JP6200720B2 - Brushless motor and method for manufacturing brushless motor - Google Patents

Description

  The present invention relates to a brushless motor and a method for manufacturing the brushless motor.

  Patent Literature 1 below discloses a brushless motor including a stator core configured by arranging a plurality of cores (divided cores) in the circumferential direction. Briefly describing the technique described in this document, the split core is provided with a tooth portion around which a conductive winding is wound, and the tooth portion and the winding portion (winding around the tooth portion of the winding) are provided. An insulating part is provided between the rotating part). Furthermore, the insulating part is connected through three connecting parts formed in an annular shape. Thereby, the split core is configured to be in three groups via the connecting portion. And the stator of a brushless motor is comprised by integrating these three groups. Further, Patent Document 2 below discloses a stator configured by integrating a stator core and a case (yoke). In the stator, the stator core and the case are integrated by disposing the stator core in a bottomed cylindrical case (yoke) and plastically deforming the outer periphery of the case toward the inside in the radial direction of the case. It has become.

JP2012-110212A JP 2011-142811 A

  However, in the configuration described in Patent Document 1, since the rigidity of each connecting portion is different, the roundness of the split cores arranged in an annular shape when the three groups of split cores are integrated (the stator core It is conceivable that the (roundness) decreases. Moreover, in the structure described in the said patent document 2, when the processing force for plastically deforming a case arises, it is possible that the roundness of the stator core arrange | positioned in the said case falls.

  An object of the present invention is to obtain a brushless motor and a method for manufacturing the brushless motor that can improve the roundness of the stator core in consideration of the above facts.

A brushless motor according to a first aspect of the present invention comprises an annular yoke and a plurality of yoke components divided in the circumferential direction of the yoke. A plurality of core components integrally including a plurality of teeth portions protruding radially inward, a plurality of winding portions wound around the teeth portions, and a plurality of phases constituting a plurality of phases It has a plurality of insulating portions that are integrated with the winding and each of the core constituent portions to insulate the teeth portion and the winding portion, and are formed in an annular shape and connect the plurality of insulating portions, and each rigidity is A plurality of insulators having a plurality of insulators having the same connecting portion; and a plurality of yokes formed in a cylindrical shape that covers the stator body from the radially outer side of the stator body. Opposite Said stator body plastically deformed portion is formed by processing force corresponding to at least one of rigidity of the portions respectively opposed to the rigid and the plurality of yoke components of the plurality of insulators to the site is added And a case for adjusting the roundness of the stator body by being integrated with the stator body.

In the first aspect of the present invention, the stator of the brushless motor is manufactured, for example, in the following manner. First, a stator core is formed by arranging each core component in an annular shape and winding a winding around each tooth portion to form a stator body. Then, a case formed in a cylindrical shape is arranged on the outer side in the radial direction of the stator body, and the stator body and the case are integrated by forming a plastic deformation portion on the outer periphery of the case. The stator of a brushless motor is manufactured by the above procedure. Here, in the present invention, at the outer peripheral portion of the case , at least one of the rigidity of the plurality of insulators and the rigidity of the portion facing the plurality of yoke components corresponding to the portions facing the plurality of yoke components, respectively. A processing force is applied. Thereby, the pressing force which the site | part in which the plastic deformation part in the case was formed presses a yoke structure part is adjusted. That is, in the present invention, the circularity of the stator body by the pressing force is adjusted is adjusted, thereby, it is possible to improve the circularity of the stator core.
The stator of the brushless motor is manufactured, for example, in the following manner. First, a core constituent part is integrated with an insulating part of each insulator to form a plurality of subassemblies. Subsequently, a winding is wound around each tooth portion of each subassembly to form a plurality of stator constituent portions. In this state, the stator constituent parts are connected by the connecting part. Then, the stator main body is formed by assembling the plurality of stator components together. Then, a case formed in a cylindrical shape is arranged on the outer side in the radial direction of the stator body, and the stator body and the case are integrated by forming a plastic deformation portion on the outer periphery of the case. The stator of a brushless motor is manufactured by the above procedure. Here, in this invention, the processing force corresponding to the rigidity of the connection part of a some insulator is respectively added to the site | part which opposes the some yoke structure part in the outer peripheral part of a case. Thereby, the pressing force which the site | part in which the plastic deformation part in the case was formed presses a yoke structure part is adjusted. That is, in the present invention, the roundness of the stator body is adjusted by adjusting the pressing force, and thereby the roundness of the stator core can be improved.
Further, since the rigidity of each connecting portion of the plurality of insulators is the same, the processing force input to the case when forming one plastic deformation portion and the other plastic deformation portion are formed. The processing force input to the case can be made the same. Thereby, in this invention, the process control at the time of integrating a stator main body and a case can be made easy.

The brushless motor according to a second aspect of the present invention is the brushless motor according to the first aspect , wherein the rigidity of each of the connecting portions is made equal by adjusting the plate thickness and width of each of the connecting portions. ing.

In the second aspect of the present invention, since the rigidity of each connecting portion is the same, it is possible to facilitate processing control when integrating the stator body and the stator case.

A brushless motor according to a third aspect of the present invention is the brushless motor according to the first aspect , wherein the connecting portion disposed radially inward of the yoke is formed using a material having a lower Young's modulus. And the rigidity of each said connection part is made the same.

According to the third aspect of the present invention, since the rigidity of each connecting portion is the same, it is possible to facilitate processing control when integrating the stator body and the stator case.

  Note that the fact that the rigidity of each connecting portion is the same is not limited to that in which the rigidity of each connecting portion is completely the same. The rigidity of each connecting portion may be slightly different within a range in which the above-described effects can be obtained.

A brushless motor according to a fourth aspect of the present invention is the brushless motor according to the first aspect, wherein the connecting portion disposed on the radially outer side of the yoke is provided with a rib projecting radially outward, and By providing a plurality of notches on the outer peripheral portion of the connecting portion disposed on the radially inner side of the yoke, the rigidity of each of the connecting portions is the same.

In the present invention described in claim 4, since the rigidity of each connecting portion is the same, it is possible to facilitate processing control when integrating the stator main body and the stator case.

A brushless motor according to a fifth aspect of the present invention is the brushless motor according to the first aspect, wherein the cross-sectional shapes cut along the inner and outer diameters of the connecting portions and the radial direction of the yoke are the same, Since each said connection part is arrange | positioned adjacent to the axial direction of the said yoke, the rigidity of each said connection part is made the same.

In the present invention described in claim 5, since the rigidity of each connecting portion is the same, it is possible to facilitate processing control when integrating the stator body and the stator case. Moreover, since a connection part can be arrange | positioned adjacent to the axial direction of a yoke, size reduction of the radial direction of a stator can be achieved.

According to a sixth aspect of the present invention, there is provided a method of manufacturing a brushless motor, comprising: a plurality of yoke components that constitute an annular yoke and divided in the circumferential direction of the yoke; A plurality of core constituent portions integrally having a plurality of teeth portions projecting radially inward of the yoke, and a plurality of winding portions each wound around the teeth portions, and constituting a plurality of phases A plurality of windings, and a plurality of insulating parts that are integrated with each core constituent part to insulate the teeth part and the winding part, and are formed in an annular shape and connected to the plurality of insulating parts And a plurality of insulators having connecting portions arranged adjacent to each other in the radial direction, and a case formed in a cylindrical shape having an inner diameter exceeding the outer diameter of the stator body having the outer diameter of the stator body. Case placement process The rigidity of the connecting portion of the plurality of insulators in the portion facing the plurality of yoke components in the outer peripheral portion of the case, and the rigidity of the portion facing the plurality of yoke components in the outer peripheral portion of the case, respectively. By applying a processing force corresponding to at least one of the rigidity, a plastic deformation portion is formed on the outer peripheral portion of the case to integrate the case and the stator body, and to integrate the case and the stator body. A caulking step for adjusting the roundness of the stator main body, and in the caulking step, facing the yoke constituent portion of the core constituent portion connected to the connecting portion disposed on the inner side Opposite to the yoke component of the core component connected to the connecting portion arranged on the outer side with a weaker machining force than the machining force applied to the part to be Added to the site that.

