JP6661237B2 - Motor device - Google Patents

Description

  The present invention relates to a motor device having a rotating shaft that is rotated by supplying a drive current.

  2. Description of the Related Art Conventionally, as a drive source of a power window device or the like mounted on a vehicle such as an automobile, a motor device provided with a speed reduction mechanism that can obtain a large output while being small is used. Then, by operating an operation switch in the vehicle interior, the motor device is rotated forward or backward, and the window glass is raised and lowered. As such a motor device, for example, a technique described in Patent Document 1 is known.

  The motor device described in Patent Literature 1 includes a motor unit and a gear unit, and an armature shaft (rotary shaft) is rotatably housed inside a motor case (housing) forming the motor unit. A worm and a worm wheel forming a speed reduction mechanism are rotatably housed in a gear case (housing) forming a gear portion. Further, a connector member and a brush holder electrically connected to each other are provided between the motor case and the gear case. Then, a driving current is supplied from the external connector on the vehicle side to the brush holder via the connector member, and the armature shaft is rotated in a predetermined rotation direction.

  In addition, a plurality of conductive members formed by bending a plate material are arranged on the front side and the back side of the bottom wall forming the brush holder. Components (brushes, capacitors, choke coils, etc.) arranged on the front and back sides of the bottom wall are electrically connected to these conductive members by connection means such as soldering.

International Publication No. WO 2014/178329

  However, in the motor device described in Patent Literature 1, it is necessary to attach a conductive member having a predetermined shape to a predetermined location on each of the front side and the rear side of the bottom wall forming the brush holder. Further, since soldering and other places, that is, places to be electrically connected are located at various places along the axial direction of the brush holder, connection work such as soldering is also difficult. Therefore, there is a problem that it is difficult to assemble the brush holder using the automatic assembling apparatus. That is, in the motor device described in Patent Document 1 described above, it is necessary to assemble the brush holder manually by an operator, and there have been problems such as an increase in manufacturing cost and a decrease in yield.

  An object of the present invention is to provide a motor device including a brush holder that can be assembled by an automatic assembling apparatus.

According to one aspect of the present invention, there is provided a motor device including a rotating shaft that is rotated by supply of a driving current, wherein a commutator provided on the rotating shaft, a brush slidably contacting the commutator, and the brush And a component mounting wall provided on the brush holder and extending in a direction intersecting the axial direction of the rotary shaft, and a brush mounting portion on one side of the component mounting wall along the axial direction of the rotary shaft. A first wall on which the brush and other components are mounted, and a second wall provided on the other side of the component mounting wall along an axial direction of the rotating shaft, and electrically connects the brush and the other components to each other A second wall surface on which the conductive member to be mounted is mounted, and a connection portion provided between the brush and the conductive member and between the other component and the conductive member, and electrically connecting each other. And the connection portion is the second connection portion. Provided only on the same plane in side, the the second wall surface a plurality of the conductive member is mounted, said plurality of at least two of the conductive member is a power supply conductive member formed by bending a plate material, The component mounting wall is provided with a bearing mounting portion on which a bearing for rotatably supporting the rotating shaft is mounted, and the bearing mounting portion along a direction intersecting the axial direction of the rotating shaft of the power supply conductive member. On one side with respect to the center, the connection portion is disposed, and on the other side around the bearing mounting portion along a direction intersecting the axial direction of the rotating shaft of the power supply conductive member, a connection terminal is disposed, In an intermediate portion between the connection portion and the connection terminal of the power supply conductive member, a width direction intersecting a thickness direction of the intermediate portion is directed in an axial direction of the rotation shaft .

  In another aspect of the present invention, the brush and the other component are provided with connecting legs extending from the first wall surface side to the second wall surface side, and the conductive member has a penetrating hole through which the connecting leg penetrates. A hole is provided, and the connection portion is provided between the connection leg and the through hole.

  In another aspect of the present invention, the conductive member does not include a portion protruding from the second wall surface side toward the first wall surface side.

  In another aspect of the present invention, a connector-side connection terminal to which the drive current is supplied from an external connector is connected to the connection terminal, and a back surface along a direction in which the connector-side connection terminal of the connection terminal is connected. The part is in contact with the bearing mounting part.

  In another aspect of the present invention, a side wall extending in the axial direction of the rotating shaft is provided around the component mounting wall, and the brush and the other component intersect with the axial direction of the rotating shaft. The side wall is covered from the direction, and the side wall is mounted on a housing that rotatably houses the rotating shaft.

  According to the present invention, a brush and other components are mounted on the first wall surface of the component mounting wall, and a conductive member for electrically connecting the brush and other components to each other is mounted on the second wall surface of the component mounting wall, A connecting portion is provided for electrically connecting the conductive member with the conductive member and between the other component and the conductive member. The connecting portion is provided only on the same plane on the second wall surface side.

  Thus, the brushes and other components can be integrated on the first wall surface side, and the conductive members and the connection portions can be integrated on the second wall surface side. Therefore, the arrangement structure of parts and the like to be assembled to the brush holder can be simplified, and the brush holder can be assembled using an automatic assembling apparatus. Further, since the connecting portion to be electrically connected is provided only on the same plane on the second wall surface side, the connecting operation of the connecting portion can be performed by the automatic assembling apparatus. Therefore, the manufacturing cost of the brush holder can be reduced, and the yield can be improved.

It is a top view showing the motor device of the present invention. FIG. 2 is a plan view showing the connector member of FIG. 1 alone. FIG. 3 is a view of the connector member of FIG. 2 as viewed from an arrow A direction. It is a perspective view which shows the brush holder of FIG. 1 by itself. FIG. 5 is a view of the brush holder of FIG. 4 as viewed from the direction of arrow B. FIG. 5 is a view of the brush holder of FIG. 4 as viewed from the direction of arrow C. It is a figure explaining the 1st assembly process of a brush holder. It is a figure explaining the 2nd assembly process of a brush holder. It is a figure explaining the 3rd assembly process of a brush holder. It is a figure explaining the 4th assembly process of a brush holder. It is a figure explaining the 5th assembly process of a brush holder.

  Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

  1 is a plan view showing the motor device of the present invention, FIG. 2 is a plan view showing the connector member of FIG. 1 alone, FIG. 3 is a view of the connector member of FIG. Is a perspective view showing the brush holder of FIG. 1 alone, FIG. 5 is a view of the brush holder of FIG. 4 viewed from the direction of arrow B, FIG. 6 is a view of the brush holder of FIG. 7 is a diagram illustrating a first assembly process of the brush holder, FIG. 8 is a diagram illustrating a second assembly process of the brush holder, FIG. 9 is a diagram illustrating a third assembly process of the brush holder, and FIG. FIG. 11 is a diagram illustrating a fourth assembly process of the brush holder, and FIG. 11 is a diagram illustrating a fifth assembly process of the brush holder.

  A motor device 10 shown in FIG. 1 is used as a drive source of a power window device mounted on a vehicle such as an automobile, and drives a window regulator that raises and lowers a window glass. The motor device 10 is a motor with a speed reduction mechanism that is small in size and capable of large output, and is installed in a narrow space in a vehicle door. The motor device 10 includes a motor unit 20 and a gear unit 40. The motor unit 20 and the gear unit 40 are connected to each other by a plurality of fastening screws 11 to form a unit.

  The motor unit 20 includes a motor case (housing) 21 formed by pressing a steel plate made of a magnetic material into a bottomed cylindrical shape. The motor case 21 includes a pair of flat wall portions 21a facing each other and a pair of arc-shaped wall portions 21b facing each other, and has a substantially oval cross-sectional shape. That is, the thickness of the motor case 21 along the direction in which the flat wall portions 21a face each other (the depth direction in FIG. 1) is reduced, so that the motor portion 20 is formed into a flat shape and the motor device 10 is formed in a narrow space inside the door. It can be placed in Here, the gear case 41 also has a flat shape following the flat shape of the motor case 21. In addition, FIG. 1 shows only the flat wall portion 21a on the near side in the figure.

  A plurality of magnets 22 having a substantially arc-shaped cross section are fixed inside each arc-shaped wall portion 21b of the motor case 21. Inside each magnet 22, an armature 24 around which a coil 23 is wound is provided rotatably via a predetermined gap. A brush holder 60 is mounted on the opening side (the left side in FIG. 1) of the motor case 21, and the opening side of the motor case 21 is closed by the brush holder 60.

  An armature shaft (rotating shaft) 26 is fixed through the center of rotation of the armature 24. The armature shaft 26 is provided so as to cross both the motor unit 20 and the gear unit 40, and one side (the right side in FIG. 1) of the armature shaft 26 in the axial direction is disposed in the motor case 21. The other side in the direction (the left side in FIG. 1) is disposed in the gear case 41. That is, the armature shaft 26 is rotatably housed inside the motor case 21 and the gear case 41.

  A commutator 27 formed in a substantially cylindrical shape is provided at a substantially intermediate portion along the axial direction of the armature shaft 26 and at a position close to the armature 24. The commutator 27 rotates integrally with the armature shaft 26, and the end of the coil 23 wound around the armature 24 is electrically connected to the commutator 27.

  A plurality of brushes 28 held by a brush holder 60 are slid on the outer periphery of the commutator 27, and each brush 28 is pressed by a spring member 29 toward the commutator 27 at a predetermined pressure. By supplying a drive current to each brush 28 from an unillustrated in-vehicle controller, a rotational force (electromagnetic force) is generated in the armature 24, and the armature shaft 26 is rotated in a predetermined rotation direction.

  An annular sensor magnet 30 is fixed to a substantially intermediate portion along the axial direction of the armature shaft 26 and to the opposite side of the commutator 27 from the armature 24 side. The sensor magnet 30 has a plurality of polarities along the rotation direction of the armature shaft 26. The sensor magnet 30 is rotated integrally with the armature shaft 26, whereby the state of the magnetic flux lines with respect to the rotation sensor 55 disposed radially outside the sensor magnet 30 changes with the rotation of the armature shaft 26. I have.

  A worm 31 is provided on the other side of the armature shaft 26 in the axial direction than the sensor magnet 30. The worm 31 is formed in a substantially cylindrical shape, and is fixed to the armature shaft 26 by press fitting or the like. The worm 31 is meshed with a tooth portion 43 a (not shown in detail) of a worm wheel 43 rotatably accommodated in a gear case 41. Thus, the worm 31 is rotated in the gear case 41 by the rotation of the armature shaft 26, and the rotation is transmitted to the worm wheel 43. Here, the worm 31 and the worm wheel 43 form a speed reduction mechanism SD.

  The bottom side (the right side in FIG. 1) of the motor case 21 is formed in a stepped shape, and a small-diameter portion 21c having a smaller diameter than the main body of the motor case 21 is provided in this portion. A first bearing member 32 is provided on the small-diameter portion 21c. The first bearing member 32 rotatably supports one side of the armature shaft 26 in the motor case 21 in the axial direction.

  The gear section 40 includes a gear case (housing) 41 and a connector member 50. The opening (the front side in FIG. 1) of the gear case 41 is closed by a gear cover 42 formed in a substantially disk shape. The gear case 41 is formed into a predetermined shape by injection molding a resin material such as plastic, and is connected to the opening side of the motor case 21 via the fastening screws 11. That is, both the gear case 41 and the motor case 21 form an outer shell of the motor device 10.

  In the gear case 41, a worm 31 fixed to the armature shaft 26 and a worm wheel 43 having teeth 43a meshing with the worm 31 on the outer periphery are rotatably housed. Here, the worm 31 is formed in a spiral shape, and the teeth 43 a are gently inclined in the axial direction of the worm wheel 43. Thus, smooth power transmission from the worm 31 to the worm wheel 43 is enabled.

  An output member 43b is provided at the center of rotation of the worm wheel 43, and the output member 43b is connected to a window regulator so as to transmit power. That is, the rotation of the armature shaft 26 is reduced in speed by the speed reduction mechanism SD to increase the torque, and the increased torque is output from the output member 43b to the window regulator.

  A second bearing member 44 is provided in a portion corresponding to the other side of the armature shaft 26 in the gear case 41 in the axial direction. The second bearing member 44 rotatably supports the other side in the axial direction of the armature shaft 26 in the gear case 41.

  A connector member assembling hole 41a is provided on a side portion (upper side in FIG. 1) of the gear case 41. The connector member 50 is inserted and fixed in the connector member assembling hole 41a. The extending direction of the connector member assembling hole 41a, that is, the inserting direction of the connector member 50 is a direction orthogonal to both the extending direction of the armature shaft 26 and the extending direction of the output member 43b.

