JPH10243591A - Motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the number of components and assembly man-hours of a motor and a controller without degrading heat-resistant properties and moisture-proof/dust-proof properties by a method wherein the coils of a stator and control electronic components are mounted on a method board and sealed with resin and a rotor having permanent magnets is rotatably supported by the metal board with bearing members therebetween. SOLUTION: The coils 3 of the stator of a motor 1 are fixed to a board 2 and sealed with molding resin 4 and the rotor 6 of the motor 1 is supported by the board 2 with bearing members 5 therebetween. Not only the coils 3 and a Hall device but also surface mount electronic components of which a controller controlling the motor 1 is composed and a surface mount power supply connector and a signal connector are soldered to the conductor patterns of the board 2. With this constitution, the controller can be integrally assembled. Therefore, a smaller number of cases, bolts, etc., for assembly are necessary in comparison with the case that the motor 1 and the controller are assembled individually, so that the number of components can be reduced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric motor provided with a control device.

[0002]

2. Description of the Related Art Conventionally, for example, a driving device for an electric bicycle has
A control device for controlling the motor is formed separately from the motor,
These are connected to each other by wiring and fixed to the vehicle body frame. An electric motor used in this type of driving device has a stator fixed to an electric motor housing and a rotatably supported rotor, and is fixed to a vehicle body frame via a driving device housing connected to the electric motor housing. The stator is formed by winding a coil around a bobbin, and the bobbin is fixed to a motor housing.

Further, the control device is formed by mounting a printed circuit board on which electronic components are mounted in a waterproof / dustproof case, and is fixed to the drive device housing by bolts or to a vehicle body frame via a bracket. doing. These electric motors and control devices are covered with a vehicle body cover so that muddy water and rainwater splashed up by the wheels are not directly splashed.

Further, since the electric motor and the control device generate a large amount of heat due to the flow of a large current, a body cover for covering the motor and the control device is formed into a shape in which hot air does not stay, and a heat sink is attached to the control device. To prevent the temperature from rising excessively.

[0005]

However, if the electric motor and the control device are formed separately as described above, there is a limit in reducing the cost of the electric bicycle. This is because a housing and fixing bolts are required for each of the electric motor and the control device, so that the number of parts increases, and accordingly, the number of assembly steps also increases. In addition, connecting the electric motor to the control device by wiring and attaching a heat sink to the control device also increase the number of parts and the number of assembly steps.

Such problems can be solved to some extent by further simplification of each component. However, in order to achieve simplification, the heat radiation and waterproof / dustproof properties of the electric motor and the control device are required. It must not fall.

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and has as its object to reduce the number of parts and the number of assembly steps of a motor and a control device without deteriorating heat dissipation and waterproof / dustproof properties. I do.

[0008]

An electric motor according to the present invention comprises:
A stator coil and a control electronic component were mounted on one surface of a metal substrate, sealed with a mold resin, and a rotor having a permanent magnet opposed to the coil was provided on the other surface of the substrate. It is rotatably supported via a bearing member.

According to the present invention, the control device can be integrated with the motor. In addition, since the coil of the stator is mounted on the board and sealed with the molding resin, the coil bobbin is not required.Moreover, since this coil is connected to the control electronic component via the conductor pattern on the board, it is conventionally used. This eliminates the need for existing wiring. Furthermore, the connection of the coils of the stator and the control electronic components can be performed by a technique of inserting them into a reflow furnace with the components mounted on the substrate and soldering them together, a so-called reflow method.

Furthermore, the heat generated by the coils of the stator and the control electronic components is transmitted to the metal substrate, and is radiated from the substrate to the atmosphere, or a member on the fixed side,
For example, the electric power is transmitted to the body frame of the electric bicycle and is emitted to the atmosphere. In addition, since the coils of the stator and the control electronic components are sealed with the mold resin, it is possible to prevent water and dust from entering without using a waterproof / dustproof case or the like.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the electric motor according to the present invention will be described below in detail with reference to FIGS. FIG. 1 is a side view of an electric motor according to the present invention, and FIG.
FIG. 3 is a side view showing the board after mounting electronic components, FIG. 4 is a side view showing the board after molding, and FIG.
Is a cross-sectional view showing the board with the bearing member attached thereto, and FIG. 6 is a side view of the second disk of the rotor.

