JP7078950B2 - Motor actuator - Google Patents

Description

The present invention relates to, for example, a motor actuator for operating a ventilation path switching door in a vehicle air conditioner.

As a motor actuator of this type, for example, Patent Document 1 describes a motor having a power supply terminal as a drive source, a connector-side terminal arranged at an insertion port of an external connector to supply external power to the motor, and this connector. A pair of power feeding terminals that are connected to the side terminals and come into contact with the power feeding terminals of the motor in a state where elastic force is applied are described. As a result, external power can be supplied to the power supply terminal of the motor and the brush connected to the power supply terminal, and when the motor operates, the blow path switching door connected to the motor actuator operates.

Japanese Unexamined Patent Publication No. 2012-90510

However, in the motor actuator described in Patent Document 1, since the power supply terminal is in contact with the power supply terminal of the motor in a state where elastic force is applied, the power supply terminal and the power supply terminal are in contact with each other due to the vibration of the motor itself or the vehicle. There is a possibility that contact failure is likely to occur at the contact portion of the electric vehicle, the contact reliability is lowered, and a chattering noise is generated, which may cause a problem especially in an electric vehicle in which quietness is required.
In addition, there are a plurality of current path connections for supplying external power to the brush, which tends to cause manufacturing defects.

Therefore, the present invention provides a motor actuator that eliminates chattering noise and enhances contact reliability.

The motor actuator of the present invention is
A motor case, a bracket mounted on the motor case , a rotor having a commutator, a rotating shaft pivotally supported by the motor case and the bracket, a power feeding terminal, and a brush in sliding contact with the commutator . With a motor,
A housing consisting of a lower case and an upper case that internally support the motor is provided.
The power supply terminal is made of a single component made of a seamless wire or plate made of a metal material.
The housing has side plates
The side plate is provided with an insertion port for an external connector.
The motor-side end of the power feeding terminal is arranged in the motor and is insert-molded into the bracket while being directly fixed to the brush provided on the motor .
The insertion port side end of the power supply terminal is arranged at the insertion port.
The power feeding terminal is characterized by being a seamless wire or plate from the motor side end to the insertion port side end .

In the connection structure of the power supply terminal of the motor used for the motor actuator, the power supply terminal and the power supply terminal consist of one part made of a seamless wire or plate material made of metal material, and this part is inserted into the bracket while being connected to the brush. Since it is molded, contact reliability is improved, chattering noise is not generated, and quietness is enhanced.
In addition, the connection part of the current path for supplying external power to the brush is one place of the power supply terminal and the brush, so that manufacturing failure is unlikely to occur.

It is a finished product excluding the upper case of the motor actuator 1a according to the first embodiment of the present invention, (a) is a plan view thereof, and (b) is the cutting line AA of (a). It is a sectional view. FIG. 1 is a cross-sectional view of the motor 30 according to FIG. 1, (a) is a cross-sectional view thereof, and (b) is a cross-sectional view of the cutting line BB of (a). It is a finished product excluding the upper case of the motor actuator 1b according to the second embodiment of the present invention, (a) is a plan view thereof, and (b) is the cutting line CC of (a). It is a sectional view. 3 is the motor 130 shown in FIG. 3, where FIG. 3A is a cross-sectional view thereof, and FIG. 3B is a cross-sectional view taken along the cutting line DD of FIG.

In the present specification, the direction parallel to the rotation axis 34a of FIGS. 1 to 4 is referred to as "axial direction", and the radial direction centered on the rotation axis is simply referred to as "diameter direction". 2 (a), FIG. 3 (a), FIG. 4 (a), the upward direction is referred to as "upward", the downward direction is referred to as "downward", and the upper and lower cases of FIGS. 1 (b) and 3 (b). The embedding direction is called "embedding direction".
It should be noted that the vertical direction does not indicate the positional relationship or direction when incorporated into an actual device.