  Here, an O-ring 53 (see FIG. 3) as a sealing member is mounted between the connector member assembling hole 41a and the connector member 50, whereby rainwater or the like enters the connector member assembling hole 41a. Approach is blocked. The connector member 50 is firmly fixed to the gear case 41 by a plurality of fixing screws (not shown) without rattling.

  The gear case 41 is provided with three fixing portions 41d. These fixing portions 41d are arranged at predetermined intervals (approximately 120 degrees intervals) around the gear case 41 so as to surround the output member 43b. A fixing bolt (not shown) for fixing the motor device 10 in the door of the vehicle is attached to each fixing portion 41d. Thus, by providing the fixed portions 41d at predetermined intervals so as to surround the output member 43b, the motor device 10 is supported in a well-balanced manner in a narrow door. Therefore, even if a high load is applied to the motor device 10, it is possible to effectively prevent the motor device 10 from rattling inside the door.

  As shown in FIGS. 2 and 3, the connector member 50 is formed in a substantially L shape by injection molding a resin material such as plastic. The connector member 50 includes an assembling portion 51 to be assembled to the gear case 41, and a connector connecting portion 52 to which an external connector CN (see FIG. 1) is connected. The connector member 50 is electrically connected to the brush holder 60 and supplies a drive current from the external connector CN to the brush holder 60.

  The assembling portion 51 includes an assembling body 51a having a circular cross-sectional shape, and a cap portion 51b is provided around the assembling body 51a. The assembly main body 51a is adapted to be inserted into the connector member assembly hole 41a (see FIG. 1). The cap portion 51b is mounted on a cylindrical portion (not shown) formed near the connector member mounting hole 41a of the gear case 41.

  With the assembly main body 51a inserted into the connector member assembly hole 41a, an O-ring 53 is sandwiched between the assembly body 51a and the connector member assembly hole 41a. That is, the O-ring 53 is in close contact with both the connector member 50 and the gear case 41 while being elastically deformed. Here, a general-purpose rubber O-ring is used for the O-ring 53.

  On the opposite side (lower side in FIG. 2) of the assembly main body 51a from the connector connection part 52 side along the axial direction, a case part 51c formed in a substantially rectangular parallelepiped shape is integrally provided. The case portion 51c extends in the axial direction of the assembly main body 51a, and includes a substrate holding portion 51d and a terminal accommodating portion 51e. The board holding section 51d holds the sensor board 54, and protrudes from the terminal accommodating section 51e to a side opposite to the connector connecting section 52 side.

  The sensor substrate 54 is formed in a substantially rectangular shape, and a rotation sensor 55 (shaded portion) is mounted on the opposite side (lower side in FIG. 2) of the connector connecting portion 52 along the longitudinal direction. The rotation sensor 55 is disposed radially outside the sensor magnet 30 (see FIG. 1), and serves as a magnetic sensor that detects the direction of a magnetic flux line of the sensor magnet 30 and its change. Thus, the rotation sensor 55 detects the rotation state of the armature shaft 26 (see FIG. 1), that is, the rotation direction and the rotation speed of the armature shaft 26. Specifically, the rotation sensor 55 is a GMR sensor that includes a magnetoresistive element (MR element) as a sensor element and further applies a giant magnetoresistance effect phenomenon (Giant Magneto Resistance Effect).

  One side in the longitudinal direction of the four conductive members 56 for sensor (shaded portions) is electrically connected to the sensor substrate 54 by connection means such as soldering. On the other hand, the other sides in the longitudinal direction of the sensor conductive members 56 are exposed inside the connector connection portion 52 (not shown in detail). Thereby, the detection signal of the rotation sensor 55 is transmitted to the on-vehicle controller via each sensor conductive member 56 and the external connector CN.

  As shown in FIG. 3, a pair of connector-side driving conductive members 57 (shaded portions) are provided in the connector member 50 in addition to the sensor conductive members 56. The connector-side female terminal (connector-side connection terminal) FT provided at one longitudinal end of each connector-side drive conductive member 57 is housed in the terminal housing portion 51e. That is, these connector-side female terminals FT are provided on the distal end side along the insertion direction of the assembly main body 51a.

  On the other hand, a connector-side male terminal (not shown) is formed on the other end in the longitudinal direction of each connector-side drive conductive member 57, and each connector-side male terminal is connected to the inside of the connector connection portion 52. It is exposed to. As a result, a drive current is supplied to each connector-side drive conductive member 57 from the on-board controller via the external connector CN.

  As shown in FIGS. 4 to 11, the brush holder 60 is provided in the motor case 21 and the gear case 41, and is formed in a predetermined shape by injection molding a resin material such as plastic. The brush holder 60 includes a holder main body 61 and a bearing holding cylinder (bearing mounting portion) 62. Here, the connector member 50 is connected to the brush holder 60. Thus, a driving current for rotating the armature shaft 26 is supplied from the external connector CN to the brush holder 60 via the connector member 50. In FIGS. 4 to 11, the components (electronic components) mounted on the brush holder 60 are hatched in order to clarify the components.

  The holder main body 61 includes a first bottom wall 61a1 and a second bottom wall 61a2. These first and second bottom wall portions 61a1 and 61a2 are each formed in a flat plate shape, and the positions of the brush holder 60 in the axial direction are different from each other. That is, the first and second bottom wall portions 61a1 and 61a2 are stepped from each other. The projection shape of the first and second bottom wall portions 61a1 and 61a2 as viewed from the axial direction of the brush holder 60 is substantially oval. Thereby, the brush holder 60 can be mounted on the opening side (the left side in FIG. 1) in the motor case 21. The area S1 of the first bottom wall 61a1 is larger than the area S2 of the second bottom wall 61a2 (S1> S2), and the first bottom wall 61a1 is approximately 2 / 3 portion.

  A side wall portion (side wall) 61b is provided around the first and second bottom wall portions 61a1 and 61a2. The side wall portion 61b extends from the periphery of the first and second bottom wall portions 61a1 and 61a2 in the axial direction of the brush holder 60 (the armature shaft 26) (the lower side in FIG. 4). Here, the first and second bottom wall portions 61a1 and 61a2 constitute a component mounting wall according to the present invention, and the first and second bottom wall portions 61a1 and 61a2 are connected to the brush holder 60 (the armature shaft 26). ) Extends in a direction intersecting the axial direction.