In this invention of Claim 6, the stator of a brushless motor is manufactured through said case arrangement | positioning process and caulking process. Here, in the present invention, in the caulking step, the above-described processing force is applied to each portion of the outer peripheral portion of the case facing the plurality of yoke components. Thereby, the pressing force which the site | part in which the plastic deformation part in the case was formed presses a yoke structure part is adjusted. That is, in the present invention, the roundness of the stator main body is adjusted by adjusting the pressing force, and thereby the roundness of the stator core is improved even if there is a difference in the rigidity of each connecting portion. be able to.
Further, the strength of the processing force is adjusted in consideration of a reaction force caused by deformation of each connecting portion when a portion of the case where the plastic deformation portion is formed presses each core component. Thereby, when the case and the stator core are integrated, the arrangement of the core components is prevented from being disturbed, and as a result, the roundness of the stator core can be improved.

According to a seventh aspect of the present invention, there is provided a brushless motor manufacturing method according to the present invention, comprising: a plurality of yoke components that constitute an annular yoke and divided in the circumferential direction of the yoke; A plurality of core constituent portions integrally having a plurality of teeth portions projecting radially inward of the yoke, and a plurality of winding portions each wound around the teeth portions, and constituting a plurality of phases A plurality of windings, and a plurality of insulating portions that are integrated with each of the core constituent portions and insulate the teeth portion and the winding portion, and are formed in an annular shape and connect the plurality of insulating portions, and A case arrangement step of arranging a case formed in a cylindrical shape having an inner diameter exceeding the outer diameter of the stator body, on the radially outer side of the stator body. Of the case At least one of the rigidity of the connecting portion of the plurality of insulators and the rigidity of the portion of the outer periphery of the case facing the plurality of yoke components at a portion facing the plurality of yoke components on the periphery A plastic deformation portion is formed on the outer peripheral portion of the case by applying a processing force corresponding to rigidity, the case and the stator body are integrated, and the case and the stator body are integrated. And a caulking step for adjusting the roundness of the main body.

According to the seventh aspect of the present invention, the stator of the brushless motor is manufactured through the case arranging step and the caulking step. Here, in the present invention, in the caulking step, the above-described processing force is applied to each portion of the outer peripheral portion of the case facing the plurality of yoke components. Thereby, the pressing force which the site | part in which the plastic deformation part in the case was formed presses a yoke structure part is adjusted. That is, in the present invention, the roundness of the stator body is adjusted by adjusting the pressing force, and thereby the roundness of the stator core can be improved.
Further, in the caulking process, the stator body and the case, in which the rigidity of each connecting portion of the plurality of insulators is the same, are integrated. Therefore, the processing force input to the case when forming one plastic deformation portion and the processing force input to the case when forming another plastic deformation portion can be made the same. Thereby, in this invention, the process control of a crimping process can be made easy.

  The manufacturing method of the brushless motor according to the present invention as set forth in claim 8 comprises a plurality of yoke components that constitute an annular yoke and are divided in the circumferential direction of the yoke, and each of the yoke components from the yoke component. A plurality of core constituent portions integrally having a plurality of teeth portions projecting radially inward of the yoke, and a plurality of winding portions each wound around the teeth portions, and constituting a plurality of phases A case arrangement step of arranging a case formed in a cylindrical shape having an inner diameter that exceeds an outer diameter of the stator body having a plurality of windings to be arranged on a radially outer side of the stator body, and contact between each of the core components A cored bar setting step for inserting a cored bar having a sensor for detecting pressure into the radially inner side of the stator main body, and outputs of the sensors at portions of the outer peripheral part of the case facing the plurality of yoke components Corresponds to the value A plastic deformation portion is formed on the outer peripheral portion of the case by applying a work force to integrate the case and the stator main body, and the case and the stator main body are integrated to form a perfect circle of the stator main body. And a caulking step for adjusting the degree.

  In this invention of Claim 8, the stator of a brushless motor is manufactured through said case arrangement | positioning process, a metal core setting process, and a caulking process. Here, in this invention, if a core structure part contact | abuts to a metal core, the sensor provided in the metal core will output the contact pressure with each core structure part. The roundness of the stator body is adjusted by adjusting the processing force applied to the outer peripheral portion of the case based on the output value, thereby improving the roundness of the stator core.

It is a top view which shows the brushless motor which concerns on this embodiment. It is a perspective view which shows the stator which concerns on this embodiment. It is a perspective view of the stator structure part of a U phase. It is a perspective view of the stator structure part of V phase. It is a perspective view of the stator structure part of W phase. It is an enlarged plan view which expands and shows the core structure part arranged in cyclic | annular form. FIG. 3 is a perspective view showing a process in which a plurality of stator constituent parts shown in FIGS. 2A to 2C are assembled to each other. It is a perspective view which shows the state which assembly | attachment advanced rather than FIG. 3A. It is an expanded sectional view which shows the connection part of the insulator which concerns on this embodiment. It is the enlarged plan view and enlarged sectional view which show the connection part of the insulator which concerns on a 1st modification. It is an expanded sectional view which shows the connection part of the insulator which concerns on a 2nd modification. It is an expansion perspective view which shows the connection part of the insulator which concerns on a 3rd modification. It is an expanded sectional view which shows the connection part of the insulator which concerns on a 4th modification. It is a longitudinal cross-sectional view which shows the state by which the metal core was penetrated to the radial inside of the stator core. It is a longitudinal cross-sectional view which shows the state which the outer peripheral surface of this variable core holding | maintenance part contact | abutted to the circular arc surface of the inner side annular part when the diameter of the variable core holding | maintenance part of a metal core expands. It is a top view which shows the state which the outer peripheral surface of this variable core holding | maintenance part contact | abutted to the circular arc surface of the inner side annular part when the diameter of the variable core holding | maintenance part of a metal core expands. It is a longitudinal cross-sectional view which shows the state by which the stator core and the stator case in which the metal core was inserted were set to the crimping jig. FIG. 8 is a perspective cross-sectional view of the cored bar, the stator core, the stator case, and the caulking jig shown in FIG. 7 as viewed from one axial direction side of the stator core. It is a longitudinal cross-sectional view which shows a metal core, a stator core, a stator case, and a caulking jig when the processing force by a press acts on the caulking jig. It is a top view which shows a stator core and stator case when the processing force by a press acts on a caulking jig. It is an enlarged plan view which expands and shows the part enclosed with the dashed-dotted line of FIG. 10A. It is a longitudinal cross-sectional view which shows a metal core, a stator core, and a stator case when a metal core is removed. It is an enlarged plan view corresponding to Drawing 10B which expands and shows a portion in which a plastic deformation part in a stator concerning a modification was formed. It is an enlarged plan view corresponding to Drawing 10B which expands and shows a part in which a plastic deformation part in a stator concerning other modifications was formed. It is a top view corresponding to FIG. 10A which shows the stator case which has a stator core and distortion | strain when the processing force by a press acts on the crimping jig. FIG. 10B is an enlarged plan view corresponding to FIG. 10A showing the stator case and the stator case having a variation in plate thickness when the processing force by the press acts on the caulking jig. It is a top view corresponding to FIG. 10A which shows a stator core, a stator case, and a metal core when the processing force by a press acts on a caulking jig. It is an enlarged plan view which expands and shows the several core structure part which has a variation in the position to the circumferential direction.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Of the present embodiment, a modification shown in FIGS. 13 to 15 among the modification described later (the modification shown in FIG. 4B to the fourth modification shown in FIG. 4E) and another method of manufacturing the stator. Up to the method corresponds to the embodiment of the present invention. For this reason, the structure shown by FIG. 4A corresponding to the part from which the rigidity of the connection part of each insulator mentioned later is not the same is made into a reference example.

  As shown in FIG. 1A, a brushless motor 60 according to this embodiment is an inner rotor type brushless motor, and includes a stator 10 that generates a rotating magnetic field and a rotor 50 that rotates by the rotating magnetic field of the stator 10. Configured. 1B, the stator 10 includes a stator case 70 as a case, a U-phase stator component 12U, a V-phase stator component 12V, and a W-phase stator component 12W. 11 and so on. Hereinafter, first, the stator case 70 will be described, then the stator components 12U, 12V, 12W and the rotor 50 will be described, and finally the method for manufacturing the stator 10 and the brushless motor 60 will be described.

