JPWO2013065577A1 - Brushless motor - Google Patents

Abstract

  A motor case 41 formed in a cylindrical shape is provided. In the motor case 41, a bus bar unit 45 having a motor side conductive plate MP to which an end portion of a coil 42b is connected and an end portion of a motor side sensor line are connected. A resolver 48 having a stator 48b for detecting the rotation of the rotor 43, and the opening 41d of the motor case 41 is covered with a bracket member 46 formed by pressing a steel plate into a disk shape. The holder member 47 for pulling out the motor-side conductive plate MP and the motor-side sensor wire to the outside is mounted while holding the stator 48b.

Description

  The present invention relates to a brushless motor that includes a stator core and a rotor that rotates within the stator core, and that is particularly suitable for use as an in-vehicle drive source.

  Conventionally, an electric power steering device (EPS) is mounted on a vehicle such as an automobile, and the electric power steering device assists the steering of a steering wheel by a driver. The electric power steering device employs a brushless motor with excellent control performance as a drive source, which allows the driver to accurately control the brushless motor in the forward and reverse directions according to the steering angle of the steering wheel. On the other hand, an appropriate operational feeling is given. As a brushless motor employed as a drive source of such an electric power steering device, for example, a technique described in Patent Document 1 is known.

  The brushless motor described in Patent Document 1 includes a housing case that houses a stator core around which an armature coil is wound, and an opening of the housing case is closed by a holder plate. A terminal holder having a conductive plate to which an end of the armature coil is connected is disposed between the stator core in the housing case and the holder plate. A bearing that rotatably supports the rotating shaft and a sensor stator that detects the rotation of the rotating shaft are mounted outside the housing case of the holder plate. That is, the holder plate is positioned between the bearing and sensor stator and the terminal holder. And a bearing plate and a sensor stator are protected by fixing a cover plate to a holder plate so that a bearing and a sensor stator may be covered.

Japanese Patent Laid-Open No. 2008-104321 (FIG. 3)

  In the technique described in Patent Document 1, both the housing case (motor case) and the holder plate (bracket member) are formed into a bottomed cylindrical shape and a disk shape by pressing a steel plate, respectively. This is a structure that can reduce the size and weight. However, the terminal holder (current collector) and sensor stator (detection unit) that require electrical wiring are separated by the holder plate, the former being disposed inside the housing case and the latter outside the housing case. . Therefore, when assembling the brushless motor, it is necessary to individually draw out the wiring from the terminal holder and the sensor stator, which causes a problem that the assembling work becomes complicated. Further, it is necessary to accurately center the cover plate for protecting the sensor stator and the bearing on the holder plate using, for example, an assembling jig and the like, and to weld and fix the two under the state. In other parts, the assembly work is complicated.

  An object of the present invention is to provide a brushless motor capable of improving assembly workability while forming a motor case and a bracket member from a steel plate to reduce manufacturing cost and reduce size and weight.

  The brushless motor of the present invention is a brushless motor including a stator core and a rotor that rotates in the stator core, and is formed in a cylindrical shape, and a motor case in which the stator core is fixed, and a winding around the stator core. A current collector having a driving conductive member provided in the motor case and connected to an end of the coil, and an end of the signal conductive member provided in the motor case. A rotation sensor having a detection unit that detects rotation of the rotor, a bracket member formed by pressing a steel plate to cover the opening of the motor case, and mounted on the bracket member. And a holder member for pulling out the signal conductive member to the outside.

  In the brushless motor of the present invention, the bracket member includes a bearing holding portion that holds a bearing member that rotatably supports a rotating shaft fixed to the rotor, and a motor case positioning that positions the bracket member with respect to the motor case. And a holder member positioning portion that positions the holder member with respect to the bracket member.

  In the brushless motor of the present invention, the holder member pulls out the driving conductive member to the outside.

  In the brushless motor of the present invention, the motor case positioning portion is an annular wall portion protruding toward the motor case side, and the bracket member is attached to the motor case by press-fitting the annular wall portion into the opening. It is characterized by being fixed to.

  In the brushless motor of the present invention, the holder member positioning portion includes an engagement hole provided in the bracket member, and an engagement claw provided in the holder member and engaged with the engagement hole. And

  The brushless motor according to the present invention is characterized in that the holder member positioning portion includes an annular holding portion having an inner diameter larger than an inner diameter of the bearing holding portion.