  The side wall 61b provided around the second bottom wall 61a2 has a shorter length along the axial direction of the brush holder 60 than the side wall 61b provided around the first bottom wall 61a1. . Therefore, the first and second bottom wall portions 61a1 and 61a2 are stepped from each other, and the first bottom wall portion 61a1 is closer to the third bearing member (bearing) 65 than the second bottom wall portion 61a2. Are located.

  Further, a plurality of press-fit projections 61b1 are integrally provided on the side wall portion 61b. These press-fit projections 61b1 are press-fit into the motor case 21. As a result, the brush holder 60 is fixed to the motor case 21 without rattling in the radial direction of the armature shaft 26, and stabilizes the sliding contact of each brush 28 with the commutator 27 (see FIG. 1).

  The bearing holding cylinder 62 is provided integrally with the first bottom wall 61a1. The bearing holding cylinder 62 extends in a direction opposite to the direction in which the side wall 61b extends (upper side in FIG. 4). The axial length of the bearing holding cylinder 62 is substantially the same as the protruding length of the side wall 61b provided corresponding to the first bottom wall 61a1.

  The bearing holding cylinder 62 includes a pair of arc-shaped walls 62a and a pair of flat walls 62b. A bearing housing 62c is formed at the end of the bearing holding cylinder 62 opposite to the first bottom wall 61a1 along the axial direction. A third bearing member 65 that rotatably supports an axially intermediate portion of the armature shaft 26 (see FIG. 1) is mounted on the bearing housing 62c.

  The sensor magnet 30 (see FIG. 1) is disposed inside the bearing holding cylinder 62, and the connector-side female terminal FT (see FIG. 1) is provided on the flat wall 62b facing the connector member mounting hole 41a (see FIG. 1). 3) is in contact with the back surface BC (see FIG. 8) of each of the brush-side male terminals MT along the connection direction. Thus, the bearing holding cylinder 62 covers the periphery of the sensor magnet 30 and supports the back surface BC of each brush-side male terminal MT. Thus, when the connector-side female terminal FT (see FIG. 3) is connected to the brush-side male terminal MT, contact between the brush-side male terminal MT and the sensor magnet 30 is prevented, and the brush-side male terminal MT is prevented. The deformation of the mold terminal MT is prevented.

  Further, the flat wall 62b of the bearing holding cylinder 62 also functions as a partition wall provided between the sensor magnet 30 and the rotation sensor 55 (see FIGS. 2 and 3). This prevents wear powder of each brush 28 on the sensor magnet 30 from adhering to the rotation sensor 55 and the sensor substrate 54. Therefore, a decrease in the detection performance of the rotation sensor 55 is suppressed for a long time.

  As shown in FIG. 5, one side of the first and second bottom wall portions 61a1 and 61a2 along the axial direction of the armature shaft 26, that is, the first and second bottom wall portions 61a1 and 61a2 along the axial direction of the brush holder 60. A first wall surface 61c is formed on the side where the side wall portion 61b is provided (on the near side in FIG. 5). A varistor V, a pair of capacitors C, a pair of choke coils CC, and a PTC (Positive Temperature Coefficient) thermistor T are mounted on the first wall surface 61c corresponding to the first bottom wall portion 61a1.

  The first wall surface 61c corresponding to the second bottom wall portion 61a2 is provided with a pair of brush cases 61d and a pair of support pins 61e. The brush 28 is accommodated in each brush case 61d so as to be movable in the radial direction of the brush holder 60. A spring member 29 is mounted on each support pin 61e.

  Here, the varistor V, the capacitor C, the choke coil CC, and the PTC thermistor T each constitute another component (electronic component) in the present invention. The varistor V, the capacitor C, and the choke coil CC absorb the electric noise generated by the sliding contact of each brush 28 with the commutator 27, and prevent the electric noise from being radiated to the outside of the motor device 10. That is, the varistor V, the capacitor C, and the choke coil CC function as a noise prevention element. Further, the PTC thermistor T reduces the drive current flowing when the motor device 10 is overheated, thereby preventing the motor device 10 from being overheated. That is, the PTC thermistor T functions as a thermal protection element that protects the motor device 10 from heat.

  In this manner, the pair of brushes 28, the varistor V, the pair of capacitors C, the pair of choke coils CC, and the PTC thermistor T, which constitute the motor device 10, are concentrated only on the first wall surface 61c side. Are located. More specifically, as shown in FIG. 5, the plurality of components are provided in a state of being appropriately dispersed within a projection range of the first wall surface 61c along the axial direction of the brush holder 60. These components do not overlap in the axial direction of the brush holder 60. Therefore, the work of arranging the plurality of components on the first wall surface 61c can be performed more easily and reliably by using an automatic assembling apparatus (not shown).

  With a pair of brushes 28, a varistor V, a pair of capacitors C, a pair of choke coils CC, and a PTC thermistor T arranged on the first wall surface 61c, these components are as shown in FIG. Further, the brush holder 60 (armature shaft 26) is covered with a side wall 61b from a direction intersecting with the axial direction. That is, as shown in FIG. 11, when the brush holder 60 is viewed from the side, the plurality of components are hidden by the side wall 61b. As a result, the plurality of components arranged on the first wall surface 61c are accommodated inside the first and second bottom wall portions 61a1 and 61a2 and the side wall portion 61b, and are used when the brush holder 60 is transferred. In this case, it is possible to reliably prevent the plurality of components from being damaged.

  The pair of brushes 28 are each connected to the base end of a pigtail (conductive wire) 28a, and the tip end of each pigtail 28a is drawn out to the second wall surface 61f side of the first bottom wall portion 61a1, as shown in FIG. Have been. The varistor V, the capacitor C, the choke coil CC, and the PTC thermistor T are provided with a pair of connection legs LG1, LG2, LG3, and LG4, respectively. The distal ends of these connection legs LG1, LG2, LG3, LG4 are also drawn out toward the second wall surface 61f of the first bottom wall portion 61a1, as shown in FIG.