In these figures, reference numeral 1 denotes an electric motor according to this embodiment. This motor 1 is a brushless DC motor, and a stator coil 3 (FIG.
3) is fixed and sealed with the mold resin 4, and the rotor 6 is rotatably supported via the bearing member 5. The substrate 2 is formed by providing a conductor pattern on one surface of a substrate body made of an aluminum alloy via an insulating film (not shown), and surrounding the coil 3 around a through hole 7 formed on one side. Are arranged.

The coil 3 is formed by winding a conductor covered with an insulating film, and both ends of the conductor are soldered to the conductor pattern. In FIG. 3, what is indicated by reference numeral 8 disposed near the coil 3 is a Hall element for detecting the position of the rotor 4. The Hall element 8 is also soldered to a conductor pattern on the substrate 2 and sealed with the mold resin 4.

The conductor pattern of the substrate 2 includes the coil 3
In addition to the hall element 8 and the surface mount type electronic component 9 constituting the control device for controlling the electric motor 1, the surface mount type power supply connector 10 and the signal connector 11 are soldered. Further, all of the electronic components 9 and the soldered portions of the connectors 10 and 11 are also sealed with the mold resin 4. The molding resin 4 is molded by a molding die (not shown) including an upper die and a lower die so as to cover substantially the entire area of the conductive pattern forming surface of the substrate 2 as shown in FIG. I have.

The bearing member 5 comprises a cylinder 5a and a flange 5b integrally formed of an aluminum alloy, and bearings 12 and 13 fitted and fixed to the inner peripheral portion of the cylinder 5a. The substrate 2 is fixed to the rear surface (the surface opposite to the conductor pattern forming surface) of the substrate 2 with four fixing bolts 14 while being fitted into the through holes 7 a of the substrate 2.

The rotor 6 includes a bearing 1 of the bearing member 5.
An output shaft 15 that fits into the base 2 and the bearing member 5 and that fits into the first and second discs 16, 13; A second disk 17 fixed to a portion of the output shaft 15 on the rear surface side of the substrate 2, and the two disks 16, 1
7 and a permanent magnet 18 fixed to the surface on the substrate 2 side. The discs 16 and 17 are integrally formed with cylinders 16a and 17a at their outer peripheral portions so as to protrude toward the substrate 2, and the cylinders 16a and 17a cover the sides of the permanent magnet 18 with the cylinders 16a and 17a. .

The permanent magnet 18 is formed in an annular shape as shown in FIG. 6, and is disposed on the same axis as the disks 16 and 17. The permanent magnet 18 fixed to the disk 16 faces the coil 3 via the mold resin 4, and the permanent magnet 18 fixed to the disk 17 faces the coil 3 via the bearing member 5 and the substrate 2.

Next, a procedure for manufacturing the electric motor 1 configured as described above will be described. First, the coil 3, the electronic component 9, and the connectors 10, 11 are soldered to the conductor pattern of the substrate 2. In this embodiment, the soldering is performed by a reflow method. That is, a solder layer is formed in advance on the soldering portion of the conductor pattern, and the board 2 is inserted into a reflow furnace (not shown) with the leads of the mounted components mounted on the solder layer. The entire board 2 including the mounted components is heated to the solder melting temperature and then cooled. In this soldering step, the coil 3 and the Hall element 8 are temporarily held by a jig (not shown) and positioned at the soldering position of the substrate 2.

After the soldering process is completed, the jig for temporarily holding the coil 3 and the Hall element 8 is removed, the substrate 2 is loaded into a mold (not shown), and the molding resin 4 is formed on the substrate 2. . By molding the mold resin 4, the coil 3 and the Hall element 8 are fixed to the substrate 2, and each mounted component on the substrate 2 is sealed. Thereafter, as shown in FIG. 5, the bearing member 5 is attached to the back surface of the substrate 2 with fixing bolts 14. This bearing member 5 is shown in FIG.
By assembling the rotor 6 as shown in FIG. 7, the manufacturing process of the electric motor 1 is completed.

In order to use the electric motor 1 thus formed as a power source of an electric bicycle, for example, the board 2 is fixed to a vehicle body frame, and the free end of the output shaft 15 is connected to a rear wheel drive transmission. In addition, the power connector 10 is connected to the battery, and the signal connector 11 is connected to the operator.