  The brushless motor of the present invention is provided with a flange portion extending radially outward of the motor case on the opening side along the axial direction of the motor case, and the flange portion penetrates in the axial direction of the motor case. A case side screw hole is provided, a bracket member side screw hole facing the motor case side screw hole is provided in the bracket member, and a fixing screw penetrating the motor case side screw hole and the bracket member side screw hole is used. The brushless motor is fixed to an object to be attached.

  The brushless motor of the present invention is characterized in that the brushless motor is a drive source of an electric power steering device.

  According to the brushless motor of the present invention, a motor case formed in a cylindrical shape is provided, and in the motor case, a current collector having a driving conductive member to which an end of a coil is connected, and an end of the signal conductive member And a rotation sensor having a detection unit that detects the rotation of the rotor connected to each other, and the opening of the motor case is covered with a bracket member formed by pressing a steel plate into a disk shape. In addition to holding the detection portion, a holder member for pulling out the signal conductive member to the outside is mounted. As a result, the current collecting device having the drive conductive member and the detection unit connected to the signal conductive member can be collectively arranged inside the motor case of the bracket member, and the signal conductive member can be disposed via the holder member. Can be pulled out of the motor case. Therefore, the motor case and bracket members are formed using steel plates to reduce the manufacturing cost and reduce the size and weight, while simplifying the pulling out of each conductive member, eliminating the cover plate that was required in the past, and assembling work. It is possible to greatly improve the performance.

  According to the brushless motor of the present invention, the bracket member includes a bearing holding portion that holds the bearing member that rotatably supports the rotating shaft fixed to the rotor, and a motor case positioning portion that positions the bracket member with respect to the motor case. And a holder member positioning portion for positioning the holder member with respect to the bracket member. As a result, the bracket member can position the bearing member, the motor case, the current collector, the holder member, and the detection unit in a state where the respective shaft cores coincide with each other. It is possible to reliably suppress the generation of sound. Moreover, since the detection part which forms a rotation sensor can be arrange | positioned inside a motor case rather than a bearing member, it becomes possible to improve the dust resistance / drip-proof property of a detection part more.

  According to the brushless motor of the present invention, since the holder member pulls out the driving conductive member to the outside, the driving conductive member and the signal conductive member can be collectively pulled out of the motor case via the holder member. Therefore, it is possible to simplify the drawing operation of each conductive member.

  According to the brushless motor of the present invention, the motor case positioning portion is an annular wall portion protruding toward the motor case, and the bracket member is fixed to the motor case by press-fitting the annular wall portion into the opening. Therefore, it is not necessary to temporarily fix both using a fixing screw or the like. As a result, for example, when the brushless motor is transported in a temporarily assembled state, it is possible to reduce the size and weight by eliminating the need for a fixing screw or the like. Therefore, it becomes possible to improve the conveyance efficiency of the brushless motor in the temporarily assembled state.

  According to the brushless motor of the present invention, the holder member positioning portion includes the engagement hole provided in the bracket member and the engagement claw provided in the holder member and engaged with the engagement hole. The bracket member can be attached with one touch, and as a result, the assembly workability can be further improved.

  According to the brushless motor of the present invention, the holder member positioning portion is composed of an annular holding portion having an inner diameter dimension larger than the inner diameter dimension of the bearing holding portion. Therefore, the holder member positioning portion is mounted by fitting the holder member to the bracket member. As a result, assembly workability can be further improved.

  According to the brushless motor of the present invention, a flange portion extending radially outward of the motor case is provided on the opening side along the axial direction of the motor case, and the flange side extends through the motor case in the axial direction of the motor case. A screw hole is provided, a bracket member side screw hole that faces the motor case side screw hole is provided on the bracket member, and the brushless motor is mounted by a fixing screw that passes through the motor case side screw hole and the bracket member side screw hole. To fix. Thereby, the main fixing of the motor case and the bracket member and the fixing of the brushless motor to the object to be attached can be performed with one fixing screw, and as a result, the assembling workability can be further improved.

  According to the brushless motor of the present invention, since the brushless motor is used as a drive source of the electric power steering apparatus, it can be applied to an electric power steering apparatus that requires low noise, low vibration, low cost and light weight. As a result, it can be easily mounted on a light vehicle or the like that requires low cost and low fuel consumption.