  However, one end of the connection leg LG2 of the capacitor C is directed toward the second wall surface 61f, but is drawn out of the side wall 61b (see FIG. 5). Thus, one connection leg LG2 of the capacitor C is electrically connected (grounded) to the motor case 21 with the brush holder 60 mounted on the motor case 21.

  As shown in FIG. 6, the other side of the first bottom wall portion 61a1 along the axial direction of the armature shaft 26, that is, the side on which the side wall portion 61b of the first bottom wall portion 61a1 along the axial direction of the brush holder 60 is provided. A second wall surface 61f is formed on the opposite side (on the front side in FIG. 6). And, on the second wall surface 61f, five conductive members 66, 67, 68, 69, 70 formed by press-forming a conductor such as brass are mounted. These conductive members 66, 67, 68, 69, and 70 extend from the first wall surface 61c side to the second wall surface 61f side (extracted) at the tip end side of the pigtail 28a and the connection legs LG1, LG2, LG3. It has a function of electrically connecting the LGs 4 to each other. Thus, an electric circuit for driving the motor device 10 is formed in the brush holder 60.

  A pair of conductive members 66 and 67 of the five conductive members are electrically connected to a pair of connector-side driving conductive members 57 (see FIG. 3) provided on the connector member 50 and are connected to the brush-side driving conductive members 57. A member (power supply conductive member) is formed. That is, the drive current from the external connector CN is supplied to the respective conductive members 66 and 67 via the respective connector-side drive conductive members 57.

  As shown in FIG. 8, each of the conductive members 66 and 67 is formed into a substantially similar crank shape by bending a plate material, and includes mounting portions 66a and 67a that are in surface contact with the second wall surface 61f. I have. Here, each of the mounting portions 66a and 67a does not include a portion protruding from the second wall surface 61f toward the first wall surface 61c. That is, each of the mounting portions 66a and 67a is in contact with the second wall surface 61f only on a flat surface. A brush-side male terminal MT is provided on the side opposite to the side where the mounting portions 66a, 67a are provided along the longitudinal direction of the conductive members 66, 67, respectively.

  Intermediate portions 66b, 67b are provided between the mounting portions 66a, 67a along the longitudinal direction of the conductive members 66, 67 and the brush-side male terminal MT, respectively. Here, the thickness direction of the intermediate portions 66b and 67b is directed in the radial direction of the brush holder 60. That is, the width direction of the intermediate portions 66b, 67b that intersects with the plate thickness direction of the intermediate portions 66b, 67b is oriented in the axial direction of the brush holder 60 (the armature shaft 26). This suppresses the brush holder 60 from increasing in size in the radially outward direction. The intermediate portions 66b and 67b are integrally provided with gripping pieces 66c and 67c which are gripped by a chuck (not shown) of the automatic assembling apparatus.

  In addition, between the intermediate portions 66b, 67b along the longitudinal direction of each of the conductive members 66, 67 and the brush-side male terminal MT, the back surface abutting on the flat wall 62b of the bearing holding cylinder 62 (see FIG. 6). Each part BC is provided. Thus, the insertion load F (see FIG. 6) of the connector member 50 is prevented from being transmitted to the mounting portions 66a, 67a, and an excessive force is applied to the connection portions CP1 to CP4 provided in the mounting portions 66a, 67a. I try not to hang.

  As shown in FIG. 6, mounting portions 66a, 67a (connecting portions CP1 to CP4) provided on one side in the longitudinal direction of each conductive member 66, 67 are bearings along a direction intersecting the axial direction of the armature shaft 26. It is arranged on one side around the holding cylinder 62, that is, on the first bottom wall 61a1 side (the lower side in FIG. 6). On the other hand, the brush-side male terminal (connection terminal) MT provided on the other side in the longitudinal direction of each of the conductive members 66 and 67 is centered on the bearing holding cylinder 62 along the direction intersecting the axial direction of the armature shaft 26. It is arranged on the other side, that is, on the second bottom wall 61a2 side (upper side in FIG. 6).

  Two connecting portions CP1 and CP2 are arranged on the mounting portion 66a of the conductive member 66. Further, two connection portions CP3 and CP4 are arranged on the mounting portion 67a of the conductive member 67. As shown in FIG. 6, the resin protrusions R corresponding to the respective mounting portions 66a and 67a are provided integrally with the brush holder 60, and the resin protrusions R are formed by using a heating jig (not shown). The conductive members 66 and 67 are fixed to the second wall surface 61f by heat caulking (crushing).

  The connection portion CP1 disposed on the mounting portion 66a is provided between one connection leg LG4 of the PTC thermistor T and a through hole H1 (see FIG. 8) provided in the conductive member 66, and each is electrically connected to each other. It is a part connected to. Specifically, the connection portion CP1 is formed by welding one of the connection legs LG4 by laser welding (see FIG. 11) with the connection leg LG4 penetrating the through hole H1 of the conductive member 66. However, the state of the connection parts CP1 to CP12 shown in FIGS. 4 and 6 shows a state before welding by laser welding. Then, after welding of the connection parts CP1 to CP12 by laser welding, the connection part WD becomes as shown by the broken line circle in FIG.

  The connection portion CP2 disposed on the mounting portion 66a is provided between one connection leg LG1 of the varistor V and a through hole H2 (see FIG. 8) provided in the conductive member 66, and each of them is Like the connection part CP1, the part is electrically connected by laser welding.

  The connection portion CP3 disposed on the mounting portion 67a is provided between one connection leg LG3 of one choke coil CC and a through hole H3 (see FIG. 8) provided in the conductive member 67, and each is connected to each other. , Are electrically connected by laser welding similarly to the connection part CP1. The connection portion CP4 disposed on the mounting portion 67a is provided between the other connection leg LG1 of the varistor V and the through hole H4 (see FIG. 8) provided in the conductive member 67, and each of them is Like the connection part CP1, the part is electrically connected by laser welding.

  As shown in FIGS. 6 and 7, a pair of conductive members 68 and 70 of the five conductive members are arranged outside the respective conductive members 66 and 67 around the bearing holding cylinder 62. Specifically, each of the conductive members 68 and 70 is disposed closer to the side wall 61b (see FIG. 5). Each of the conductive members 68 and 70 is formed into a substantially rectangular flat plate by pressing a plate material, and each of the conductive members 68 and 70 is formed on the second wall surface 61f on the first bottom wall portion 61a1 side. Are in surface contact. Here, each of the conductive members 68 and 70 also does not include a portion protruding from the second wall surface 61f toward the first wall surface 61c. That is, the conductive members 68 and 70 are in contact with the second wall surface 61f only on a plane.