(Stator case 70)
As shown in FIG. 1A and FIG. 1B, the stator case 70 is formed in a thin cylindrical shape and uses a soft magnetic metal (eg, “steel”, “aluminum alloy”, “steel alloy”, etc.). It is integrally formed along the circumferential direction. Further, the inner diameter D1 of the stator case 70 before the plastic deformation portion 72 described later is formed is an inner diameter that exceeds the outer diameter D2 of the stator core 20 (the core constituent portions 14U, 14V, 14W arranged in an annular shape). .

  In addition, a plurality of plastic deformation portions 72 (12 plastic deformation portions 72 in the present embodiment) arranged at equal intervals along the circumferential direction of the stator case 70 are formed on the outer peripheral surface of the stator case 70. Yes. By forming the plastic deformation portion 72 in the stator case 70, the inner diameter of the portion of the stator case 70 where the plastic deformation portion 72 is formed decreases, and the portion of the stator case 70 where the plastic deformation portion 72 is formed and the stator core 20 abuts. Thereby, the stator case 70 and the stator core 20 are integrated, that is, the stator case 70 and the stator main body 11 are integrated.

  Moreover, the plastic deformation part 72 is formed in the site | part facing each convex part 78U, 78V, 78W formed in the yoke structure part 22U, 22V, 22W explained in full detail behind.

(Stator components 12U, 12V, 12W)
As shown in FIG. 2A, the U-phase stator component 12U includes a plurality of core components 14U, a winding 16U, and an insulator 18U. The plurality of core components 14U constitute a stator core 20 (all of which are shown in FIG. 1A) by a plurality of V-phase core components 14V described later and a plurality of W-phase core components 14W. The yoke component 22U, a plurality of teeth 24U, and a plurality of cored bar contact portions 25U are provided.

  As shown in FIG. 2A and FIG. 2D, the plurality of yoke components 22U includes the yoke 40 with a plurality of V-phase yoke components 22V, which will be described later, and a plurality of W-phase yoke components 22W. Each of them is formed in an arc shape. Each of the plurality of tooth portions 24U is integrally formed with the yoke component 22U, and protrudes radially inward of the yoke 40 from the yoke component 22U.

  Moreover, the convex part 78U which protrudes toward the radial direction outer side of the yoke component 22U and extends in the axial direction of the yoke component 22U is formed in a portion of the yoke component 22U facing the tooth portion 24U. ing. Further, the intermediate portion of the convex portion 78U (the intermediate portion in the circumferential direction of the yoke component 22U) is opened toward the radially outer side of the yoke component 22U and is along the axial direction of the yoke component 22U. A U-shaped groove-shaped recess 80U is formed.

  In addition, a core extending along the circumferential direction of the rotor 50 (along the magnets 54S and 54N arranged in an annular shape) at the end of the tooth portion 24U on the side close to the rotor 50 (see FIG. 1A). A gold contact portion 25U is provided. The core metal abutting portion 25U constitutes an inner annular portion 41 with a V-phase core metal abutting portion 25V and a W-phase core metal abutting portion 25W, which will be described later. The surfaces of the portions 25U, 25V, and 25W on the rotor 50 side are arcuate surfaces R having the rotor 50 as an axis center.

  As shown in FIG. 2A, the winding 16U forms a U phase, and has a plurality of winding portions 26U and a plurality of crossover wires 28U. The plurality of winding portions 26U are intensively wound around the tooth portion 24U via insulating portions 32U described later, and are connected to each other by a plurality of crossover wires 28U. The connecting wire 28U is wired (wrapped) along the outer peripheral surface of the connecting portion 34U formed in the insulator 18U described later. Further, the end portions 30U on both ends of the winding 16U are led out from the teeth portion 24U to one axial side of the stator 10 (arrow Z1 side).

  The insulator 18U is made of resin and integrally includes a plurality of insulating portions 32U and a connecting portion 34U. The plurality of insulating portions 32U are provided in the same number as the plurality of tooth portions 24U described above. The plurality of insulating portions 32U include an insulating main body portion 32U1 and an extending portion 32U2. The insulating main body 32U1 is integrated with the surfaces of the above-described plurality of core components 14U by being integrally formed, fitted and fitted to each other, and the tooth portion 24U and the winding portion 26U formed in the core component 14U. And is insulated. The extending part 32U2 is positioned radially inward from the core constituting part 14U and extends from the insulating main body part 32U1 along one axial side (Z1 side) of the yoke 40.

  The connecting portion 34U is provided on one axial side (Z1 side) of the plurality of insulating portions 32U. The connecting portion 34U is formed in a ring shape (annular), and includes a plurality of insulating portions 32U (more specifically, extended end portions (end portions on the Z1 side) of the extending portions 32U2 in the plurality of insulating portions 32U. )) And is located radially inward of the core component 14U. Between the plurality of insulating portions 32U on the outer peripheral surface of the connecting portion 34U, a plurality of protruding holding portions 36U protrude outward in the radial direction. The holding portion 36U holds the above-described connecting wire 28U from the other axial side (arrow Z2 side) of the connecting portion 34U. In addition, a plurality of notches 38U that open to the other axial side (arrow Z2 side) are formed between the plurality of insulating portions 32U in the connecting portion 34U.

  The V-phase stator component 12V shown in FIG. 2B has the same basic configuration as the U-phase stator component 12U. That is, the V-phase stator component 12V includes a plurality of yoke components 22V, a plurality of teeth 24V, a plurality of cored bar contact portions 25V, a winding 16V, and an insulator 18V. Has been. The plurality of yoke components 22V, the plurality of teeth 24V, the plurality of cored bar contact portions 25V, the winding 16V, and the insulator 18V include the above-described plurality of yoke components 22U and the plurality of teeth. This corresponds to 24U, a plurality of cored bar contact portions 25U, a winding 16U, and an insulator 18U (all refer to FIG. 2A). Moreover, the convex part 78V and the recessed part 80V are corresponded to the above-mentioned convex part 78U and the recessed part 80U. In the V-phase stator constituting portion 12V, the connecting portion 34V is formed in a ring shape and has a smaller diameter than the above-described U-phase connecting portion 34U (see FIG. 2A). The holding portion 36V holds the connecting wire 28V from one axial side (arrow Z1 side) of the connecting portion 34V, and is positioned radially inward from the core constituting portion 14V.

  The basic configuration of the W-phase stator component 12W shown in FIG. 2C is the same as that of the U-phase stator component 12U. That is, the W-phase stator component 12W includes a plurality of yoke components 22W, a plurality of teeth 24W, a plurality of cored bar contact portions 25W, a winding 16W, and an insulator 18W. Has been. The plurality of yoke components 22W, the plurality of teeth 24W, the plurality of cored bar contact portions 25W, the winding 16W, and the insulator 18W include the above-described plurality of yoke components 22U and the plurality of teeth. This corresponds to 24U, a plurality of cored bar contact portions 25U, a winding 16U, and an insulator 18U (all refer to FIG. 2A). Moreover, the convex part 78W and the recessed part 80W are equivalent to the above-mentioned convex part 78U and the recessed part 80U. In the W-phase stator constituting portion 12W, the connecting portion 34W is formed in a ring shape and has a smaller diameter than the above-described V-phase connecting portion 34V (see FIG. 2B). Further, the above-described notch (see the notch 38U in FIG. 2A) is omitted from the connecting portion 34W. Further, the holding portion 36W holds the crossover wire 28W from the one axial side (arrow Z1 side) of the connecting portion 34W, and is positioned radially inward from the core constituting portion 14W.

  As shown in FIG. 1A, the plurality of stator constituent portions 12U, 12V, and 12W are assembled to each other and then held on the stator case 70 from the outer peripheral portion, as will be described in detail later. Is configured. Further, in the stator 10, an annular yoke 40 is formed by a plurality of yoke components 22U, 22V, 22W.

  Further, the convex portions 78U, 78V, 78W formed on each of the yoke components 22U, 22V, 22W constituting the yoke 40 are equally spaced along the circumferential direction when viewed from the axial direction of the yoke 40. Is arranged.