It is explanatory drawing explaining the outline | summary of the electric power steering apparatus provided with the brushless motor which concerns on this invention. It is sectional drawing explaining the internal structure of the brushless motor of FIG. It is a perspective view which shows the output side (reduction gear case side) of the brushless motor of FIG. It is a perspective view which shows a motor case (with a stator core). It is a perspective view which shows a bus-bar unit. It is a perspective view which shows a bracket member (with a bearing). It is a perspective view which shows a holder member (with a conductive member and a detection part). It is the elements on larger scale explaining the connection operation | work of a motor side conductive plate and a controller side conductive plate. It is sectional drawing explaining the internal structure of the brushless motor of 2nd Embodiment. FIG. 10 is a perspective view showing the holder member (with a signal conductive member and a detection unit) in FIG. 9. FIG. 10 is a perspective view showing the stator core (with current collector and drive conductive member) of FIG. 9. It is sectional drawing explaining the internal structure of the brushless motor of 3rd Embodiment. It is a perspective view which shows the 1st holder member (with a conductive member for signals) of FIG. It is a perspective view which shows the 2nd holder member (with a conductive member for signals and a detection part) of FIG. It is sectional drawing explaining the internal structure of the brushless motor of 4th Embodiment. FIG. 16 is a perspective view showing the holder member (with a signal conductive member and a detection unit) in FIG. 15.

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

  1 is an explanatory view for explaining an outline of an electric power steering apparatus provided with a brushless motor according to the present invention, FIG. 2 is a sectional view for explaining an internal structure of the brushless motor of FIG. 1, and FIG. 3 is a brushless of FIG. FIG. 4 is a perspective view showing a motor case (with a stator core), FIG. 5 is a perspective view showing a bus bar unit, and FIG. 6 is a bracket member (with a bearing). 7 is a perspective view showing a holder member (with a conductive member and a detection unit), and FIG. 8 is a partially enlarged view for explaining the connection work between the motor side conductive plate and the controller side conductive plate. Represents.

  As shown in FIG. 1, an electric power steering device 10 is mounted on a vehicle body (not shown) of a vehicle such as an automobile, and the electric power steering device 10 is connected to a steering wheel 11 operated by a driver. The steering shaft 12 assists the steering of the front wheels 13. The electric power steering device 10 is a so-called column assist type that is provided in the middle of the steering shaft 12 and is mounted at a predetermined location in a vehicle compartment (not shown).

  A pinion 15 is provided on the front wheel 13 side (lower side in the figure) of the steering shaft 12 via a universal joint 14, and the pinion 15 is meshed with a rack 17 formed integrally with the tie rod 16. These mechanisms are installed in a housing (not shown). As a result, the steering (rotational motion) of the steering wheel 11 is converted into the lateral movement (linear motion) of the tie rod 16 via the steering shaft 12, the universal joint 14, the pinion 15 and the rack 17, and as a result, The front wheel 13 is steered leftward or rightward.

  The electric power steering apparatus 10 includes a brushless motor 20 that is a drive source, and a speed reduction mechanism 30 that reduces the rotation of the brushless motor 20 to increase the torque. The brushless motor 20 and the speed reduction mechanism 30 are mechanically coupled to each other by three fixing screws S (only one is shown in the drawing) shown in FIG.

  As shown in FIG. 1, the brushless motor 20 includes a drive connection connector PC and a signal connection connector SC, and a power supply wiring 18a from the control device 18 is electrically connected to the drive connection connector PC. ing. As a result, a drive current having a predetermined magnitude is supplied from the control device 18 toward the brushless motor 20. On the other hand, the signal wiring 18b of the control device 18 is electrically connected to the signal connection connector SC. As a result, a detection signal (rotation position or the like) from a stator 48b (see FIG. 2) of a resolver 48 provided in the brushless motor 20 described later is transmitted to the control device 18.

  The control device 18 is also electrically connected to a wiring 19 a of a torque sensor 19 provided on the steering shaft 12. As a result, the control device 18 calculates the assist amount (rotation torque, rotation speed, etc.) of the brushless motor 20 based on the detection signal from the torque sensor 19, the detection signal from the stator 48b, and the like. The reflected drive current is supplied to the brushless motor 20.

  The speed reduction mechanism 30 includes a worm 31 that rotates integrally with the rotation shaft 44 of the brushless motor 20 via the connecting member CN and the worm shaft 31a, and a worm wheel 32 that meshes with the worm 31 and rotates integrally with the steering shaft 12. It has. The worm 31 and the worm wheel 32 are accommodated in a reduction gear case 33, and the reduction gear case 33 is connected to the brushless motor 20 by each fixing screw S. Thereby, the rotation of the rotating shaft 44 of the brushless motor 20 is decelerated by the decelerating mechanism 30 to increase the torque, and is transmitted to the steering shaft 12. Here, the reduction gear case 33 constitutes an attached object in the present invention.