Hereinafter, embodiments of the present invention will be exemplified below with reference to the drawings.

(Example of the first embodiment)
The motor actuator of the present invention is shown in FIG. 1, and is used, for example, as a drive source for an air flow control valve of an air control device.

The motor actuator 1a includes a lower case 10, an upper case (not shown), a motor 30, a reduction gear 50, an output shaft 60, and a rotation angle detector 70.

The lower case 10 has a substantially quadrilateral bottom plate 11, a side plate 12 erected from the peripheral edge of the bottom plate 11, and an open end formed by the side plate 12.
The upper case has a substantially quadrilateral upper plate, side plates laid down from the periphery of the upper plate, and an open end formed by the side plates.
The open end of the upper case is incorporated into the lower case 10 to form a housing having a predetermined internal space. A motor 30, a reduction gear 50, an output shaft 60, and a rotation angle detector 70 are arranged in this housing.
Further, the lower case 10 is formed with a recess 11a for inserting and fixing the motor 30, and the upper case is formed with a recess (not shown) for inserting and fixing the motor 30.

One of the side plates of the housing is formed with an insertion port 37 for one external connector protruding from the side plate. The insertion port 37 has a tubular portion 37a and an upper portion 37b. The open end of the tubular portion 37a protrudes outward and inward from the side plate of the housing, respectively, and the upper portion 37b is integrally formed at the open end protruding inward of the housing. A connector (not shown) is inserted into the insertion port 37 from an external device. When the connector is inserted into the insertion port 37, the external device is electrically connected to the power supply terminal 38 and the sensor terminal 72a provided in the insertion port 37, which will be described later.

Further, the insertion port 37 is formed in a side plate 12 facing the bracket 32 described later of the motor 30. The side plate 12 is formed in the direction perpendicular to the axial direction. Further, the insertion port 37 and the motor 30 are arranged so as not to overlap with each other in the axial direction of the motor. Further, the insertion direction of the insertion port 37 is parallel to the axial direction of the motor. Further, the axial height of the lower end of the upper portion 37b is formed to be substantially the same as the axial height of the lower end of the bracket 32.

The motor 30, which is shown in FIG. 2, has a motor case 31, a bracket 32, a stator 33, a rotor 34, a brush 36, and a power supply terminal 38, and includes a lower case 10 and an upper case. It is inserted into the recess and fixed.

The motor case 31 is made of a metal material, is composed of a cylindrical portion 31a and an upper plate 31b, and a radial bearing 31c is press-fitted into the central portion of the upper plate 31b.
The bracket 32 is fitted into the opening of the motor case 31 and integrally molded with an insulating material such as resin. A circular recess 32a is formed in the central portion of the bracket 32, and the bottom surface of the recess 32a is a thrust bearing 32b. A radial bearing 32c is press-fitted into the recess 32a. The outer diameter of the bracket 32 is substantially the same as the inner diameter of the cylindrical portion 31a.

The stator 33 is fixed to the inner peripheral surface of the cylindrical portion 31a of the motor case, and is formed of a permanent magnet having a cylindrical shape and having N poles and S poles alternately magnetized along the circumferential direction.
The rotor 34 includes a rotating shaft 34a, an armature core 34b attached to the rotating shaft 34a and having a plurality of thin steel plates laminated, a copper wire 34c coiled around the armature core 34b, and copper. It has a commutator 34d, which is electrically connected to the wire 34c.
The rotary shaft 34a is inserted through the radial bearings 31c and 32c and rotatably supported. One end of the rotating shaft 34a protrudes from the motor case 31 and the worm gear 35 is fixed, and the other end is supported by a thrust bearing 32b.

Further, side plates are arranged in close proximity to the axial tip of the worm gear 35 and the lower end of the bracket 32.