  Further, as shown in FIGS. 3A, 3B and 4A, the plurality of connecting portions 34U, 34V, 34W are arranged with a gap in the radial direction inside the yoke 40 in the radial direction, and the yoke 40 and the same axis. The V-phase holding portion 36V is fitted to the inner peripheral surface of the U-phase connecting portion 34U, and the W-phase holding portion 36W is fitted to the inner peripheral surface of the V-phase connecting portion 34V. Yes. Thus, the plurality of connecting portions 34U, 34V, 34W are held in a state of being separated from each other in the radial direction. That is, the holding portions 36U, 36V, and 36W are provided between the plurality of connecting portions 34U, 34V, and 34W in the radial direction and hold the plurality of connecting portions 34U, 34V, and 34W in a state of being radially separated from each other. It also serves as a spacer.

  Further, a cross section of a portion where the holding portion 36U and the notch 38U are not formed in the U-phase connecting portion 34U, a cross section of a portion where the holding portion 36V and the notch 38V are not formed in the V-phase connecting portion 34V, and W The cross-sectional shape and cross-sectional area of the portion where the holding portion 36W and the notch 38W are not formed in the phase coupling portion 34W are the same. As a result, the rigidity of the V-phase connecting part 34V is higher than the rigidity of the U-phase connecting part 34U, and the rigidity of the W-phase connecting part is higher than the rigidity of the V-phase connecting part 34V. Yes.

  Further, as described above, in the state where the plurality of connecting portions 34U, 34V, 34W are arranged with gaps in the radial direction of the yoke 40, the V-phase connecting wire 28V is connected to the U-phase connecting portion 34U. It passes through the inside of the formed notch 38U (accommodated in the notch 38U), and the W-phase connecting wire 28W is connected to the notch 38U formed in the U-phase connecting portion 34U and the V-phase It passes through the inside of the notch 38V formed in the connecting portion 34V (accommodated in the notch 38U and the notch 38V).

(Rotor 50)
As shown in FIG. 1A, the rotor 50 is disposed on the radially inner side of the stator 10, and is supported along a rotation shaft portion 52 that is rotatably supported around the axis line, and along the circumferential direction of the rotation shaft portion 52. The magnets 54S and 54N are disposed. Specifically, the rotating shaft portion 52 is formed by subjecting a rod-shaped steel material to surface treatment such as carburizing treatment, and the rotating shaft portion 52 is rotatably supported by a bearing member (not shown). Yes. Further, around the rotating shaft portion 52, S-pole magnets 54S and N-station magnets 54N are alternately arranged along the circumferential direction. The magnets 54 </ b> S and 54 </ b> N are fixed to the rotary shaft portion 52 via a support member 56.

(Manufacturing method of stator 10 and brushless motor 60)
Next, a method for manufacturing the stator 10 and the brushless motor 60 having the above-described configuration will be described.

  First, as shown in FIG. 2A, the core component 14U is integrated with the insulating portion 32U of the insulator 18U to form a U-phase subassembly 42U including the insulator 18U and a plurality of core components 14U. Similarly, as shown in FIG. 2B, the core constituent part 14V is integrated with the insulating part 32V of the insulator 18V to form a V-phase subassembly 42V composed of the insulator 18V and the plurality of core constituent parts 14V. 2C, the core component 14W is integrated with the insulating portion 32W of the insulator 18W to form a W-phase subassembly 42W including the insulator 18U and the plurality of core components 14V. In this way, the subassemblies 42U, 42V, and 42W are formed for each of the U phase, the V phase, and the W phase (subassembly forming step).

  Subsequently, as shown in FIG. 2A, the winding 16U is wound around each tooth portion 24U of the U-phase subassembly 42U from the outside in the radial direction by using a flyer device (not shown), and a plurality of windings are wound around the subassembly 42U. The U-phase stator constituting portion 12U in which the winding portion 26U is formed is formed.

  Similarly, as shown in FIG. 2B, a winding 16V is wound around each tooth portion 24V of the V-phase subassembly 42V from the outside in the radial direction using the above-described flyer device, and a plurality of turns are wound around the subassembly 42V. The stator component 12V of the V phase in which the portion 26V is formed is formed. Further, as shown in FIG. 2C, the winding 16W is wound around each tooth portion 24W of the W-phase subassembly 42W from the outside in the radial direction by using the above-described flyer device, and a plurality of winding portions are wound around the subassembly 42W. A W-phase stator constituting portion 12W formed with 26W is formed.

  At this time, as shown in FIG. 2A, the plurality of connecting wires 28U are wired along the outer peripheral surface of the connecting portion 34U. Further, the plurality of connecting wires 28U are held from the other axial side (arrow Z2 side) of the connecting portion 34U by the protruding holding portion 36U. Similarly, as shown in FIG. 2B, the plurality of connecting wires 28V are wired along the outer peripheral surface of the connecting portion 34V. Further, the plurality of connecting wires 28V are held from one side (arrow Z1 side) in the axial direction of the connecting portion 34V by the protruding holding portion 36V. Further, as shown in FIG. 2C, the plurality of crossover wires 28W are wired along the outer peripheral surface of the connecting portion 34W. Further, the plurality of connecting wires 28W are held from one axial side (arrow Z1 side) of the connecting portion 34W by the protruding holding portion 36W.

  Further, as shown in FIG. 2A, the terminal portions 30U on both ends of the winding 16U are led out from the teeth portion 24U to one axial side of the stator 10 (arrow Z1 side). Similarly, as shown in FIG. 2B, the terminal portions 30V on both ends of the winding 16V are led out from the teeth portion 24V to one side in the axial direction of the stator 10. Further, as shown in FIG. 2C, the end portions 30 </ b> W on both ends of the winding 16 </ b> W are led out from the teeth portion 24 </ b> W to one side in the axial direction of the stator 10. In this way, the stator components 12U, 12V, and 12W are formed for each of the U phase, V phase, and W phase (stator component forming step).

  Next, as shown in FIGS. 3A and 3B, the V-phase stator component 12V is shifted in the circumferential direction by a predetermined angle with respect to the W-phase stator component 12W. Is assembled to the W-phase stator constituting portion 12W from one axial side (arrow Z1 side). In addition, with the U-phase stator component 12U shifted from the V-phase stator component 12V by a predetermined angle in the circumferential direction, the U-phase stator component 12U is moved from one axial side (arrow Z1 side) to the V-phase stator component 12U. It is assembled to the stator component 12V of the phase and the stator component 12W of the W phase.

  At this time, the plurality of core components 14U, 14V, and 14W are arranged in an annular shape, and the inner peripheral ends of the plurality of yoke components 22U, 22V, and 22W are adjacent to both sides as shown in FIG. 2D. It contacts the inner peripheral ends of the pair of yoke components 22U, 22V, 22W (core arrangement step).

3A and 3B, the V-phase holding portion 36V is fitted to the inner peripheral surface of the U-phase connecting portion 34U, and the W-phase holding portion 36W is connected to the V-phase. It fits in the inner peripheral surface of the part 34V. In this way, the plurality of connecting portions 34U, 34V, 34W are held in a state of being radially separated from each other by the protruding holding portions 36U, 36V, 36W.

  Further, at this time, the V-phase connecting wire 28V is passed inside the notch 38U formed in the U-phase connecting portion 34U, and the W-phase connecting wire 28W is formed in the U-phase connecting portion 34U. It passes through the notch 38U and the notch 38V formed in the V-phase connecting portion 34V.

  Next, the process of integrating the stator case 70 and the stator core 20 (stator body 11) will be described.

  As shown in FIG. 5, the stator case 70 is disposed radially outside the stator core 20, that is, the stator case 70 is disposed along the yoke 40 of the stator core 20 (case arranging step). The inner diameter D1 (see FIG. 1A) of the stator case 70 before the plastic deformation portion 72 is formed is larger than the outer diameter D2 (see FIG. 1A) of the stator core 20, but the difference between D1 and D2 Is minute. Therefore, in FIG. 5, it appears that the inner diameter D1 of the stator case 70 and the outer diameter D2 of the stator core 20 coincide.

