JP5088655B2 - Motor and motor manufacturing method - Google Patents

Description

  The present invention comprises a stator that is classified into a plurality of phases and in which a coil is wound for each phase, and a rotor that is rotated by excitation of the coil, and a rotary shaft attached to the rotor is configured to support the rotation shaft via a bearing. The present invention relates to a motor protruding from a motor case that houses a stator and a rotor.

Conventionally, an electric power steering unit has been applied as an assist in operating a steering in a vehicle. A motor (hereinafter referred to as “EPS motor”) that is a drive source of the electric power steering unit is connected to a coil of each phase of the stator.
The terminal block having the shape of Patent Document 2 is fitted with an insulator disposed on the end face of the stator core and placed on the upper part of the stator. The structure to be inserted into the general structure was common (see Patent Document 3 and Patent Document 4).
JP 2003-103558 A JP 2003-324883 A JP 2004-157056 A JP 2004-304945 A

  However, since the terminal block used in the above structure inserts the rotor into the stator later, it is necessary to provide an inner diameter hole larger than the rotor diameter at the center of the terminal block, and the terminal block is large.

  In addition, a brushless motor requires a rotor position detection sensor (resolver, etc.) in order to energize each phase coil, and requires a space for placing the resolver and hall sensor that are generally used, as well as a structure and parts to hold. Therefore, it was a complicated structure.

  An object of the present invention is to obtain a motor that can be reduced in cost by reducing the size of the terminal block and reducing the number of parts by improving the arrangement and shape of the motor terminal block in consideration of the above facts.

The present invention comprises a stator that is classified into a plurality of phases and in which a coil is wound for each phase, and a rotor that is rotated by excitation of the coil, and a rotary shaft attached to the rotor is configured to support the rotation shaft via a bearing. A motor that protrudes from a motor case that houses the stator and the rotor, and a terminal block that connects coils of each phase of the stator when viewed from the rotor side, along the central axis of the rotor In contrast, it is characterized by being arranged outside the bearing arrangement position .

According to the present invention, since the heat generated when the coil is energized is easily released to the outside, the terminal block can be prevented from being affected by the heat.

  In the above invention, the coil of each phase passes through the motor case, and on the mounting surface of the motor case, the terminal block disposed in the housing in which the bearing, the rotor position sensor, and the like are housed, and arc welding and fuse It is characterized by being connected by ging or the like.

  Since the terminal block is present in the inlay of the motor case, it is difficult to be affected by the heat generated by the coil, a low grade resin material can be applied, and the terminal block can be manufactured at low cost.

  For example, PPS (polyphenylene sulfide) can be changed to PET (polyethylene terephthalate), PBT (polybutylene terephthalate), or the like.

  In the invention described above, the terminal block is formed integrally with a stator portion of a resolver that functions as the position detection sensor, and has a function of adjusting the advance angle of the resolver.

  The number of components can be reduced by integrally forming the stator portion of the resolver and the terminal block. In addition, the advance angle adjustment of the resolver becomes easy.

  As described above, the present invention has an excellent effect that the terminal block can be downsized and the cost can be reduced by reducing the number of parts by improving the arrangement and shape of the motor terminal block.

  1 and 2 show an electric power steering motor (EPS motor) 10 according to the present embodiment. The main part of the EPS motor 10 is housed in a cylindrical motor case 12, and the internal space is almost sealed. A rotor shaft 14, which will be described later, protrudes from one end surface (left end surface in FIG. 1) of the motor case 12. Further, a flange 16 whose cross section is bent into an approximately L shape is provided on the left end side of the case 12 in FIG.

  The flange 16 has a role of connecting and fixing to a gear box unit (not shown) that is a speed change mechanism. The rotor shaft 14 is supported by bearings 20 provided at the left and right ends of the motor case 12 in FIG. 1, and is fitted to the rotor 22 inside the case 12.

  The rotor 22 has a three-layer structure of a rotor core 24, a magnet 26, and a rotor cover 28 in order from the inner side in a cross-section perpendicular to the rotor shaft 14.