  As shown in FIG. 2, the brushless motor 20 includes a motor case 41 formed into a bottomed cylindrical shape by pressing (deep drawing) a steel plate that is a magnetic material. The motor case 41 includes a main body cylinder portion 41a, a first bottom wall 41b, and a second bottom wall 41c, and an opening portion 41d is formed on one side (upper side in the drawing) of the main body cylinder portion 41a. The other side in the axial direction of 41a (the lower side in the figure) is closed by the bottom walls 41b and 41c.

  The first bottom wall 41b forms an annular space AS in the motor case 41, and is wound around the stator core 42 formed by laminating a plurality of magnetic steel plates via the insulator 42a in the annular space AS. The arranged coil 42b is arranged. The second bottom wall 41c forms a cylindrical space CS in the motor case 41, and the base end side (lower side in the figure) of the rotating shaft 44 is freely rotatable in the cylindrical space CS. The first bearing B1 to be supported is fixed. Here, a ball bearing (not shown in detail) is used as the first bearing B1.

  As shown in FIGS. 2 to 4, on the opening 41 d side along the axial direction of the motor case 41, three flange portions 41 e are arranged at equal intervals (120 ° intervals) along the circumferential direction of the main body cylinder portion 41 a. Is provided. Each flange portion 41e is provided so as to extend outward in the radial direction of the motor case 41, and each flange portion 41e is provided with a motor case side screw hole 41f penetrating in the axial direction of the motor case 41. A fixing screw S is inserted into each motor case side screw hole 41f. As a result, the motor case 41 is firmly fixed to the reduction gear case 33 together with the bracket member 46 by a total of three fixing screws S without rattling.

  On the opening 41d side of the motor case 41, a first notch 41g, a second notch 41h, and a third notch 41i are formed at predetermined intervals along the circumferential direction of the main body cylinder 41a. Each notch part 41g-41i is provided between the adjacent flange parts 41e, respectively, and is notched by the same depth toward the axial direction of the motor case 41, respectively. The positioning engagement portions 47b, the first engagement arm portions 47c, and the second engagement arm portions 47d (see FIGS. 3, 7, and 8) of the holder member 47 enter and engage with the notches 41g to 41i, respectively. It is like that. That is, each of the notches 41g to 41i has a function of positioning the holder member 47 with respect to the motor case 41 in the axial direction and in the circumferential direction. Further, the other end side of each motor side conductive plate MP and the other end side of each motor side sensor line ML are connected to the motor case 41 via each controller side conductive plate CP and each controller side sensor line CL of the holder member 47. Has a function to pull it out.

  Here, as shown in FIG. 4, the second cutout portion 41h and the third cutout portion 41i are arranged close to each other with one flange portion 41e on the front side in the drawing, for example, at 60 ° intervals. Thereby, the other end side of each motor side conductive plate MP and the other end side of each motor side sensor line ML are shown in FIGS. 3 and 7 via each controller side conductive plate CP and each controller side sensor line CL. In addition, the motor case 41 can be pulled out in the same direction.

  As shown in FIGS. 2 and 4, a ring-shaped stator core 42 is fixed inside the main body cylinder portion 41a, and the stator core 42 is interposed with an insulator 42a made of a nonmagnetic material such as plastic. The U-phase, V-phase, and W-phase coils 42b are respectively wound with a predetermined winding method and number of turns.

  A rotor 43 is provided inside the stator core 42 through a minute gap (air gap), and the rotor 43 rotates in the forward and reverse directions by supplying drive current to the U, V, and W phase coils 42b. It is like that. The rotor 43 is formed by laminating a plurality of annularly formed permanent magnets 43a in the axial direction, and each permanent magnet 43a is covered with a rotor case 43b formed by forming a steel plate into a cylindrical shape.

  A rotation shaft 44 is fixed through the rotation center of the rotor 43, that is, the rotation center of each permanent magnet 43a, and the rotation shaft 44 rotates integrally with the rotor 43. The distal end side (upper side in the figure) of the rotating shaft 44 is rotatably supported by a second bearing (bearing member) B2 fixed to a bracket member 46 that covers and closes the opening 41d of the motor case 41. Here, a ball bearing (not shown in detail) is used as the second bearing B2.