  Next, by inserting the variable core holding portion 102 of the core metal 100 into the inner peripheral side of the inner annular portion 41 of the stator core 20 and expanding the diameter of the variable core holding portion 102 as shown in FIGS. 6A and 6B, The outer peripheral surface of the variable core holding part 102 is brought into contact with the circular arc surface R of the cored bar contact parts 25U, 25V, 25W. Then, by further expanding the diameter of the variable core holding portion 102, the outer peripheral surface of the yoke 40 (the convex portions 78U, 78V, 78W formed on the yoke components 22U, 22V, 22W) is changed to the inner peripheral surface of the stator case 70. In contact with the core (core metal setting step). Note that the outer diameter of the variable core holding portion 102 when the variable core holding portion 102 is inserted into the inner annular portion 41 of the stator core 20 is sufficiently reduced corresponding to the inner diameter of the inner annular portion 41.

  Here, the configuration of the cored bar 100 will be briefly described. The cored bar 100 includes twelve variable core holding parts 102 arranged in an annular shape, and twelve arranged in an annular shape while supporting the variable core holding part 102. An upper holding portion 104 and a lower holding portion 106 that expand the diameter of the variable core holding portion 102 outward in the radial direction are configured as main elements. The outer peripheral surface of the variable core holding portion 102 is formed in a circular arc shape corresponding to the circular arc surface R of the cored bar abutting portions 25U, 25V, 25W, and the inner peripheral portion of the variable core holding portion 102 is the cam portion 102A. Has been. The upper holding portion 104 and the lower holding portion 106 are formed in a circular plate shape, and inclined surfaces 104A and 106A are formed on the outer peripheral portions of the upper holding portion 104 and the lower holding portion 106, respectively. . The cam portion 102A of the variable core holding portion 102 is held between the inclined surface 104A of the upper holding portion 104 and the inclined surface 106A of the lower holding portion 106. Further, a through hole is formed in the center portion in the circumferential direction of the upper holding portion 104 and the lower holding portion 106, and a shaft portion 108 is inserted into the through hole. Thereby, the upper holding part 104 and the lower holding part 106 can slide along the shaft part 108. The upper holding portion 104 and the lower holding portion 106 slide along the shaft portion 108, and the interval between the upper holding portion 104 and the lower holding portion 106 is narrowed, so that 12 variable core holdings arranged in an annular shape are held. It is the structure which the part 102 expands in diameter.

  A spring 110 is inserted through the shaft portion 108, and the spring 110 further biases the lower holding portion 104 toward the upper holding portion 106 side. Thereby, the variable core holding | maintenance part 102 is pressing the core structure parts 14U, 14V, and 14W with the predetermined pressing force F1. Further, when the pressing force input to the outer peripheral portion of the stator case 70 to form the plastic deformation portion 72 exceeds a predetermined value, the pressing force F1 (the spring 110 of the spring 110) is reduced so that the diameter of the variable core holding portion 102 is reduced. Initial) is set. A positioning jig 112 for positioning the variable core holding portion 102 with respect to the stator core 20 and the stator case 70 is attached to the shaft portion 108.

  Next, as shown in FIGS. 7 and 8, the stator case 70, the stator core 20, and the core metal 100 are set on the caulking jig 114.

  Here, the caulking jig 114 will be briefly described. The caulking jig 114 includes a cylindrical base portion 116 that supports the stator case 70, the stator core 20, and the core metal 100, and an upper end portion of the base portion 116 along the radial direction thereof. 12 punches 118 that are movably supported and arranged at equal intervals along the circumferential direction of the base portion 116, and a press portion 120 that moves the punch 118 radially inward of the base portion 116. Configured as an element. Twelve concave grooves (not shown) that are arranged at equal intervals along the circumferential direction and extend along the radial direction of the base portion 116 are formed in the upper end portion of the base portion 116. By accommodating the punch 118 in the concave groove, the punch 118 can slide in the radial direction of the base portion 116. Further, the punch 118 is formed in a rectangular block shape, and one end thereof is a contact portion that contacts the outer peripheral surface of the stator case 70. Further, as shown in FIG. 10B, the contact portion is provided with a pair of protrusions 118 </ b> A that protrude inward in the radial direction of the stator case 70 and the stator core 20 when viewed from the axial direction of the stator case 70 and the stator core 20. It has been. Further, the pair of protrusions 118A are recessed 80U, 80V formed in the protrusions 78U, 78V, 78W in a state of facing the protrusions 78U, 78V, 78W provided in the core components 14U, 14V, 14W. , 80W. As shown in FIGS. 7 and 8, the other end of the punch 118 is an inclined surface 118 </ b> B that is inclined toward one end (contact portion) side of the punch 118 toward the press portion 120 side. The press portion 120 is formed in a cylindrical shape, and a portion of the inner peripheral surface of the press portion 120 on the base portion 116 side is a tapered surface 120A that increases in diameter toward the base portion. The tapered surface 120A abuts on an inclined surface 118B formed at the other end of the punch 118, and the interval between the press portion 120 and the base portion 116 is narrowed, so that twelve punches are directed radially inward of the base portion 116. And slide.

  As shown in FIGS. 9, 10 </ b> A, and 10 </ b> B, the processing force F <b> 2 by the press machine is input to the press unit 120 and the protrusion 118 </ b> A of the punch 118 presses the outer peripheral portion of the stator case 70. Twelve plastic deformation portions 72 are formed at equal intervals along the circumferential direction of the stator case 70 on the outer periphery of the stator case 70. As a result, the portion of the stator case 70 where the plastic deformation portion 72 is formed is reduced in diameter, and the portion presses each of the core constituent portions 14U, 14V, and 14W. As a result, the stator case 70 and the stator core 20 (the stator body 11 (see FIG. 1B)) are integrated (caulking process).

  Here, in this embodiment, when forming the plastic deformation part 72 in the site | part which opposes the U phase yoke structure part 22U, the processing force F3 input into the stator case 70, the V phase yoke structure part 22V, The stator case 70 is formed when the plastic deformation portion 72 is formed at a portion facing the processing force F4 input to the stator case 70 when the plastic deformation portion 72 is formed at the opposite portion and the W-phase yoke component 22W. Is adjusted in accordance with the rigidity of the connecting portions 34U, 34V, 34W (see FIG. 1B) of the insulators 18U, 18V, 18W. Specifically, when the portion of the stator case 70 where the plastic deformation portion 72 is formed presses each of the core constituent portions 14U, 14V, 14W, the core constituent portions 14U, 14V, 14W are the same radially inward. F3, F4, and F5 are set to move the distance. More specifically, the processing force F4 is greater than the processing force F3 and the processing force F5 is greater than the processing force F4 in consideration of the reaction force caused by the deformation of the connecting portions 34U, 34V, 34W. Is set larger. In addition, what is necessary is just to determine these processing force F3, F4, F5 by performing calculation or trial manufacture.

  By using the processing forces F3, F4, and F5 described above, when the stator case 70 and the stator core 20 are integrated, the arrangement of the core components 14U, 14V, and 14W (stator components 12U, 12V, and 12W) Is suppressed, and as a result, the roundness of the stator core 20 (stator body 11) is improved. In other words, the stator case 70 in which the plastic deformation portion 72 is formed by applying the processing forces F3, F4, and F5 functions as an adjustment member that adjusts the roundness of the stator core 20 (stator body 11). Yes.

  Next, as shown in FIG. 11, the stator case 70, the stator core 20, and the core metal 100 are removed from the caulking jig 114. Then, by releasing the tension of the spring 110, the diameter of the variable core holding portion 102 is reduced, and the core metal 100 inserted through the stator core 20 is removed from the stator core 20.

  Through the above steps, the stator case 70 and the stator core 20 (stator body 11) are integrated to constitute the stator 10 described above. And the brushless motor 60 is manufactured by arrange | positioning a rotor inside the radial direction of the stator 10 (rotor arrangement | positioning process).

(Operation and effect of this embodiment)
Next, the operation and effect of this embodiment will be described.

  As shown in FIG. 1A, the brushless motor 60 of the present embodiment includes the rotor 50, the stator core 20 and the stator case 70 having the above-described configuration. When the winding 16 is energized and a rotating magnetic field is generated in the stator core 20 and the stator case 70, the rotor 50 having the magnets 54S and 54N rotates around the rotating shaft 52.