  The conductive member 68 is provided with three connection portions CP5, CP6, and CP7. Further, three connection portions CP8, CP9, and CP10 are arranged on the conductive member 70. As shown in FIG. 6, the resin projections R corresponding to the conductive members 68 and 70 are provided integrally with the brush holder 60, and the resin projections R are caulked using a heating jig. Each conductive member 68, 70 is fixed to the second wall surface 61f.

  The connecting portion CP5 disposed on the conductive member 68 is provided between the tip end side of the pigtail 28a of one of the brushes 28 and the through hole H5 (see FIG. 7) provided on the conductive member 68. Like the connection part CP1, the part is electrically connected by laser welding. Further, the connection portion CP6 disposed on the conductive member 68 is provided between the other connection leg LG2 of one capacitor C and the through hole H6 (see FIG. 7) provided on the conductive member 68, and each of them is provided. These portions are electrically connected to each other by laser welding similarly to the connection portion CP1. Further, the connection portion CP7 disposed on the conductive member 68 is provided between one connection leg LG3 of the other choke coil CC and the through hole H7 (see FIG. 7) provided on the conductive member 68, and Are electrically connected to each other by laser welding similarly to the connection portion CP1.

  The connecting portion CP8 disposed on the conductive member 70 is provided between the tip end side of the pigtail 28a of the other brush 28 and the through hole H8 (see FIG. 7) provided on the conductive member 70. Like the connection part CP1, the part is electrically connected by laser welding. Further, the connection portion CP9 arranged on the conductive member 70 is provided between the other connection leg LG2 of the other capacitor C and the through hole H9 (see FIG. 7) provided on the conductive member 70, each of which is provided. These portions are electrically connected to each other by laser welding similarly to the connection portion CP1. Further, the connection portion CP10 arranged on the conductive member 70 is provided between the other connection leg LG3 of one choke coil CC and the through hole H10 (see FIG. 7) provided on the conductive member 70, and Are electrically connected to each other by laser welding similarly to the connection portion CP1.

  As shown in FIGS. 6 and 7, one of the five conductive members 69 is disposed between the conductive member 66 and the conductive member 68. Specifically, the conductive member 69 is formed into a substantially rectangular flat plate having a shorter length than the conductive members 68 and 70 by press-molding a plate material, and the conductive member 69 is formed of a first bottom wall portion 61a1. It is in surface contact with the second wall surface 61f on the side. Here, the conductive member 69 also has no portion protruding from the second wall surface 61f toward the first wall surface 61c. That is, the conductive member 69 is in contact with the second wall surface 61f only on a flat surface.

  Two connecting portions CP11 and CP12 are arranged on the conductive member 69. As shown in FIG. 6, the resin protrusions R corresponding to the conductive members 69 are provided integrally with the brush holder 60, and the resin protrusions R are thermally caulked using a heating jig to thereby form the conductive members 69. Is fixed to the second wall surface 61f.

  The connection portion CP11 disposed on the conductive member 69 is provided between the other connection leg LG3 of the other choke coil CC and the through hole H11 (see FIG. 7) provided on the conductive member 69, and each is connected to each other. , Are electrically connected by laser welding similarly to the connection part CP1. Further, the connection portion CP12 disposed on the conductive member 69 is provided between the other connection leg LG4 of the PTC thermistor T and the through hole H12 (see FIG. 7) provided on the conductive member 69, and each of them is mutually connected. , Are electrically connected by laser welding similarly to the connection part CP1.

  The conductive member 69 is integrally provided with a gripping piece 69a which is gripped by a chuck (not shown) of the automatic assembling apparatus. Here, the pair of conductive members 68 and 70 are not provided with gripping pieces. This is because each of the conductive members 68 and 70 is larger than the conductive member 69 and has a space that can be gripped by the chuck of the automatic assembly device.

  As shown in FIG. 7, between the first wall surface 61c and the second wall surface 61f on the first bottom wall portion 61a1 side, there are provided a plurality of communication holes HL that communicate between them. The connection legs LG1, LG2, LG3, and LG4 of the varistor V, the capacitor C, the choke coil CC, and the PTC thermistor T are inserted into these communication holes HL, respectively. Further, a pair of partition walls 71a and 71b are integrally provided on the second wall surface 61f on the first bottom wall portion 61a1 side. This reliably prevents a short circuit between adjacent conductive members. In addition, by providing the partition walls 71a and 71b, the distance between the adjacent conductive members can be reduced, which is advantageous in reducing the size of the brush holder 60.

  Next, the procedure for assembling the brush holder 60 formed as described above will be described in detail with reference to the drawings.

[First assembly process]
As shown in FIG. 7, first, three conductive members 68, 69, and 70 manufactured in different manufacturing steps are prepared, and a brush holder 60 in which the third bearing member 65 is assembled to the bearing housing portion 62c is prepared. . However, the third bearing member 65 may be assembled to the brush holder 60 after (last) the fifth assembling step.

  Then, the brush holder 60 is set on a base (not shown) of the automatic assembling apparatus. Here, as shown in FIG. 7, the brush holder 60 is set on the base so that the bearing holding cylinder 62 faces upward. Here, the base is provided with a plurality of positioning pins (not shown) that are inserted into a plurality of communication holes HL provided in the brush holder 60. Thereby, the brush holder 60 is accurately positioned without rattling on the base.

  Next, as shown by an arrow (1) in FIG. 7, each conductive member 68, 69, 70 faces the brush holder 60, and each conductive member 68, 69, 70 is moved to the first bottom wall 61a1 side. It is placed on each of the two wall surfaces 61f. Here, the work of placing each of the conductive members 68, 69, 70 on the second wall surface 61f is performed by a work robot (not shown). Here, since each of the conductive members 68, 69, and 70 is merely mounted on the second wall surface 61f located at the same height position, the mounting operation can be easily and accurately performed by the simple control of the work robot.

  As a result, the conductive members 68, 69, and 70 are accurately positioned by the positioning pins (not shown) and the resin protrusions R of the brush holder 60 as shown in FIG. Thereby, the first assembly process is completed.