  The distal end side of the rotation shaft 44 extends to the outside of the motor case 41 via the bracket member 46, and the distal end portion of the rotation shaft 44 that extends to the outside of the motor case 41 is formed in a cylindrical shape. The connecting member CN (see FIG. 1) is fixed. The connecting member CN and the worm shaft 31a are fixed to each other by serration fitting, so that the rotating shaft 44 and the worm 31 rotate integrally.

  As shown in FIG. 2, a bus bar unit (current collector) 45 formed in an annular shape is provided in the motor case 41 and between the stator core 42 and the holder member 47 in the same manner as the stator core 42. . As shown in FIG. 5, the bus bar unit 45 includes an annular main body 45a, and the annular main body 45a is formed of an insulating material such as plastic. A plurality of motor-side conductive plates (drive conductive members) MP are embedded in the annular main body 45a by insert molding.

  From the outer peripheral part of the annular main body 45a, one end side of each motor-side conductive plate MP projects radially outward in the radial direction of the annular main body portion 45a. The ends (see FIG. 4) of the coils 42b corresponding to the V, W and W phases are electrically connected to each other. On the other hand, each motor-side conductive plate MP is bundled inside the annular main body 45a, whereby the other end side of each motor-side conductive plate MP is consolidated into three corresponding to the U, V, and W-phase coils 42b. ing. And the other end side of these three motor side electroconductive plates MP protrudes toward the axial direction of the said annular main-body part 45a from the annular main-body part 45a.

  Here, the other end side of the three motor side conductive plates MP protrudes from the opening 41d of the motor case 41 in a state where the bus bar unit 45 is housed in the motor case 41 (FIG. 8). reference). This facilitates welding work between the other end side of each motor side conductive plate MP and one end side of each controller side conductive plate CP on the opening 41d side (bracket member 46 side) of the motor case 41. The assembly workability of the brushless motor 20 is improved.

  As shown in FIGS. 2, 3, and 6, the bracket member 46 is formed in a substantially disk shape by pressing the same steel plate as the motor case 41. A bearing holding portion 46a is formed at the center portion of the bracket member 46 so as to protrude toward the side opposite to the motor case 41 (upper side in the drawing). The second bearing B2 is provided in the bearing holding portion 46a. Is held. Further, a through hole 46 b is formed in the bearing holding portion 46 a, whereby the tip end side of the rotating shaft 44 that is rotatably supported by the second bearing B 2 is extended to the outside of the motor case 41.

  On the radially outer side of the bearing holding portion 46a, an annular convex portion 46c that protrudes toward the side opposite to the motor case 41 side is formed in the same manner as the bearing holding portion 46a. The circular convex portion 46c is formed with a circular arc hole 46d formed in a substantially circular arc shape. The circular arc hole 46d has a second end side of each motor-side conductive plate MP and a side of each controller when the brushless motor 20 is assembled. One end side of the conductive plate CP is arranged (see FIG. 8). That is, the circular arc hole 46d forms a connection work space for electrically connecting the other end side of each motor side conductive plate MP and one end side of each controller side conductive plate CP. The arc hole 46d is sealed with a rubber cover CO (see FIG. 3) after connecting the other end side of each motor side conductive plate MP and one end side of each controller side conductive plate CP. Also good.

  An annular holder fixing portion 46e is formed on the radially outer side of the annular convex portion 46c. The holder fixing portion 46e is an annular convex portion that protrudes toward the motor case 41 side (lower side in the figure), and the annular and convex holder fixing portion 46e is an outer peripheral wall portion as an annular wall portion. (Motor case positioning part) 46i is provided. The outer peripheral wall 46i is press-fitted into the opening 41d of the motor case 41. That is, the outer peripheral wall 46i of the holder fixing portion 46e has a function of positioning the bracket member 46 with respect to the motor case 41. I have.

  The holder member 47 is fixed to the holder fixing portion 46e on the motor case 41 side, and the holder fixing portion 46e is engaged with engaging holes (engagement holes 47h) of the holder member 47. A holder member positioning portion) 46f is formed. Each engagement claw 47h of the holder member 47 enters into each engagement hole 46f while being elastically deformed, whereby each engagement claw 47h is engaged with each engagement hole 46f, and the bracket member A holder member 47 is fixed to 46. That is, each engagement hole 46f has a function of positioning the holder member 47 with respect to the bracket member 46. Here, by engaging each engagement claw 47h with each engagement hole 46f so that each controller side conductive plate CP of the holder member 47 is positioned in the arc hole 46d of the bracket member 46, The holder member 47 can be fixed with a single touch with high accuracy.