  Further, in the present embodiment, the stator core 20 is configured to include the yoke 40, the tooth portion 24, and the inner annular portion 41 configured as described above, and the stator core 20 is integrated with the stator case 70. Here, in the present embodiment, the surface on the rotor 50 side (the inner peripheral surface of the cored bar contact portions 25U, 25V, 25W) in the inner annular portion 41 is an arc surface R centering on the rotor 50. Yes. Therefore, the plastic deformation portion 72 can be formed on the outer peripheral portion of the stator case 70 in a state where the core metal 100 (see FIG. 5) corresponding to the inner diameter of the arcuate surface R is disposed on the radially inner side of the inner annular portion 41. It becomes. Thereby, even if the part in which the plastic deformation part 72 in the stator case 70 is formed presses the yoke 40 (convex part 78U, 78V, 78W) of the stator core 20, the roundness of the inner annular part 41 of the stator core 20 is increased. Kept.

  Further, in the present embodiment, the convex portions 78U, 78V, 78W formed on the yoke components 22U, 22V, 22W of the stator core 20 and the plastic deformation portion 72 formed on the outer peripheral portion of the stator case 70 face each other. Yes. Therefore, when the plastic deformation portion 72 is formed on the outer peripheral portion of the stator case 70, the portion where the plastic deformation portion 72 is formed in the stator case 70 and the convex portions 78U in the yoke components 22U, 22V, 22W of the stator core 20. , 78V, 78W, stress concentrates on the site. As a result, the degree of adhesion between the portion of the stator case 70 where the plastic deformation portion 72 is formed and the portion of the stator core 20 where the yoke portions 22U, 22V, and 22W are formed with the convex portions 78U, 78V, and 78W increases. The fixing force between the case 70 and the stator core 20 is improved.

  Moreover, in this embodiment, convex part 78U, 78V, 78W formed in the yoke structure part 22U, 22V, 22W is seen at equal intervals along the circumferential direction of the yoke 40 seeing from the axial direction of the yoke 40. The plastic deformation portions 72 formed in the stator case 70 are arranged at equal intervals along the circumferential direction of the yoke 40 when viewed from the axial direction of the yoke 40. Therefore, the yoke 40 is equally pressed against the stator case 70 along the circumferential direction.

  In summary, in the brushless motor 60 of the present embodiment, the roundness of the stator core 20 and the fixing force between the stator case 70 and the stator core 20 are improved.

  Further, in the present embodiment, the convex portions 78U, 78V, 78W formed on the yoke constituting portions 22U, 22V, 22W are arranged at portions facing the teeth portion 24. Therefore, the variable core holder 102 (see FIG. 5) can vertically support the pressing force input from the punch 118 through the stator case 70. Thereby, the adhesion degree of the site | part in which the plastic deformation part 72 in the stator case 70 was formed, and the site | part in which the convex part 78U, 78V, 78W in the yoke structure part 22U, 22V, 22W of the stator core 20 improved. As a result, in this embodiment, the fixing force between the stator case 70 and the stator core 20 can be further improved.

  Further, in the present embodiment, the number of plastic deformation portions 72 of an integer multiple of 3 or an integer multiple of 4 (12 (locations)) is formed on the outer peripheral portion of the stator case 70. Therefore, the support force of the stator core 20 by the stator case 70 can be made uniform along the circumferential direction of the stator case 70, and the punch 118 for forming the plastic deformation portion 72 is brought into contact with the outer peripheral portion of the stator case 70. This makes it easy to control the processing.

  In the present embodiment, the stator core 20 is divided into twelve core constituent portions 14U, 14V, and 14W, and twelve (placed) plastic deformation portions 72 are formed on the outer peripheral portion of the stator case 70. ing. Thereby, the support force of each core structure part 14U, 14V, 14W by the stator case 70 can be equalized.

  Further, in the method for manufacturing the stator 10 according to the present embodiment, a case arranging step of arranging the stator case 70 formed in a cylindrical shape having an inner diameter exceeding the outer diameter of the stator core 20 along the yoke 40 of the stator core 20 is performed. Therefore, the generation | occurrence | production of the burr | flash by the inner peripheral surface of the stator case 70 and the outer peripheral surface (convex part 78U, 78V, 78W) of the stator core 20 can be suppressed. Thereby, malfunctions, such as a motor lock and a circuit short, can be suppressed.

  Furthermore, as FIG. 6A-FIG. 11 show, in this embodiment, the above-mentioned cored bar setting process is passed. Then, a plurality of plastic deformation portions 72 are formed on the outer peripheral portion of the stator case 70, and a caulking process is performed in which the stator case 70 and the stator core 20 are integrated. Here, in the present embodiment, the outer peripheral surface of the variable core holding portion 102 and the arcuate surface R of the cored bar contact portions 25U, 25V, 25W are in contact with each other, that is, the inner annular portion is moved by the variable core holding portion 102. A plastic deformation portion 72 is formed on the outer peripheral surface of the stator case 70 in a state where the roundness of 41 (core metal contact portions 25U, 25V, 25W) is ensured. Therefore, even when an external force for forming the plastic deformation portion 72 is applied to the outer peripheral surface of the stator case 70, the roundness of the inner annular portion 41 is maintained.

  Further, in this embodiment, when an external force for forming the plastic deformation portion 72 on the outer peripheral surface of the stator case 70 is input from the punch 118, this external force is supported by the variable core holding portion 102 of the core metal 100. That is, when an external force for forming the plastic deformation portion 72 is applied to the outer peripheral surface of the stator case 70, the inner annular portion 41 of the stator core 20 does not shrink. As a result, the degree of adhesion between the portion of the stator case 70 where the plastic deformation portion 72 is formed and the yoke 40 (projections 78U, 78V, 78W) of the stator core 20 is increased, and the fixing force between the stator case 70 and the stator core 20 is increased. improves.

  In summary, in the stator manufacturing method of the present embodiment, the roundness of the stator core 20 and the fixing force between the stator case 70 and the stator core 20 can be improved.

  Further, in the present embodiment, the variable core holding part 102 is expanded after the outer peripheral surface of the variable core holding part 102 comes into contact with the arcuate surface R of the cored bar contact parts 25U, 25V, 25W. As the core holding portion 102 further expands in diameter, the outer peripheral surface (projections 78U, 78V, 78W) of the yoke 40 of the stator core 20 and the inner peripheral surface of the stator case 70 come into contact with each other. Then, the plastic deformation portion 72 is formed on the outer peripheral surface of the stator case 70 in a state where the outer peripheral surface (projections 78U, 78V, 78W) of the yoke 40 and the inner peripheral surface of the stator case 70 are in contact with each other. Thereby, the adhesion degree between the portion of the stator case 70 where the plastic deformation portion 72 is formed and the yoke 40 (projections 78U, 78V, 78W) of the stator core 20 is further increased. As a result, in this embodiment, the fixing force between the stator case 70 and the stator core 20 can be further improved.

  Furthermore, in this embodiment, the initial of the spring 110 is adjusted so that the diameter of the variable core holding portion 102 is reduced when the external force (pressing force) for forming the plastic deformation portion 72 on the outer peripheral surface of the stator case 70 exceeds a predetermined value. Is set. Thereby, in this embodiment, the stator case 70 and the stator core 20 can be integrated with a desired fixing force.

  Next, characteristic effects of the present embodiment will be described.

  As shown in FIG. 10A, in the present embodiment, when the portion of the stator case 70 where the plastic deformation portion 72 is formed presses each of the core constituent portions 14U, 14V, 14W, the connecting portions 34U, 34V, 34W. The processing forces F3, F4, and F5 are set in consideration of reaction force due to deformation (see FIG. 1B). Thereby, when the stator case 70 and the stator core 20 are integrated, the arrangement of the core constituent portions 14U, 14V, 14W (stator constituent portions 12U, 12V, 12W) is prevented from being disturbed, and consequently the stator core 20 (stator) The roundness of the main body 11) can be improved.

  In the present embodiment, the example in which the concave portions 80U, 80V, and 80W are formed in the convex portions 78U, 78V, and 78W of the yoke components 22U, 22V, and 22W has been described, but the present invention is not limited thereto. For example, as shown in FIG. 12A, the concave portions 80U, 80V, and 80W may not be formed in the convex portions 78U, 78V, and 78W. As described above, whether or not the concave portions 80U, 80V, and 80W are formed in the convex portions 78U, 78V, and 78W is appropriately set in consideration of the contact pressure between the convex portions 78U, 78V, and 78W and the stator case 70. do it.

