JP3487679B2 - Small electric motor - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotating field type in which a stator is wound with a plurality of phases and a rotor is provided with a permanent magnet. The present invention relates to a small motor. 2. Description of the Related Art Conventionally, a small electric motor of this type, for example, a brushless motor, has a stator on which a multi-phase winding is wound as disclosed in, for example, Japanese Patent Application Laid-Open No. Hei 4-26351 (H02K29 / 00). A motor body is configured by disposing a rotor having a permanent magnet therein. On the coil end side of the stator winding, a board is mounted separately from the board, and the winding is connected to this board and supplied with power, and the board detects the magnetism of the permanent magnet of the rotor. A magnetic sensor was installed for it. This magnetic sensor comprises a Hall element or a Hall IC, detects a magnetic pole position of the rotor based on a magnetic field from a permanent magnet of the rotor, and supplies current to windings of each phase of the stator. It outputs a signal for determining the timing. Conventionally, such a magnetic sensor (position detection sensor) has a structure in which it is soldered directly to a wiring pattern of a substrate, or a holder having a predetermined shape is attached to the substrate and then inserted and fixed in the holder. It had been. However, a Hall element or a Hall IC (magnetic sensor) is directly or
If the holder is inserted after it is mounted, the mounting position of the magnetic sensor will not be stable, causing an error. If the position of the magnetic sensor shifts, the timing of switching the current supply to the stator winding shifts, causing acceleration and deceleration of the rotor, increasing electromagnetic vibrations and noise, and reducing operating efficiency. . The present invention has been made to solve the above-mentioned conventional technical problem, and an object of the present invention is to provide a small electric motor capable of improving the mounting accuracy of a magnetic sensor while simplifying an assembling operation. Aim. [0006] A small electric motor according to the present invention comprises:
Stator with stator winding and rotor with permanent magnet
And outputs a signal by detecting the magnetic field from the permanent magnet.
Magnetic sensor, and the magnetic sensor and stator winding
A substrate to be connected, and the substrate is a metal plate
A predetermined wiring pattern consisting of
Leaving the connection where the air sensor and stator windings are connected
A molding material having electrical insulation to be molded and a wiring
Is molded at the same time at the mall de material at the turn of the mold, magnetic
The holding part for positioning the air sensor and the connection part
And the cut-and-raised portion where the stator winding is locked
Things. According to the small motor of the present invention, the substrate is made of metal.
A predetermined wiring pattern made of a plate and this wiring pattern
Leave the connection where the magnetic sensor and stator windings are connected
Material with electrical insulation to be molded and wiring
Simultaneously molded with mold material when pattern is molded,
And a holding unit for positioning the magnetic sensor.
Therefore, simply attaching it to this holding part
The mounting position of the sir is determined. Therefore, the magnetic sensor
Position accuracy is improved, electromagnetic vibration and noise are reduced, and
The number of parts and assembly
The number of products can be reduced, leading to a reduction in manufacturing costs.
Can be achieved. [0008] In particular, the connecting portion to which the stator winding is connected is
A cut-and-raised portion is formed to lock the stator winding.
Therefore, when connecting the stator winding to the board,
Entangle the winding end and solder it in a temporarily fixed state
And the like. Therefore, the assembly workability is
It will be much better. An embodiment of the present invention will be described below in detail with reference to the drawings. FIG. 1 is a partially longitudinal side view of a DC brushless motor 1 as an embodiment of a small motor using the present invention, FIG. 2 is a side view of a stator 2, FIG. 3 is a plan view of the stator 2, and FIG. 5, FIG. 5 is a rear view of the substrate 3, and FIG.
7 is an enlarged sectional view of the substrate 3 at the lead wire connecting portion 36, FIG. 8 is an enlarged sectional view of the substrate 3 at the lead wire connecting portion 36 with the lead wire 81 connected, and FIG. FIG. 10 is an enlarged rear view of the substrate 3 in the holding portion 48, and FIG.
FIG. 11 is a perspective view of the Hall IC 51, FIG. 12 is an enlarged plan view of the substrate 3 of the winding connection portion 27, FIG. 13 is a diagram showing a wiring pattern of the substrate 3, and FIG.