[Second assembly process]
Next, as shown in FIG. 8, two conductive members (power supply conductive members) 66 and 67 manufactured in different manufacturing steps are prepared. Then, as shown by an arrow (2) in FIG. 8, the conductive members 66 and 67 are made to face the brush holder 60, and the conductive members 66 and 67 are placed on the second wall surface 61f on the first bottom wall portion 61a1 side. Put on. Here, the work of mounting the conductive members 66 and 67 on the second wall surface 61f is also performed by the same work robot as in the first assembly process.

  As described above, since each of the conductive members 66, 67 is merely mounted on the second wall surface 61f at the same height position as each of the conductive members 68, 69, 70, it is easily and accurately mounted by simple control of the work robot. Work can be done. As a result, the conductive members 66 and 67 are accurately positioned by the positioning pins (not shown) and the resin protrusions R of the brush holder 60 as shown in FIG. Thus, the second assembling step is completed.

[Third assembly process]
After that, as shown in FIG. 9, while the brush holder 60 is set on the same base as in the first and second assembling steps, heat caulking is performed by another work robot. Specifically, by controlling the work robot, a heating jig (not shown) is made to face the tip of the resin projection R as shown by an arrow (3) in FIG. The tip is heated and deformed. In this embodiment, the number of the resin protrusions R is seven in total.

  Thereby, the conductive members 66, 67, 68, 69, 70 are firmly fixed on the second wall surface 61f (on the same plane) on the first bottom wall portion 61a1 side of the brush holder 60 without rattling. Here, also in the work of fixing the conductive members 66, 67, 68, 69, and 70 on the second wall surface 61f, the position of the heating jig of the working robot is controlled at the same height position on the second wall surface 61f. The fixing work can be easily and accurately performed by simple control of the work robot. Thereby, the third assembling step is completed.

[Fourth assembly process]
Next, as shown in FIG. 10, the brush holder 60 is moved from the base used in the first to third steps to a base (not shown) for the fourth step. At this time, the brush holder 60 is set on the base of the fourth step so that the bearing holding cylinder 62 faces downward. Thereafter, as shown by an arrow (4) in FIG. 10, by controlling the work robot, a pair of brushes is attached to the first wall surface 61c (see FIG. 5) of the first bottom wall portion 61a1 and the second bottom wall portion 61a2. 28, a pair of spring members 29, a varistor V, a pair of capacitors C, a pair of choke coils CC, and a PTC thermistor T are respectively mounted.

  Thereby, as shown in FIG. 5, the plurality of components are accurately mounted at predetermined locations on the first wall surface 61c. Thereby, the fourth assembling step is completed.

[Fifth assembly process]
Thereafter, as shown in FIG. 11, the brush holder 60 is moved from the base used in the fourth step to a base (not shown) for the fifth step. At this time, the brush holder 60 is set on the base of the fifth step so that the bearing holding cylinder 62 faces upward. Thereafter, the work robot is controlled to move the processing head (torch) 81 of the laser welding machine 80 as shown by the dashed arrow M in FIG. 11 to form a total of 12 connection portions CP1 to CP12. .

  Here, the laser welding machine 80 includes an oscillator 82 for generating a YAG (yttrium, aluminum, garnet) laser, and a flexible optical fiber 83 is provided between the oscillator 82 and the processing head 81. . Thereby, the laser beam L of high energy is irradiated from the processing head 81 onto the second wall surface 61f of the brush holder 60, and the connection portions CP1 to CP12 can be quickly formed under the same conditions.

  The irradiation time of the laser beam L required to form one connection portion is generally set to 0.1S to 0.2S, though it depends on the energy amount of the laser beam L. Therefore, the time can be greatly reduced as compared with the case of performing soldering or the like. As shown in FIG. 11, the connection portions CP1 to CP12 are provided only on the same plane on the second wall surface 61f side of the first bottom wall portion 61a1. Therefore, the work robot does not need to control the height of the processing head 81 (movement in the vertical direction in FIG. 11).

  Therefore, the connection operation can be performed while the distance S between the processing head 81 and the connection portions CP1 to CP12 is kept constant and the energy amount of the laser beam L is not changed. Therefore, the connection operation can be easily and accurately performed by the simple control of the work robot, and the connection portions CP1 to CP12 can be changed to the connection portions WD with no variation and beautiful appearance as shown by the dashed circles. . Thus, the fifth assembling step is completed, and the brush holder 60 is completed.

  As described in detail above, according to the motor device 10 of the present embodiment, the brush 28, the varistor V, the capacitor C, and the choke coil CC are provided on the first wall surface 61c of the first and second bottom wall portions 61a1 and 61a2. , A PTC thermistor T, and conductive members 66 to 70 for electrically connecting the brush 28, the varistor V, the capacitor C, the choke coil CC, and the PTC thermistor T to each other on the second wall surface 61f of the first bottom wall portion 61a1. The connecting portions CP1 to CP12 are provided between the conductive members 66 to 70 and mounted between the brush 28, the varistor V, the capacitor C, the choke coil CC, the PTC thermistor T and the conductive members 66 to 70, and these connecting portions are provided. CP1 to CP12 are provided only on the same plane on the second wall surface 61f side.

  Thereby, the brush 28, the varistor V, the capacitor C, the choke coil CC, and the PTC thermistor T are integrated on the first wall surface 61c side, and the conductive members 66 to 70 and the connection portions CP1 to CP12 are integrated on the second wall surface 61f side. be able to. Therefore, the arrangement structure of components and the like to be assembled to the brush holder 60 can be simplified, and the brush holder 60 can be assembled using an automatic assembling apparatus. Further, since the connection portions CP1 to CP12 to be electrically connected are provided only on the same plane on the second wall surface 61f side, the connection work of the connection portions CP1 to CP12 can also be performed by the automatic assembling apparatus. Therefore, the manufacturing cost of the brush holder 60 can be reduced, and the yield can be improved.

  Further, according to motor device 10 of the present embodiment, since conductive members 66 to 70 do not include a portion protruding from second wall surface 61f toward first wall surface 61c, conductive members 66 to 70 are not provided. The operation of mounting the brush holder 70 on the brush holder 60 does not have to be complicated. Therefore, from this point as well, the structure is advantageous for assembling with the automatic assembling apparatus.