The bracket 32 is provided with a pair of brushes 36 so as to be in sliding contact with the commutator 34d and allow a current to flow. The brush 36 is formed entirely in an L shape by a conductive elastic material such as copper or a copper alloy, and one end of the brush is fixed to the bracket 32 with the center of the rotation axis as point symmetry. The other end is in sliding contact with the rectifier 34d.

The power supply terminal 38 is an elongated wire or plate made of a metal material, and is provided in accordance with the two brushes 36, respectively. The power feeding terminal 38 of this example is formed of a wire having a square cross section, but the cross-sectional shape is not limited to this. Further, the power feeding terminal 38 of this example may be formed of a plated wire having a plating treatment on the surface of the core material thereof.

The power supply terminal 38 is provided with a motor connection portion 38a, an intermediate portion 38b, and an external connection portion 38c in order from one end (motor side) to the other end (insertion port side), and these are processed for forming or the like. As a result, the seamless wire rod is integrally formed into a predetermined shape to form one component. That is, the power supply terminal 38 is not a component in which two or more components are connected and integrated.

Further, the power supply terminal 38 self-holds a predetermined shape as long as no external force is applied after processing such as forming.

Next, in FIG. 1A, the power supply terminal 38 will be specifically described.
The intermediate portion 38b is arranged parallel to the side plate on which the bracket 32 faces.
The motor connection portion 38a is a curved line that is bent three times at a substantially right angle from the intermediate portion 38b toward the motor side. Specifically, the motor connection portion 38a is bent downward at a substantially right angle from the intermediate portion 38b, its tip is bent at a substantially right angle toward the motor side, and its tip is further bent at a right angle upward. Has been done.
Further, the external connection portion 38c is bent once from the intermediate portion 38b at a substantially right angle to the insertion port side and arranged at the insertion port 37 to form a connector pin.
The two power supply terminals are arranged side by side in the axial direction.

Next, in FIG. 1B, the power supply terminal 38 will be specifically described.
The motor connecting portion 38a, the intermediate portion 38b, and the external connecting portion 38c are formed at the same height in the incorporating direction.
Further, the two power supply terminals are arranged at the same height in the built-in direction.

Such a motor connecting portion 38a, an intermediate portion 38b, and an external connecting portion 38c are arranged so as to project outward in the radial direction of the motor.

In this example, the formed power supply terminal 38 is electrically connected to one end of the brush by being directly metal-bonded by spot welding or mechanically bonded by caulking. Then, one end of the power supply terminal and one end of the brush are connected to form a connecting component, and the connecting portion 36a of the connecting component is insert-molded so as to be completely covered with the hard resin of the insulating material and integrally molded into the bracket. Further, the other end of the brush is drawn out in the radial direction from the upper surface of the bracket 32 toward the rotation shaft 34a and is in sliding contact with the commutator 34d. Further, the motor connection portion 38a is pulled out in the axial direction from the lower end of the bracket 32.

The reduction gear 50 has two and is connected to the worm gear 35.
The output shaft 60 is made of a hard resin and has a flange-shaped output gear having a groove on the outer periphery thereof, and the output gear is connected to the reduction gear 50. Further, the output shaft 60 is pivotally supported by a shaft hole (not shown) by the lower case and the upper case.

The rotation angle detector 70 is composed of a potential meter, and has a rotating body made of a hard resin having a mounting hole through which a part of the output shaft 60 is inserted, and a non-rotating body 72 that pivotally supports the rotating body. A brush is provided on the rotating body. On the other hand, the non-rotating body 72 is provided with a resistor substrate that is slidably contacted with the brush. The brush and the resistor substrate function as detection means for detecting the rotation angle of the output shaft 60 by the rotation of the rotating body. The rotation angle detector 70 has three linear sensor terminals 72a that output a signal of the rotation angle of the output shaft 60 to the outside.

