blower 1 is arranged so as to be able to communicate with the dust collecting section 102.

When operating the vacuum cleaner 100, when a switch (not shown) for driving the electric blower 1 of the operation unit 101c is turned on, power is supplied from the secondary battery 111 to the electric blower 1. When the electric blower 1 to which electric power has been supplied starts driving, the suction air generated by the electric blower 1 starts suctioning air containing dust from the opening of the suction tool 104.

Air containing dust sucked from the opening of the suction tool 104 passes through an unillustrated ventilation path of the extension tube 103, passes through the suction air path 112 in the main body pipe section 101a of the main body 101, and rotates the dust collecting section 102. The information is sent to section 113.

The air containing dust is rotated and centrifuged in a rotating section 113, and the dust and air are separated in a separating section 114. The separated dust is stored in the dust collection chamber 102a, and the separated air is sucked into the electric blower 1 through the intake port 2a of the electric blower 1, and sent out to the outside of the electric blower 1 from the exhaust port 4b of the electric blower 1. Then, it is discharged to the outside of the main body 101 from a main body exhaust port 101d provided in the main body 101 shown in FIG.

In this way, the vacuum cleaner 100 performs cleaning by generating suction air by driving the electric blower 1 to suck air containing dust, separating the dust, and storing it in the dust collection chamber 102a. . Since the vacuum cleaner 100 incorporating the electric blower 1 according to the first embodiment incorporates the electric blower 1 with small imbalance, the vibration generated during driving is small, and the usability and reliability of the vacuum cleaner 100 are improved. can be improved.

Although the vacuum cleaner 100 having the configuration of a cordless vertical vacuum cleaner has been described above as an example of the vacuum cleaner according to the present disclosure, the vacuum cleaner according to the present disclosure is not limited to this configuration. The vacuum cleaner according to the present disclosure is also applicable to, for example, a canister type vacuum cleaner or a robot vacuum cleaner. Further, the vacuum cleaner according to the present disclosure is not limited to a rechargeable vacuum cleaner, and may be one that receives power from an outlet via a power cord. Further, the vacuum cleaner according to the present disclosure is not limited to a cyclone type vacuum cleaner, and may be, for example, a paper pack type vacuum cleaner.

Hereinafter, various aspects of the present disclosure will be collectively described as supplementary notes.

(Additional note 1)
frame and
a shaft rotatably supported with respect to the frame;
a rotor core attached to the shaft;
a stator core disposed around the rotor core and held by the frame;
an impeller attached to the shaft;
a rectifier that adjusts the airflow sent out by the rotation of the impeller;
Equipped with
The rectifier includes a first rectifier component that corresponds to a half-circumferential portion in the circumferential direction centering on the axis, and a separate body from the first rectifier component, and corresponds to the remaining half-circumferential portion in the circumferential direction. An electric blower formed by attaching a second rectifying component to the frame.
(Additional note 2)
The electric blower according to Supplementary Note 1, wherein an unbalance correcting section for correcting rotational unbalance is provided at an end of the rotor core.
(Additional note 3)
The electric blower according to Supplementary Note 2, wherein the unbalance correction section is a ring-shaped member and is arranged at an end of the rotor core on the opposite side to the impeller side.
(Additional note 4)
The fitting portion provided on the first rectifying component and the fitting portion provided on the second rectifying component are fitted, so that the first rectifying component and the second rectifying component are integrated. The electric blower according to any one of Supplementary notes 1 to 3.
(Appendix 5)
a cover that covers the impeller;
a bracket having a fixing part fixed to the cover and attached to the frame;
Equipped with
The electric blower according to any one of Supplementary Notes 1 to 4, wherein the bracket is a ring-shaped component that is not divided into a plurality of parts in the circumferential direction.
(Appendix 6)
comprising a bearing portion for receiving the shaft;
The frame includes a housing that holds the bearing part,
The electric blower according to appendix 5, wherein the bracket is attached to an outer peripheral portion of the housing.
(Appendix 7)
The outer peripheral portion of the frame is provided with a protrusion that protrudes radially outward,
The rectifying portion is provided with a concave portion recessed inward in the radial direction,
The electric blower according to any one of Supplementary notes 1 to 6, wherein the protrusion and the recess are fitted.
(Appendix 8)
A vacuum cleaner equipped with the electric blower according to any one of Supplementary notes 1 to 7.

1 electric blower, 2 cover, 2a intake port, 2b engaging part, 3 rectifying part, 3X first rectifying part, 3Y second rectifying part, 3a blade row, 3b notch part, 3x fitting claw, 3y fitting hole , 4 bracket, 4a fitting part, 4b exhaust port, 4c convex part, 5 frame, 5a body part, 5b housing, 5c flange part, 5d opening part, 5e protrusion, 5f hole, 6 rotor assembly, 7 stator assembly , 8 shaft, 9 rotor core, 10 end cap, 11 impeller, 11a disk part, 11b impeller part, 12a first bearing, 12b second bearing, 13 preload part, 14 stator core, 15a insulator, 15b insulator, 16 coil, 17 terminal, 18 screw, 19 nut, 20 rotor-impeller assembly, 30 board, 50 cutting tool, 100 vacuum cleaner, 101 main body, 101a main body pipe section, 101b handle, 101c operating section, 101d main body exhaust port , 102 dust collection section, 102a dust collection chamber, 103 extension pipe, 104 suction tool, 111 secondary battery, 112 suction air path, 113 swirling section, 114 separation section

Claims (8)

frame and
a shaft rotatably supported with respect to the frame;
a rotor core attached to the shaft;
a stator core disposed around the rotor core and held by the frame;
an impeller attached to the shaft;
a rectifier that adjusts the airflow sent out by the rotation of the impeller;
Equipped with
The rectifier includes a first rectifier component that corresponds to a half-circumferential portion in the circumferential direction centering on the axis, and a separate body from the first rectifier component, and corresponds to the remaining half-circumferential portion in the circumferential direction. An electric blower formed by attaching a second rectifying component to the frame. The electric blower according to claim 1, wherein an unbalance correcting section for correcting rotational unbalance is provided at an end of the rotor core. The electric blower according to claim 2, wherein the unbalance correction section is a ring-shaped member and is arranged at an end of the rotor core on the opposite side to the impeller side. The fitting portion provided on the first rectifying component and the fitting portion provided on the second rectifying component are fitted, so that the first rectifying component and the second rectifying component are integrated. The electric blower according to any one of claims 1 to 3. a cover that covers the impeller;
a bracket having a fixing part fixed to the cover and attached to the frame;
Equipped with
The electric blower according to any one of claims 1 to 3, wherein the bracket is a ring-shaped component that is not divided into a plurality of parts in the circumferential direction. comprising a bearing portion for receiving the shaft;
The frame includes a housing that holds the bearing part,
The electric blower according to claim 5, wherein the bracket is attached to an outer peripheral portion of the housing. The outer peripheral portion of the frame is provided with a protrusion that protrudes radially outward,
The rectifying portion is provided with a concave portion recessed inward in the radial direction,
The electric blower according to any one of claims 1 to 3, wherein the protrusion and the recess are fitted into each other. A vacuum cleaner equipped with the electric blower according to any one of claims 1 to 3.

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