  In the present embodiment, an example in which the plastic deformation portion 72 is formed on the outer peripheral portion of the stator case 70 using a punch having a pair of protrusions 118A has been described, but the present invention is not limited to this. . For example, as shown in FIG. 12B, the plastic deformation portion 72 is formed by pressing a punch 122 formed so as to be narrowed toward the tip side against a portion facing the recesses 80U, 80V, 80W in the stator case 70. It can also be set as the structure which carried out. In this case, the fixing force between the stator case 70 and the stator core 20 is further improved.

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

(Modification)
Next, a stator according to a modification of the above embodiment will be described. In addition, about the structure fundamentally similar to the structure of the said embodiment, the code | symbol same as the structure of embodiment described previously is attached | subjected, and the description is abbreviate | omitted.

  As shown in FIG. 4B, the stator according to this modification is characterized in that the rigidity of the connecting portions 34U, 34V, 34W of the insulators 18U, 18V, 18W is the same. Specifically, the U-phase connecting portion 34U having the largest inner diameter and outer diameter among the plurality of connecting portions 34U, 34V, 34W has a plate thickness (wall thickness) in the radial direction of T1. In addition, the width in the axial direction of the portion where the holding portion 36U and the notch 38U are not formed in the U-phase connecting portion 34U is W1.

  Furthermore, the radial thickness of the connecting portion 34V disposed on the radially inner side of the U-phase connecting portion 34U is set to a plate thickness T2 that is thinner than T1, and the holding portions 36V and 36V in the V-phase connecting portion 34V and The width in the axial direction of the portion where the notch 38V is not formed is a width W2 narrower than W1.

  Further, the radial thickness of the connecting portion 34W disposed on the radially inner side of the V-phase connecting portion 34V is set to a plate thickness T3 that is thinner than T2, and the holding portion 36W in the W-phase connecting portion 34W includes the holding portion 36W. The width in the axial direction of the portion not formed is a width W3 narrower than W2.

  As described above, the rigidity of each of the connecting portions 34U, 34V, 34W is made the same by adjusting the plate thicknesses T1, T2, T3 and the widths W1, W2, W3 of the connecting portions 34U, 34V, 34W. Yes.

  Moreover, in the said modification, the rigidity of each connection part 34U, 34V, 34W is made the same by adjusting plate | board thickness T1, T2, T3 and width W1, W2, W3 of connection part 34U, 34V, 34W. However, the rigidity of each of the connecting portions 34U, 34V, 34W can be made the same by other methods. For example, as in the second modification shown in FIG. 4C, adjustment is made so that the rigidity of each of the connecting portions 34U, 34V, 34W becomes the same by changing the material of each of the connecting portions 34U, 34V, 34W. You can also. In the second modification, as an example, the material of the U-phase connecting portion 34U is an aluminum alloy, the material of the V-phase connecting portion 34V is polyacetal, and the material of the W-phase connecting portion 34V is a polyamide synthetic fiber. Thus, the rigidity of each of the connecting portions 34U, 34V, 34W is adjusted. In other words, the rigidity of each of the connecting portions 34U, 34V, and 34W is adjusted by using a material having a lower Young's modulus for the connecting portion disposed radially inward.

  Further, as in the third modification shown in FIG. 4D, a rib 124 extending outward in the radial direction of the connecting portion 34U is provided at the end on the other axial side (arrow Z2 side) of the U-phase connecting portion 34U. And by providing a plurality of notches 126 on the outer peripheral portion of the W-phase connecting portion 34W, that is, by adjusting the cross-sectional shape of each connecting portion 34U, 34V, 34W, each connecting portion 34U, 34V, The stiffness of 34W can also be adjusted.

Further, as in the fourth modification shown in FIG. 4E, the inner and outer diameters of the connecting portions 34U, 34V, and 34W are made the same, and the connecting portions 34U, 34V, and 34W are adjacent to each other in the axial direction. In addition, by arranging the connecting sections 34U, 34V, and 34W to have the same cross-sectional shape, the rigidity of the connecting sections 34U, 34V, and 34W can be adjusted to be the same. Further, when the connecting portions 34U, 34V, 34W are arranged, the stator 10 can be reduced in the radial direction.

(Operation and effect of the modified example)
In the stator according to the above modification, the rigidity of the connecting portions 34U, 34V, and 34W of the insulators 18U, 18V, and 18W is the same. Therefore, as shown in FIG. The processing forces F3, F4, and F5 for forming the plastic deformation portion 72 can be the same processing force. Thereby, in this modification, the process control at the time of integrating the stator core 20 (stator main body 11) and the stator case 70 can be made easy.

  In the above modification, the configurations shown in FIGS. 4B to 4E are given in order to make the rigidity of the connecting portions 34U, 34V, and 34W of the plurality of insulators 18U, 18V, and 18W the same. The invention is not limited to this. Other methods may be used in order to make the rigidity of the connecting portions 34U, 34V, and 34W the same, and each connecting portion 34U, The stiffness of 34V and 34W may be the same.

  In the embodiment and the modification, the U-phase stator component 12U is supported by the connecting portion 34U, the V-phase stator component 12V is supported by the connecting portion 34V, and the W-phase stator component 12W is connected. Although the example supported by 34W has been described, the present invention is not limited to this. For example, one connecting portion may be configured to support the U-phase stator component 12U, the V-phase stator component 12V, and the W-phase stator component 12W. That is, the connecting portion may not be provided for each phase.

(Other manufacturing method of stator 10)
Next, another method for manufacturing the stator 10 will be described with reference to FIGS.

  In the manufacturing method shown in FIG. 13 and FIG. 14, in addition to the outer periphery of the stator case 70 from each punch 118 in consideration of the rigidity of the portion pressed by the punch 118 in the stator case 70 in the aforementioned caulking step. It is characterized in that the machining force to be adjusted is adjusted.

  As shown in FIG. 13, when the shape of the stator case 70 viewed from the axial direction is distorted in an elliptical shape, the outer peripheral portion of the stator case 70 is pressed from the major axis direction toward the radial inner side. The displacement of the pressed portion P1 is smaller than the displacement of the pressed portion P2 when the outer peripheral portion of the stator case 70 is pressed from the minor diameter direction toward the radial inner side. In other words, the rigidity of the part P1 in the major axis direction of the stator case 70 is higher than the rigidity of the part P2 in the minor axis direction of the stator case 70. Therefore, the processing force F6 that presses the portion P1 in the major axis direction of the stator case 70 is set larger than the processing force F9 that presses the portion P2 in the minor axis direction. Further, an intermediate portion between the major axis portion P1 and the minor axis direction portion P2 of the stator case 70 is adjusted so as to be pressed by the processing forces F7 and F8 which are smaller than the processing force F6 and larger than the processing force F9. Yes. The processing forces F6, F7, F8, and F9 are determined based on the shape data of the stator case 70.

  As shown in FIG. 14, when the thickness of the stator case 70 is not constant along the circumferential direction, the thickened portion of the stator case 70 is radially inward. The displacement of the pressed portion when pressed toward the surface is smaller than the displacement of the pressed portion when the thinned portion of the stator case 70 is pressed radially inward. In other words, the rigidity of the thickened portion of the stator case 70 is higher than the rigidity of the thinned portion of the stator case 70. For this reason, the processing force F6 for pressing the thickened portion of the stator case 70 is set larger than the processing forces F7, F8, and F9 for pressing the thinned portion. The processing forces F6, F7, F8, and F9 are determined based on the thickness data of each part of the stator case 70.