The lower case 10 has a riser (not shown) to which the non-rotating body 72 is fixed in the housing. When the rotation angle detector 70 is fixed to the rising portion, the sensor terminal 72a is arranged at the insertion port 37. Then, the external connection portion 38c and the sensor terminal 72a are arranged in the same insertion port 37, and the rotation angle detector 70 outputs a voltage signal corresponding to the rotation angle of the output shaft 60 to the external device through the sensor terminal 72a. ..
The external connection portion 38c and the sensor terminal 72a are arranged side by side at equal intervals in the direction perpendicular to the axial direction.

Next, the assembly process of the motor and the assembly process of the motor actuator of this example will be described. In this example, the motor assembly step is performed as the first step, and the motor actuator assembly step is performed as the second step.

First, the motor assembly process will be described. A forming-processed power supply terminal 38 and a brush 36 are prepared. For example, the motor connection portion 38a and one end of the brush are spotted to become a connection component, and the connection portion 36a of the connection component is insert-molded into the bracket 32.
Next, a rotor 34, a motor case 31 having a built-in stator 33, and a worm gear 35 are prepared. A rotor 34 and a motor case 31 having a built-in stator 33 are combined with a bracket 32 in which a power supply terminal 38 is insert-molded, and a worm gear 35 is connected to the tip of a rotating shaft 34a. It becomes.

However, since the finished motor product is provided with a power supply terminal 38 protruding from the bracket 32, if the distance between the motor assembly process and the motor actuator assembly process is long, the power supply terminal 38 is used when the finished motor product is transported. Is easily deformed and the quality may deteriorate. Therefore, in order to improve the quality by making the power supply terminal 38 less likely to be deformed when the finished motor product is transported, it is desirable that the distance between the motor assembly process and the motor actuator assembly process be close.

Next, the assembly process of the motor actuator will be described. A lower case 10, an upper case, a reduction gear 50, an output shaft 60, and a rotation angle detector 70 are prepared. Then, the above-mentioned finished motor product is arranged in the lower case 10, and the external connection portion 38c is arranged in the insertion port 37 to become the first semi-finished product. Then, the rotation angle detector 70 is arranged in the first semi-finished product, and the sensor terminal 72a is arranged in the insertion port 37 to become the second semi-finished product. Then, the reduction gear 50 and the output shaft 60 are arranged in the second semi-finished product, and the upper case is incorporated therein to become the finished product of the motor actuator.

With the above configuration, the rotation of the motor 30 can be transmitted to, for example, the rotation shaft of the air flow control valve of the air adjustment device via the worm gear 35, the reduction gear 50, and the output shaft 60.

Such a motor actuator 1a of this example includes a motor case 31, a bracket 32 mounted on the motor case 31, a rotating shaft 34a pivotally supported by the motor case 31 and the bracket 32, a power feeding terminal 38, and a brush. It includes a motor 30 having 36 and a housing including a lower case 10 and an upper case that internally support the motor 30.
Further, the power supply terminal 38 is made of a single component made of a seamless wire or plate made of a metal material.
The housing also has a side plate 12.
Further, the side plate 12 is provided with an insertion port 37 for an external connector.
Further, one end of the power feeding terminal is insert-molded into the bracket 32 while being connected to the brush 36.
Further, the other end of the power feeding terminal is arranged in the insertion port 37.

In the connection structure of the power supply terminal of the motor used for such a motor actuator, the power supply terminal and the power supply terminal are made of a single component made of a seamless wire or plate made of a metal material, and this component is connected to the brush. Since the bracket is insert-molded, contact reliability is improved, chattering noise is not generated, and quietness is improved.
Further, in the configuration as in the conventional example, the number of parts of the current path for supplying external power to the brush is 4 points (connector side terminal, power supply terminal, power supply terminal, brush), and the connection part is manufactured in 3 places. Although it tends to be defective, the connection part of this example is one place between the power supply terminal and the brush, so that manufacturing defects are less likely to occur and reliability is improved.

Further, since the power supply terminal 38 is pulled out from the bracket 32 outward in the axial direction, it can be realized with a simple configuration.