  Furthermore, according to motor device 10 according to the present embodiment, in the intermediate portions 66b, 67b of the conductive members 66, 67, the width direction intersecting the plate thickness direction of the intermediate portions 66b, 67b is defined by the axis of the armature shaft 26. Orientation. Thereby, the conductive members 66 to 70 and the connection portions CP1 to CP12 can be integrated on the second wall surface 61f side while keeping the physical size of the brush holder 60 the same as the conventional one.

  Further, according to motor device 10 according to the present embodiment, back surface BC of brush-side male terminal MT along the direction in which connector-side female terminal FT is connected to flat wall 62 b of bearing holding cylinder 62. Touched. Thereby, the connection parts CP1 to CP4 provided on the mounting parts 66a and 67a are prevented from being subjected to excessive force, and the occurrence of poor current supply and the like can be reliably prevented, and the yield can be improved.

  Further, according to motor device 10 of the present embodiment, brush 28, varistor V, capacitor C, choke coil CC, and PTC thermistor T are covered by side wall portion 61b from a direction intersecting the axial direction of armature shaft 26. Therefore, the plurality of components arranged on the first wall surface 61c can be accommodated inside the first and second bottom wall portions 61a1 and 61a2 and the side wall portion 61b. Therefore, it is possible to reliably prevent the plurality of components from being damaged when the brush holder 60 is transported.

  The present invention is not limited to the above embodiment, and it goes without saying that various changes can be made without departing from the scope of the invention. For example, in the above embodiment, the motor device 10 is used as a drive source of a power window device mounted on a vehicle. However, the present invention is not limited to this, and another drive source such as a sunroof device is used. Can also be used.

  In addition, the materials, shapes, dimensions, numbers, installation locations, and the like of the components in the above embodiment are arbitrary as long as the present invention can be achieved, and are not limited to the above embodiment.

DESCRIPTION OF SYMBOLS 10 Motor apparatus 11 Fastening screw 20 Motor part 21 Motor case (housing)
21a Flat wall portion 21b Arc-shaped wall portion 21c Small diameter portion 22 Magnet 23 Coil 24 Armature 26 Armature shaft (rotary shaft)
27 commutator
28 brush 28a pigtail 29 spring member 30 sensor magnet 31 worm 32 first bearing member 40 gear part 41 gear case (housing)
41a Connector member assembling hole 41d Fixed portion 42 Gear cover 43 Worm wheel 43a Tooth portion 43b Output member 44 Second bearing member 50 Connector member 51 Assembling portion 51a Assembling body 51b Cap portion 51c Case portion 51d Board holding portion 51e Terminal accommodating portion 52 Connector connection part 53 O-ring 54 Sensor board 55 Rotation sensor 56 Sensor conductive member 57 Connector-side drive conductive member 60 Brush holder 61 Holder body 61a1 First bottom wall (part mounting wall)
61a2 Second bottom wall (part mounting wall)
61b Side wall (side wall)
61b1 Press-fit projection 61c First wall surface 61d Brush case 61e Support pin 61f Second wall surface 62 Bearing holding cylinder (bearing mounting part)
62a arc-shaped wall 62b plane wall 62c bearing housing portion 65 third bearing member (bearing)
66, 67 conductive member (power supply conductive member)
68-70 Conductive member 66a, 67a Mounting part 66b, 67b Intermediate part 66c, 67c, 69a Gripping piece 71a, 71b Partition wall 80 Laser welding machine 81 Processing head 82 Oscillator 83 Optical fiber BC Back part C Capacitor (other parts)
CC choke coil (other parts)
CN external connector CP1-CP12 connection part FT female terminal on connector side (connector terminal on connector side)
H1 to H12 Through hole HL communication hole L Laser beam LG1 to LG4 Connection leg MT Male terminal on brush side (connection terminal)
R Resin protrusion SD Reduction mechanism T PTC thermistor (other parts)
V Varistor (other parts)
WD connection (after welding)

Claims (5)

A motor device having a rotating shaft that is rotated by supplying a driving current,
A commutator provided on the rotating shaft;
A brush that slides on the commutator;
A brush holder for holding the brush,
A component mounting wall provided on the brush holder and extending in a direction intersecting an axial direction of the rotation shaft;
A first wall surface provided on one side of the component mounting wall along the axial direction of the rotating shaft, on which the brush and other components are mounted;
A second wall surface provided on the other side of the component mounting wall along the axial direction of the rotating shaft, on which a conductive member that electrically connects the brush and the other component to each other is mounted;
A connection portion that is provided between the brush and the conductive member and between the other component and the conductive member, and electrically connects each other,
Has,
The connection portion is provided only on the same plane on the second wall surface side ,
A plurality of the conductive members are mounted on the second wall surface, and at least two of the plurality of the conductive members are power supply conductive members formed by bending a plate material,
The component mounting wall is provided with a bearing mounting portion on which a bearing that rotatably supports the rotating shaft is mounted,
On one side around the bearing mounting portion along the direction intersecting the axial direction of the rotating shaft of the power supply conductive member, the connection portion is disposed,
A connection terminal is disposed on the other side of the power supply conductive member around the bearing mounting portion along a direction intersecting the axial direction of the rotating shaft,
In an intermediate portion between the connection portion and the connection terminal of the power supply conductive member, a width direction intersecting a thickness direction of the intermediate portion is directed in an axial direction of the rotation shaft .
Motor device. The motor device according to claim 1,
The brush and the other component are provided with connecting legs extending from the first wall surface side to the second wall surface side,
The conductive member is provided with a through hole through which the connection leg penetrates,
The connection portion is provided between the connection leg and the through hole,
Motor device. In the motor device according to claim 1 or 2,
The conductive member does not include a portion protruding from the second wall surface side toward the first wall surface side,
Motor device. The motor device according to any one of claims 1 to 3 ,
A connector-side connection terminal to which the drive current is supplied from an external connector is connected to the connection terminal,
A back portion of the connection terminal along the direction in which the connector-side connection terminal is connected is in contact with the bearing mounting portion,
Motor device. In the motor device according to any one of claims 1 to 4 ,
Around the component mounting wall, a side wall extending in the axial direction of the rotating shaft is provided,
The brush and the other component are covered by the side wall from a direction intersecting the axial direction of the rotation shaft,
The side wall is mounted on a housing that rotatably houses the rotation shaft,
Motor device.

Images