  In the manufacturing method shown in FIG. 15, the stator 10 is formed using a cored bar 128 that includes a sensor 130 that detects a contact pressure with the cored bar contact portions 25U, 25V, and 25W of the core components 14U, 14V, and 14W. Manufactured. First, the configuration of the cored bar 128 will be described. The cored bar 128 includes a base portion 132 formed in a columnar shape and twelve sensors 130 fixed to the outer peripheral portion of the base portion 132. Has been. The twelve sensors 130 are arranged at equal intervals along the circumferential direction of the base portion 132. The sensor 130 is a pressure sensor that outputs a signal when pressed inward in the radial direction of the base portion 132. After the above-described case arranging step, the above-described cored bar 128 is inserted inside the stator main body 11 in the radial direction, that is, through a region surrounded by the cored bar abutting portions 25U, 25V, and 25W (a cored bar setting step). ). Then, the protrusions 118 </ b> A of the punch 118 press the outer peripheral portion of the stator case 70, so that twelve plastic deformation portions 72 are formed at equal intervals along the circumferential direction of the stator case 70. (Caulking process). As a result, the portion of the stator case 70 where the plastic deformation portion 72 is formed is reduced in diameter, and the portion presses each of the core constituent portions 14U, 14V, 14W and the core of each of the core constituent portions 14U, 14V, 14W. The gold contact portions 25U, 25V, and 25W press the sensors 130, respectively. In the present embodiment, the processing forces F6, F7, F8, and F9 applied to the outer peripheral portion of the stator case 70 from the punch 118 are adjusted based on the output values of the sensors 130. As an example, in this embodiment, the processing forces F6, F7, F8, and F9 are adjusted so that the output values of the sensors 130 are the same.

As a reference example, in the manufacturing method shown in FIG. 16, in the above-described caulking process, the processing applied to the outer peripheral portion of the stator case 70 from each punch 118 in consideration of the arrangement of the core constituent portions 14U, 14V, 14W. It is characterized by the force being adjusted. Specifically, in the stator case 70, the processing force F <b> 5 input to the portion facing the core components 14 </ b> U, 14 </ b> V, 14 </ b> W that is offset radially outward from the reference circle S in the stator case 70 is the reference in the stator case 70. The machining force F3 is set to be larger than the processing force F3 input to the portion facing the core components 14U, 14V, and 14W that are offset radially inward from the circle S. In addition, the processing force F4 input to the part facing the core components 14U, 14V, and 14W having no offset amount with respect to the reference circle S in the stator case 70 is smaller than the processing force F5 and larger than the processing force F3. It is regarded as a large processing force.

  According to the manufacturing method described above, the processing force adjustment applied to the stator case 70 from the punch 118 in consideration of the rigidity of each part of the stator case 70, the output value from the sensor 130, and the arrangement of the core components 14U, 14V, 14W. By doing so, the roundness of the stator core 20 can be improved.

DESCRIPTION OF SYMBOLS 11 ... Stator main body, 14U ... Core component, 14V ... Core component, 14W ... Core component, 16U ... Winding, 16V ... Winding, 16W ... Winding, 18U ... Insulator, 18V ... Insulator, 18W ... Insulator, 22U ... yoke component, 22V ... yoke component, 22W ... yoke component, 24U ... teeth, 24V ... teeth, 24W ... teeth, 26U ... winding, 26V ... winding, 26W ... Winding part, 32U ... insulating part, 32V ... insulating part, 32W ... insulating part, 34U ... connecting part, 34V ... connecting part, 34W ... connecting part, 40 ... yoke, 128 ... cored bar, 130 ... sensor, F3 F4, F5, F6, F7, F8, F9 ... Machining force

Claims (8)

A plurality of yoke components constituting an annular yoke and divided in the circumferential direction of the yoke, and a plurality of teeth portions protruding from the yoke component toward the radially inner side of the yoke, respectively. And a plurality of winding parts wound around the teeth part, respectively, a plurality of windings constituting a plurality of phases, and integrated with each of the core constituent parts. A plurality of insulators having a plurality of insulating portions that insulate the teeth portion and the winding portion, and having a connecting portion formed in an annular shape and connecting the plurality of insulating portions and having the same rigidity. A stator body having
The stator body is formed in a cylindrical shape that covers the stator body from the outside in the radial direction, and the rigidity of the plurality of insulators and the plurality of yokes are respectively provided on the outer peripheral portion facing the plurality of yoke components. By applying a processing force corresponding to the rigidity of at least one of the rigidity of the parts facing the component part, a plastic deformation part is formed and integrated with the stator body, and by being integrated with the stator body A case for adjusting the roundness of the stator body;
Brushless motor with The brushless motor according to claim 1, wherein the rigidity of each of the connecting portions is made the same by adjusting a plate thickness and a width of each of the connecting portions. 2. The brushless motor according to claim 1, wherein a material having a lower Young's modulus is used for the connecting portion arranged on the radially inner side of the yoke so that the rigidity of each of the connecting portions is the same. . A rib protruding outward in the radial direction is provided on the connecting portion disposed on the radially outer side of the yoke, and a plurality of notches are provided on an outer peripheral portion of the connecting portion disposed on the radially inner side of the yoke. The brushless motor according to claim 1, wherein each of the connecting portions has the same rigidity. The inner and outer diameters of each of the connecting portions and the cross-sectional shape cut along the radial direction of the yoke are the same, and the connecting portions are arranged adjacent to each other in the axial direction of the yoke. The brushless motor according to claim 1, wherein each of the connecting portions has the same rigidity. A plurality of yoke components constituting an annular yoke and divided in the circumferential direction of the yoke, and a plurality of teeth portions protruding from the yoke component toward the radially inner side of the yoke, respectively. And a plurality of winding parts wound around the teeth part, respectively, a plurality of windings constituting a plurality of phases, and integrated with each of the core constituent parts. and having a plurality of insulating portions for insulating said winding portion and the tooth portion, is formed annularly and in a state in which a plurality of insulating portions coupled, having a connecting portion arranged adjacent in the radial direction A case arrangement step of arranging a case formed in a cylindrical shape having an inner diameter exceeding the outer diameter of the stator body having a plurality of insulators, on a radially outer side of the stator body;
At least the rigidity of the connecting portion of the plurality of insulators and the rigidity of the portion of the outer periphery of the case facing the plurality of yoke components at the portion of the outer periphery of the case facing the plurality of yoke components. A plastic deformation portion is formed on the outer periphery of the case by applying a processing force corresponding to any rigidity, and the case and the stator body are integrated, and the case and the stator body are integrated. A caulking step of adjusting the roundness of the stator body by
In the caulking step, a processing force that is weaker than the processing force applied to the portion of the core component that is connected to the connecting portion that is disposed on the inner side and that faces the yoke component is disposed on the outer side. A method of manufacturing a brushless motor that is added to a portion of the core component that is connected to the connecting portion and that faces the yoke component. A plurality of yoke components constituting an annular yoke and divided in the circumferential direction of the yoke, and a plurality of teeth portions protruding from the yoke component toward the radially inner side of the yoke, respectively. And a plurality of winding parts wound around the teeth part, respectively, a plurality of windings constituting a plurality of phases, and integrated with each of the core constituent parts. A plurality of insulators having a plurality of insulating portions that insulate the teeth portion and the winding portion, and having a connecting portion formed in an annular shape and connecting the plurality of insulating portions and having the same rigidity . A case arrangement step of arranging a case formed in a cylindrical shape having an inner diameter exceeding the outer diameter of the stator body having the outer side in the radial direction of the stator body;
At least the rigidity of the connecting portion of the plurality of insulators and the rigidity of the portion of the outer periphery of the case facing the plurality of yoke components at the portion of the outer periphery of the case facing the plurality of yoke components. A plastic deformation portion is formed on the outer periphery of the case by applying a processing force corresponding to any rigidity, and the case and the stator body are integrated, and the case and the stator body are integrated. A caulking step of adjusting the roundness of the stator body by:
A method for manufacturing a brushless motor. A plurality of yoke components constituting an annular yoke and divided in the circumferential direction of the yoke, and a plurality of teeth portions protruding from the yoke component toward the radially inner side of the yoke, respectively. The outer diameter of the stator body having a plurality of core constituent parts integrally having a plurality of winding parts wound around the teeth parts and constituting a plurality of phases. A case arranging step of arranging a case formed in a cylindrical shape of an inner diameter on a radially outer side of the stator body;
A cored bar setting step of inserting a cored bar provided with a sensor for detecting a contact pressure with each of the core constituent parts into a radially inner side of the stator body;
A plastic deformation portion is formed on the outer peripheral portion of the case by applying a processing force corresponding to the output value of the sensor to a portion of the outer peripheral portion of the case facing the plurality of yoke components, and the case and the case A caulking step of adjusting the roundness of the stator body by integrating the stator body and integrating the case and the stator body;
A method for manufacturing a brushless motor.

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