3 is an electric circuit diagram of the DC brushless motor 1. FIG. A DC brushless motor 1 according to an embodiment is used for, for example, a blower fan of a home air conditioner, and includes a stator 2, a rotor 4 disposed inside the stator 2, Rotary shaft 6 attached to rotor 4
And a board 3 provided on the coil end side of the stator 2 so as to be separated therefrom, and a bracket 7 for accommodating them. The stator 2 includes a stator core 8 in which a plurality of electromagnetic steel plates are laminated, and a plurality of phase windings 11 wound around the stator core 8 via an insulator 9. , Is fixed in the bracket 7. The rotor 4 includes a field permanent magnet 12 and is rotatably supported by bearings 13 and 14 of the bracket 7. On the other hand, the substrate 3 has a donut shape as a whole, and an upper metal plate 16 and a lower metal plate 17 each having a predetermined wiring pattern shape, and a polyphenylene for molding the periphery thereof in a state where they are separated from each other. And a molding material 18 made of sulfide resin. The outer peripheral edge of the substrate 3 is formed with four engaging portions 22... To which the support pins 21 of the insulator 9 are engaged and welded. An outlet portion 24 is formed, which communicates with the outlet. A winding connection portion 2 is provided on the outer peripheral edge of the substrate 3.
6 to 31 are formed at six places apart from each other. In each of the winding connection portions 26 to 31, the metal plate 16, 17 is exposed without being filled with the molding material 18, and in the winding connection portions 26, 28, 30, the metal plate 17 is exposed. In the portions 27, 29 and 31, the metal plate 16 is exposed. Further, cut-and-raised portions 32 are formed on the exposed metal plate 16 or 17 at the respective winding connection portions 26 to 31 as shown in FIG. Furthermore, the winding connection part 2 close to the lead-out part 24
Between 6 and 27 and between winding connections 28 and 29,
Lead wire connection parts 33-36, lead wire connection parts 37-40
Are formed at four places each. The metal plate 16 or 17 is exposed at each of the lead wire connecting portions 33 to 40, and the through holes 20 are respectively formed as shown in FIG. ing. Also, the lead wire connection part 33 is connected to the winding connection part 26,
The lead wire connection portion 34 is electrically connected to the winding connection portion 30, and the lead wire connection portion 37 is electrically connected to the winding connection portion 28. Furthermore,
The winding connection portions 27, 29, and 31 are conducted and become a neutral point. The first to third holders 46 are located at 180 °, 120 °, and 60 ° to the right of the outlet 24 on the inner peripheral edge of the substrate 3. , 47 and 48 are simultaneously and integrally molded with the molding material 18 when the metal plates 16 and 17 are molded. Each of the holding portions 46 to 48 protrudes downward (backward) and serves as a magnetic sensor as shown in FIG.
3, and a lower output hole as a terminal connection portion formed in the metal plates 16 and 17 exposed from the molding material 18 at the upper end of each of the storage portions 54. 56, a grounding hole 57 on the right side, and a power supply hole 58 at a substantially triangular position on the center outer peripheral side. A cutout window 61 for exposing the Hall ICs 51 to 53 is formed on the inner side wall of each storage section 54, and a power supply terminal for Hall ICs 51 to 53 described later is formed on the upper side of the inner side wall. 71 is the power supply hole 5 on the outer peripheral side
8 is formed. The power supply holes 58 of the holding portions 46 to 48 are connected to the lead wire connection portions 3.
5 and the ground holes 57 are connected to the lead wire connecting portion 38. The output hole 56 of the first holding portion 46 is connected to the lead wire connecting portion 36, the output hole 56 of the second holding portion 47 is connected to the lead wire connecting portion 40, and the output hole 56 of the third holding portion 48 is connected. Are electrically connected to the lead wire connection portions 39, respectively. On the other hand, the Hall ICs 51 to 51 shown in FIG.
Numeral 53 denotes a rectangular wave output which is generated by magnetic lines of force penetrating the main body. The rectangular main body 70 has a central power supply terminal 71 protruding from the upper surface thereof, a left output terminal 72 and a right ground terminal 73. Have. Next, the procedure for assembling the substrate 3 and assembling it to the stator 2 according to the present invention will be described. First, each hall IC
51, 52, and 53 are inserted from below (the back side) into the storage portions 54 of the first to third holding portions 46, 47, and 48 formed integrally with the molding material 18 of the substrate 3. At this time, the left and right output terminals 72 and the installation terminals 72 are inserted into the output holes 56 and the installation holes 57 of the holding portions 46 to 48, respectively, and the central power supply terminal 71 is inserted into the inclined wall 62 as shown in FIG.