Therefore, in the electric motor 1, the stator coil 3, the hall element 8, the control electronic component 9, and both connectors 10, 11 are mounted on one substrate 2, and these mounted components are sealed with the mold resin 4. Therefore, the control device can be assembled integrally. For this reason, compared with the case where the electric motor and the control device are formed separately, the number of cases and fixing bolts can be reduced. In addition, the motor and the control device can be assembled at one time.

Further, since the coil 3 is mounted on the substrate 2 and sealed with the molding resin 4, a coil bobbin is not required as compared with the prior art, and the coil 3 is controlled via a conductor pattern on the substrate 2. Connected to the electronic component 9 for
The wiring used conventionally is unnecessary.

Further, if a structure is adopted in which the coil 3 and the electronic component 9 are mounted on one substrate 2, as shown in this embodiment, the reflow method may be used for soldering these mounted components. Can be manufactured and the production becomes easy. Furthermore, the heat generated by the coil 3 and the electronic components 9 is transmitted to the metal substrate 2 and is radiated from the substrate 2 to the atmosphere, or a member to be fixed via the substrate 2 such as an electric bicycle. Since the heat is transmitted to the body frame, the heat can be efficiently dissipated without using a heat-dissipating component such as a heat sink. In addition, since the coil 9 and the electronic component 9 are sealed with the mold resin 4, it is possible to prevent water and dust from entering without using a waterproof / dustproof case or the like.

As shown in this embodiment, when the coil 3 of the stator and the Hall element 8 for detecting the position of the rotor 6 are temporarily held by a jig and soldered to the substrate 2,
The coil 3 and the Hall element 8 can be positioned at accurate positions, and the rotation can be controlled with high precision.

In this embodiment, an example is shown in which the substrate body of the substrate 2 is formed of an aluminum alloy.
This substrate body may be formed of iron.

[0026]

As described above, in the electric motor according to the present invention, the coil of the stator and the control electronic parts are mounted on one surface of the metal substrate, sealed with the mold resin, and opposed to the coil. Since the rotor having the permanent magnet is rotatably supported via a bearing member provided on the other surface of the substrate, the control device can be integrally assembled.

Therefore, compared with the case where the electric motor and the control device are separately formed, the number of cases and fixing bolts may be smaller, and the number of parts can be reduced. Moreover,
When the electric motor and the control device are fixed to, for example, the body frame of the electric bicycle, both can be assembled at once,
Assembly man-hours can also be reduced.

Further, since the coil of the stator is fixed to the substrate by the mold resin, the coil bobbin is not required.
In addition, since this coil is connected to the control electronic component via the conductor pattern on the substrate, the wiring conventionally used becomes unnecessary. From this point as well, the number of parts and the number of assembly steps can be reduced. Furthermore, the connection work of the coils of the stator and the electronic components for control can be carried out by a technique of inserting them into a reflow furnace with the components mounted on the board and soldering them together, that is, a so-called reflow method. , Easy to manufacture.

Furthermore, the heat generated by the coils of the stator and the control electronic components is conducted to the metal substrate, and is radiated from the substrate to the air, or is fixed via the substrate, for example, to a member on the fixed side, such as an electric motor. The electric power is transmitted to the bicycle body frame and released from the air to the atmosphere. For this reason, heat dissipation is promoted without using a heat sink or the like, and a high cooling effect is achieved while reducing the number of components.

In addition, since the coils of the stator and the control electronic components are sealed with the mold resin, waterproofing can be achieved without using a waterproof case or the like. For this reason, a high waterproof effect is achieved while reducing the number of parts.

[Brief description of the drawings]

FIG. 1 is a side view of an electric motor according to the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a side view showing a board after mounting electronic components.

FIG. 4 is a side view showing the substrate after molding.

FIG. 5 is a cross-sectional view showing the board in a state where a bearing member is mounted.

FIG. 6 is a side view of a second disk of the rotor.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Electric motor, 2 ... Board, 3 ... Coil, 4 ... Mold resin, 5 ... Bearing member, 6 ... Rotor, 9 ... Electronic parts.

Claims (1)

[Claims] 1. A coil of a stator and electronic components for control are mounted on one surface of a metal substrate, and these coils and electronic components are sealed with a mold resin.
An electric motor, wherein a rotor having a permanent magnet facing the coil is rotatably supported via a bearing member provided on the other surface of the substrate.