(Example of the second embodiment)
The motor actuator 1b, which is an example of the second embodiment of the present invention, will be described with reference to FIG. 3, and the motor 130 will be described with reference to FIG. In FIG. 3 or FIG. 4, the same parts as those in FIGS. 1 and 2 are designated by the same reference numerals, and the description of overlapping portions will be omitted.

The power supply terminal 38 of the first embodiment was pulled out from the bracket 32 in the axial direction outward, whereas the power supply terminal 138 of the second embodiment is outward from the bracket 132 in the axial direction and the vertical direction. It is pulled out to the direction.

Further, in the first embodiment, one end of the brush is fixed to the bracket 32 with the center of the rotation axis as point symmetry, but in the second embodiment, the fixing position of the brush 136 is changed and one end of the brush is changed. Is fixed to the bracket 132 in line symmetry with respect to the surface through which the center of the rotation shaft 34a passes when viewed from the axial direction.

Next, in FIG. 3A, the power supply terminal 138 will be specifically described.
The intermediate portion 138b is arranged parallel to the side plate on which the bracket 132 faces.
The motor connecting portion 138a is formed linearly from the intermediate portion 138b with respect to the motor side.
The external connection portion 138c is bent once from the intermediate portion 138b at a substantially right angle to the insertion port side and arranged at the insertion port 37 to form a connector pin.
The two power supply terminals are arranged side by side in the axial direction.

Next, in FIG. 3B, the power supply terminal 138 will be specifically described.
The motor connecting portion 138a, the intermediate portion 138b, and the external connecting portion 138c are formed at the same height in the incorporating direction.
Further, the two power supply terminals are arranged at the same height in the built-in direction.

Further, the motor connecting portion 138a, the intermediate portion 138b, and the external connecting portion 138c are arranged so as to project outward in the radial direction of the motor.

Further, in FIG. 3A, the entire surface of the bracket 132 directly faces the side plate facing the bracket 132, and no component, for example, a power supply terminal is arranged between the bracket 132 and the side plate. Will be.

Further, in order to maintain the insulation between the motor connection portion 138a and the motor case 131, a square notch 131a is formed at the opening end of the cylindrical portion of the motor case 131, and the motor connection portion 138a forms the notch 131a. It is pulled out from the bracket 132 outward in the direction perpendicular to the axial direction without contacting the motor case 131 via the bracket 132.

Therefore, this example has the operation and effect of the first embodiment, and the total length of the power supply terminal is shorter than that of the first embodiment. Therefore, from the motor assembly process to the motor actuator assembly process. It becomes a power supply terminal that is not easily deformed during transportation and can improve quality.

Further, the power supply terminal 138 is pulled out from the bracket 132 outward in the direction perpendicular to the axial direction. Further, the insertion port 37 and the motor 130 are arranged so as not to overlap with the axial direction of the motor, and the side plate is arranged so as to directly face the bracket. Then, there is no power supply terminal between the bracket 132 and the side plate facing the bracket 132. Therefore, in this example, since the side plate facing the bracket can be arranged closer to the bracket, the axial direction of the motor actuator can be reduced as compared with the first embodiment.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above, and can be modified in various ways other than the above within a range not deviating from the gist thereof.

In the above-described embodiment, the two power supply terminals are arranged side by side in the axial direction and at the same height in the built-in direction, but the present invention is not limited to this (modifications 1 and 2). ).

(Modification 1)
For example, in FIG. 1, the intermediate portion 38b and the motor connecting portion 38a of the two power feeding terminals may be arranged at the same height in the axial direction and arranged side by side in the incorporating direction. Then, in this example, since the side plate facing the bracket can be arranged closer to the bracket, the axial direction of the motor actuator can be further miniaturized as compared with the first embodiment.