0 and is bent to the outer peripheral side so that each of the holding portions 46 to
48 are inserted into the feeding holes 58. Due to the bending of the power supply terminal 71, each of the Hall ICs 51 to 53 is temporarily fixed in each of the storage portions 54 without applying stress to the main body 70. At this time, the terminals 71 to 73 of the Hall ICs 51 to 53 are connected.
Is adjusted to the cut size after soldering. The terminals 71 to 73 are connected to the metal plates 16 and 17 around the holes 56 to 58 by soldering from the front side of the substrate 3. Also in this case, since each of the Hall ICs 51 to 53 is temporarily fixed as described above,
Soldering work becomes easy. Thereby, each hall I
The power supply terminals 71 of C51 to C53 are electrically connected to the lead wire connection portion 35, the ground terminal 73 is electrically connected to the lead wire connection portion 38, the output terminal 72 of the Hall IC 51 is connected to the lead wire connection portion 36, and the output of the Hall IC 52 is The terminal 72 is connected to the lead wire connecting portion 40, and the output terminal 72 of the Hall IC 53 is connected to the lead wire connecting portion 39. Then, the through hole 2 of the lead wire connecting portion 33 is formed.
For example, a U-phase power supply lead wire (lead wire) is provided at 0, a V-phase power supply lead wire is provided at the lead wire connecting portion 34, and a W-phase power supply lead wire is provided at the lead wire connecting portion 37. Each is inserted (each lead wire is indicated by 81; the same applies hereinafter). The lead connection portion 35 has a Hall IC power supply lead wire from the front side, the lead connection portion 36 has an output lead wire of the Hall IC 51, and the lead wire connection portion 40 has an output lead wire of the Hall IC 52. However, an output lead wire of the Hall IC 53 is inserted into the lead wire connecting portion 39, and a Hall IC grounding lead wire is inserted into the lead wire connecting portion 38, respectively. Also in this case, since the molding material 18 around the through hole 70 at each connection portion is inclined and expanded, the leading end of the lead wire is guided by this inclined surface and smoothly inserted into the through hole. . Note that the conductor that is not inserted bends in each connecting portion as shown in FIG. 8, so that no problem occurs. Therefore, the preliminary soldering to the conductor can be omitted. Then, each lead wire 81 is connected to each metal plate 16 or 17 around the through hole 20 by soldering from the back side. Then, all the lead wires 81 are bundled, inserted into the opening 23, and pulled out from the outlet portion 24 to the rear surface side (FIG. 3). At this time, each of the lead wire connection portions 33 to
Since 40 is in the vicinity of the outlet 24, the lead wire 81 can be easily routed. The back surface side of the substrate 3 assembled in this manner is used as the stator 2 side, and the support pins 21 of the insulator 9 are engaged with the engaging portions 22. 2
Assemble to. In this state, the ends of the windings 11 of the respective phases are entangled with the cut-and-raised portions 32 of the respective winding connection portions 26 to 31 (FIG. 1).
2) Temporarily fix. Then, the winding 11 is conducted to the metal plates 16 and 17 by soldering from the front side. In this manner, since the end of the winding 11 can be entangled with the cut-and-raised portion 32 and soldered or the like can be performed in a temporarily fixed state, the assembling workability is further improved. Then, the rotor 4 is inserted inside the stator 2, and at this time, each of the Hall ICs 51 to 53 is connected to the rotor 4.
(See FIG. 1). The bracket 7 is composed of a first bracket 7A and a second bracket 7B in the shape of a circular container. After the above-mentioned parts are housed inside, they are pressed against each other.
The DC brushless motor 1 is completed by fixing with the screw 7C. At this time, the lead portion 24 of the board 3 is fitted into the second bracket 7B, and the lead wire 81 is drawn out of the bracket 7. The lead wire 81 is connected to a controller (control circuit) 82 shown in FIG. 14 via a coupler (not shown). The controller 82 is connected to each of the Hall ICs 51.