  A stator 32 is press-fitted into the inner peripheral surface of the motor case 12 and faces the outer peripheral surface of the rotor 22. The stator 32 has a structure in which a stator coil 38 is wound with the insulator 36 inserted in the stator core 34.

  By causing a change in the magnetic field between the stator 32 and the rotor 22, both rotate relative to each other (substantially, the rotor 22 rotates), and this rotational driving force is externally (via the rotor shaft 14). For example, it can be output to a gear box.

  A resolver rotor 39 </ b> A is attached to an output side end portion (left end portion in FIG. 1) of the rotor shaft 14. The resolver rotor 39A has an outer diameter enlarged with respect to the outer diameter of the rotor shaft 14, and the outer peripheral surface of the resolver rotor 39A faces the resolver stator 39B attached to the terminal block 40 with a predetermined gap.

  The terminal block 40 is fixed to the spigot of the motor case 12 by screws 44. The terminal block 40 has a function of connecting a stator coil 38 wound around the insulator 36 of the stator 32 classified into each phase and a lead wire 46 from the outside. 40A is attached in advance. A coil insertion hole 40B is drilled at one end of the terminal 40A provided on the terminal block 40, and the stator coil 38 is inserted from the coil insertion hole 40B and crimped to the terminal 40A. As a result, the stator coil 38 and the terminal 40A are electrically connected.

  On the other hand, a lead wire terminal 46A is spot welded to the conductive wire exposed from the lead wire 46. After inserting the lead wire terminal 46A into the bush 12A provided in the motor case 12, the terminal 40A of the terminal block 40 is inserted. And electrical welding is realized by arc welding.

  The rotor 22 is rotated by receiving current from the outside by the lead wire 46 and passing current through the stator coils 38 of the respective phases sequentially.

  The terminal block 40 is disposed outside the bearing 20 and can be mounted after the rotor 22 mounted on the rotor shaft 14 is accommodated in the motor case 12. In order to accommodate the rotor 22 when it is attached, it has a structure that does not require a hole (inner diameter hole).

  Further, a boss 50 is attached to the outer side of the terminal block 40 and is used for connection with the input shaft of the gear box described above. As shown in FIG. 2, the coil 30 </ b> A passes through the flange 16 and is connected to the terminal block 40. Reference numeral 52 denotes a sensor lead wire.

  The operation of this embodiment will be described below. The rotor 22 includes a rotor core 24 arranged coaxially with the rotor shaft 14 and a magnet 26 fixed to the outer periphery of the rotor core 24 with a rotor cover 28, and press-fitted and fixed to the bearing 20 arranged in the motor case 12. 39A is inserted into the rotor shaft 14, and the boss 50 is press-fitted to fix the resolver rotor 39A.

  The stator 32 is obtained by winding a stator coil 38 in a state where the insulator 36 is inserted into the stator core 34 and press-fitting the stator coil 38 into the motor case 12.

  After inserting the rotor 22 into the stator 32, the terminal block 40 is inserted into the motor case 12, and the stator coil 38 wound around the insulator 36 of the stator 32 is passed through the coil insertion hole 40 </ b> B of the terminal block 40. The terminal 40A and the stator coil 38 are caulked.

  A resolver stator 39B is integrally formed on the terminal block 40. After adjusting the angle of the terminal block 40 to adjust the advance angle, the resolver stator 39B is fixed to the inlay of the motor case 12 with a screw 44. Thereafter, the terminal block 40 and the stator coil 38 are arc welded.

  Next, the lead wire 46 is inserted into the bush 12 </ b> A, and the lead wire terminal 46 </ b> A spot-welded to the exposed lead wire of the lead wire 46 and the terminal 40 </ b> A of the terminal block 40 are arc-welded to achieve conduction.

  In the present embodiment, the terminal block 40 is exposed with the opening of the motor case 12, that is, the inlay opened, but as shown in FIGS. 3 and 4, the cover made of synthetic resin is used. 52 may be attached (Modification 1).