(Modification 2)
Further, for example, in FIG. 3, the intermediate portion 138b and the motor connecting portion 138a of the two power feeding terminals may be arranged at the same height in the axial direction and arranged side by side in the incorporating direction. In this example, since the side plate facing the bracket can be arranged closer to the bracket, the axial direction of the motor actuator can be further miniaturized as compared with the second embodiment. Further, since the height of the bracket 132 in the axial direction can be further reduced, the axial direction of the motor actuator can be further reduced.

(Modification 3)
Next, the connection portion 36a described above is insert-molded so that the connection portion 36a is completely covered with the hard resin of the insulating material. The configuration may be as follows. For example, a part of the connecting portion 36a may be inserted, or a part of the connecting part may be inserted. In these cases, the other end of the brush is pulled out from the upper surface of the bracket and is in sliding contact with the commutator, and the power supply terminal is pulled out from the bracket.
If the connection portion 36a is not completely covered with the hard resin of the insulating material and the connection portion 36a is arranged below the bracket, the contact reliability of the connection portion can be obtained, but the motor itself or the vehicle can be used for a long period of time. There is a possibility that vibrations such as the above will be transmitted to the connection portion and the contact stability will be slightly reduced. On the other hand, if the connecting portion 36a is insert-molded so as to be completely covered with the hard resin of the insulating material, the contact reliability of the connecting portion due to the vibration of the motor itself or the vehicle can be maintained for a long period of time.

It should be noted that the power supply terminals, the sensor terminals, or the power supply terminal and the sensor terminal are not in contact with each other and maintain insulation.

1a Motor actuator 1b Motor actuator 10 Lower case 11 Bottom plate 11a Recess 12 Side plate 30 Motor 31 Motor case 31a Cylindrical part 31b Upper plate 31c Radial bearing 32 Bracket 32a Recess 32b Thrust bearing 32c Radial bearing 33 Rotor 34 Child core 34c Copper wire 34d Rectifier 35 Worm gear 36 Brush 36a Connection part 37 Insertion port 37a Cylinder part of insertion port 37b Upper part of insertion port 38 Power supply terminal 38a Motor connection part 38b Intermediate part 38c External connection part 50 Reduction gear 60 Output shaft 70 Rotation angle detector 72 Non-rotating body 72a Sensor terminal 130 Motor 131 Motor case 131a Notch 132 Bracket 136 Brush 138 Power supply terminal 138a Motor connection 138b Intermediate 138c External connection

Claims (4)

A motor case, a bracket mounted on the motor case , a rotor having a commutator, a rotating shaft pivotally supported by the motor case and the bracket, a power feeding terminal, and a brush in sliding contact with the commutator . With a motor,
A housing consisting of a lower case and an upper case that internally support the motor is provided.
The power supply terminal is made of a single component made of a seamless wire or plate made of a metal material.
The housing has side plates
The side plate is provided with an insertion port for an external connector.
The motor-side end of the power feeding terminal is arranged in the motor and is insert-molded into the bracket while being directly fixed to the brush provided on the motor .
The insertion port side end of the power supply terminal is arranged at the insertion port.
The power feeding terminal is a motor actuator characterized by being a seamless wire or plate from the motor side end to the insertion port side end . The motor actuator according to claim 1, wherein the power feeding terminal is pulled out from the bracket outward in the axial direction. It has an output shaft driven by the motor and a rotation angle detector that detects the rotation angle of the output shaft.
The rotation angle detector is formed with a sensor terminal connected to an external device.
The power supply terminal is pulled out from the bracket in the direction perpendicular to the axial direction.
The side plate is formed so as to directly face the bracket and in the direction perpendicular to the axial direction of the motor.
The insertion port and the motor are arranged so as not to overlap with each other in the axial direction of the motor.
The motor actuator according to claim 1, wherein the sensor terminal is arranged at the insertion port. The motor actuator according to claim 1 to 3, wherein the connection portion between the power supply terminal and the brush is insert-molded so as to cover all of them.

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