Using the output signals (SU, SV, SW) from the reference numerals 53 to 53, the magnetic pole position of the rotor 4 is detected based on the magnetic field from the permanent magnet 12 of the rotor 4, and the windings 11 of each phase of the stator 2 And the operation control of the DC brushless motor 1 is executed. Also in this case, since the holding portions 46 to 48 are integrally formed with the molding material 18 of the substrate 3, each of the Hall ICs 51 to 5 can be simply mounted on the holding portions 46 to 48.
The mounting position of No. 3 can be determined. Therefore, the Hall ICs 51 to 51
The mounting position accuracy of the 53 is improved, and noise reduction and efficiency improvement can be realized. Further, since it is no longer necessary to mount the holder on the substrate as in the related art, it is possible to reduce the number of parts and the number of assembly steps, thereby achieving a reduction in manufacturing cost. Although the embodiment has been described with the components inserted into the bracket 7, the present invention is also effective for a so-called molded motor in which the entire stator is molded with molding resin. In the embodiment, the magnetic sensor for detecting the rotational position of the DC brushless motor has been described. However, the present invention may be applied to a magnetic sensor for detecting the rotational speed of an induction motor. As described above in detail, according to the present invention, the substrate
Is a predetermined wiring pattern made of a metal plate, and the wiring pattern
Connection to the magnetic sensor and stator winding
Material with electrical insulation to mold with leaving
And mold material at the same time
And a holding part for positioning the magnetic sensor.
It can be attached only to this holding part
The mounting position of the magnetic sensor is determined. Therefore, the magnetic sensor
Servo mounting position accuracy is improved, reducing electromagnetic vibration and noise
In addition to improving the efficiency,
And the number of assembly steps can be reduced.
Can be reduced. In particular, the connecting portion to which the stator winding is connected
A cut-and-raised portion is formed to lock the stator winding.
Therefore, when connecting the stator winding to the board,
Entangle the winding end and solder it in a temporarily fixed state
And the like. Therefore, the assembly workability is
It will be much better.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partial longitudinal side view of a DC brushless motor as an embodiment of a small electric motor using the present invention. FIG. 2 is a side view of a stator of the DC brushless motor according to the embodiment. FIG. 3 is a plan view of a stator. FIG. 4 is a plan view of a substrate. FIG. 5 is a rear view of the substrate. FIG. 6 is a sectional view taken along line AA of FIG. 4; FIG. 7 is an enlarged cross-sectional view of a substrate at a lead wire connection portion. FIG. 8 is an enlarged cross-sectional view of a substrate at a lead wire connection portion where lead wires are connected. FIG. 9 is an enlarged rear view of the substrate in the holding section. FIG. 10 is an enlarged cross-sectional view of a substrate in a holding portion. FIG. 11 is a perspective view of a Hall IC. FIG. 12 is an enlarged plan view of a substrate at a winding connection portion. FIG. 13 is a diagram showing a wiring pattern of a substrate. FIG. 14 is an electric circuit diagram of a DC brushless motor. [Description of Signs] 1 DC brushless motor 2 Stator 3 Substrate 4 Rotor 11 Winding 12 Permanent magnet 16, 17 Metal plate 18 Molding material 32 Cut-and-raised 46 to 48 Holder 51 to 53 Hall IC

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-61-251462 (JP, A) JP-A-3-117351 (JP, A) Fully open 58-196570 (JP, U) Really open 1980 125082 (JP, U) JP-A-6-84782 (JP, U) JP-A-2-49373 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) H02K 29/00 H02K 21 / 00

Claims (1)

(57) [Claim 1] A stator having a stator winding and a permanent magnet
A small motor comprising a rotor having a magnetic field for detecting a magnetic field from the permanent magnet and outputting a signal
The sensor is connected to the magnetic sensor and stator winding.
And a predetermined wiring pattern made of a metal plate.
Wiring pattern is connected to the magnetic sensor and stator winding
With electrical insulation to mold leaving the connection part
The molding material and the mold at the time of molding the wiring pattern.
The magnetic sensor is molded at the same time, and the position of the magnetic sensor is determined.
And a stator formed at the connection part and the stator
Characterized in that the winding has a cut and raised portion.
Small electric motor.