  Further, in the present embodiment, the terminal block 40 is disposed in the spigot of the motor case 12, but as shown in FIGS. 5 and 6, the right side of the motor case 12 in FIG. It is also possible to provide the terminal block 40 on the side opposite to the output (protruding) side end of the rotor shaft 14 by making the detachable (Modification 2).

  As described above, in the present embodiment, by disposing the terminal block 40 outside the bearing 20 (inlay of the motor case 12), an inner diameter hole for inserting the rotor 22 becomes unnecessary, and the terminal block 40 Can be miniaturized. Further, since the resolver stator 39B can be integrally formed with the terminal block 40, the number of parts can be reduced. Furthermore, the heat generated when the stator coil 38 is energized is easily released to the outside, and accordingly, the terminal block 40 can be made of a low-grade synthetic resin material. For example, while PPS is conventionally applied, PET and PBT are applicable to the structure of the present embodiment.

  In addition, arc welding between the stator coil 38 and the terminal 40 </ b> A of the terminal block 40, arc welding of the lead wire terminal 46 </ b> A of the lead wire 46 and the terminal 40 </ b> A of the terminal block 40, etc. are all performed in the inlay of the motor case 12. The work process can be reduced.

  Furthermore, since only the stator 32 and the rotor 22 are provided inside the motor case 12, the occurrence of motor lock due to cracking or chipping of parts is reduced.

It is the front view which looked at the steering motor which concerns on this Embodiment from the axial direction. FIG. 2 is a right side cross-sectional view of FIG. 1 according to the present embodiment. It is the front view which looked at the steering motor concerning modification 1 from the axial direction. FIG. 4 is a right side cross-sectional view of FIG. 3 according to Modification 1; FIG. 6 is a right side cross-sectional view of FIG. 5 according to Modification 2. It is the front view which looked at the steering motor concerning modification 2 from the axis perpendicular direction.

Explanation of symbols

10 Motor for electric power steering (motor)
12 Motor Case 14 Rotor Shaft 16 Flange 20 Bearing 22 Rotor 24 Rotor Core 26 Magnet 28 Rotor Cover 32 Stator 34 Stator Core 36 Insulator 38 Stator Coil
39A Resolver rotor 39B Resolver stator 40 Terminal block 40A Terminal 40B Coil insertion hole 44 Screw 46 Lead wire 46A Lead wire terminal 50 Boss 52 Sensor lead wire

Claims (4)

A stator that is classified into a plurality of phases and in which a coil is wound for each phase, and a rotor that rotates by excitation of the coil, and a rotating shaft attached to the rotor is connected to the stator and the rotor via a bearing. A motor projecting from a motor case containing
The rotor has a rotor core to which a magnet is fixed at a position facing the inner peripheral surface of the stator,
Terminal block for connecting the coils of each phase of the stator, when viewed from the rotor core side, is disposed outside the Oite bearing arrangement position in a direction along the central axis of said rotor, said terminal block Is a motor integrally formed with a stator portion of a resolver that functions as a position detection sensor of the rotor.   The coils of each phase pass through the motor case, and are connected to the terminal block disposed in the housing in which the bearing, the rotor position sensor, and the like are housed on the mounting surface of the motor case by welding or the like. The motor according to claim 1.   The motor according to claim 2, wherein the terminal block has an advance angle adjusting function of the resolver. A stator that is classified into a plurality of phases and in which a coil is wound for each phase, and a rotor that rotates by excitation of the coil, and a rotating shaft attached to the rotor is connected to the stator and the rotor via a bearing. A method of manufacturing a motor protruding from a motor case containing
The rotor has a rotor core to which a magnet is fixed at a position facing the inner peripheral surface of the stator,
A first step of attaching the rotor inside the motor case;
A terminal block that is integrally formed with a stator portion of a resolver that functions as a position detection sensor of the rotor and that connects coils of each phase of the stator, when viewed from the rotor core side, is along the central axis of the rotor. a second step of arranging on the outer side than Oite bearing arrangement position in the direction,
The method for manufacturing a motor is characterized in that the second step is performed after the first step.

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