  Three flange portions 46g are provided on the outer side in the radial direction of the holder fixing portion 46e so as to be equidistant (120 ° intervals) along the circumferential direction of the holder fixing portion 46e. Each flange portion 46g is provided to extend radially outward of the holder fixing portion 46e, and each flange portion 46g is provided with a bracket member side screw hole 46h through which the fixing screw S (see FIG. 2) is inserted. ing. Each bracket member-side screw hole 46h is opposed to each motor case-side screw hole 41f, whereby the bracket member 46 is secured by a total of three fixing screws S penetrating each of the screw holes 46h and 41f. The motor case 41 and the speed reducer case 33 are firmly fixed without rattling.

  As shown in FIGS. 2, 3, and 7, the holder member 47 is formed in a predetermined shape from an insulating material such as plastic and is attached to the bracket member 46. The holder member 47 includes a disc-like main body portion 47a formed in a substantially disc shape, and a positioning engagement portion 47b, a first engagement arm portion 47c, and a second engagement portion are provided on the outer peripheral portion of the disc-like main body portion 47a. The arm portions 47d are integrally provided so as to extend outward in the radial direction. The positioning engagement portion 47b is engaged with the first cutout portion 41g of the motor case 41, the first engagement arm portion 47c is engaged with the second cutout portion 41h of the motor case 41, and the second engagement arm portion 47d is The motor case 41 is adapted to be engaged with the third notch 41i. Thereby, the holder member 47 is accurately positioned with respect to the motor case 41.

  A sensor holder mounting portion 47i to which a sensor holder (second holder member) 47e that holds the stator 48b that forms the resolver 48 can be mounted is integrally provided at a substantially central portion of the disc-shaped main body portion 47a. An arc hole 47f formed in a substantially arc shape is formed between the sensor holder 47e and the first engagement arm portion 47c along the radial direction of the disc-like main body portion 47a, and the arc hole 47f is a disc-like main body portion. It penetrates in the thickness direction of 47a. One end side of three controller side conductive plates (drive conductive members) CP embedded in the first engagement arm portion 47c by insert molding is exposed from the arc hole 47f, and one end side of each controller side conductive plate CP is exposed. Is extended from the arc hole 47f toward the bracket member 46 along the axial direction of the disc-shaped main body 47a. In this manner, the holder member 47 can draw the other end side of each motor side conductive plate MP to the outside of the motor case 41 via each controller side conductive plate CP of the first engagement arm portion 47c. .

  The sensor holder 47e is formed of an insulating material such as plastic, and includes a cylindrical portion 61 formed in a substantially cylindrical shape, and a first arm portion 62 provided integrally so as to extend outward in the radial direction of the cylindrical portion 61. I have. Further, the stator 48b is formed by laminating a plurality of magnetic steel plates, and a plurality of teeth portions are provided toward the inner peripheral side, and an insulator portion 48b1 is provided so as to cover the peripheral surface of each tooth portion. Yes. The insulator portion 48b1 is formed integrally with the cylindrical portion 61, and a coil 48c is wound around each tooth portion via the insulator portion 48b1.

  Further, a plurality of fitting portions (see the second embodiment in FIG. 10) are provided on the outer peripheral portion of the stator 48 b so as to protrude outward in the radial direction of the cylindrical portion 61. It is provided integrally. Each fitting portion is adapted to be fitted into the sensor holder mounting portion 47i by press fitting. The sensor holder 47e is configured as a subunit by outsert-molding the cylindrical portion 61 and the insulator portion 48b1 with a resin material on the stator 48b. Thus, the holder member 47 has a function of positioning the resolver 48 at a predetermined position of the bracket member 70 in addition to the function of holding the sensor holder (second holder member) 47e.

  Between the sensor holder 47e and the second engagement arm portion 47d along the radial direction of the disk-shaped main body portion 47a, a hollow portion 47g that communicates with the sensor holder 47e and is depressed in the thickness direction of the disk-shaped main body portion 47a is formed. Has been. The first arm portion 62 of the sensor holder 47e is positioned in the recess portion 47g, embedded in the first arm portion 62 by insert molding, and one end side is connected to the coil 48c. The other end side of the conductive member ML is exposed. Also, one end side of six controller side sensor wires (signal conductive members) CL embedded in the second engagement arm portion 47d by insert molding is exposed in the recess portion 47g. The recess 47g connects the other end side of each motor-side sensor line ML and one end side of each controller-side sensor line CL when the holder member 47 is assembled by incorporating the stator 48b or the like into the disc-shaped main body portion 47a. It becomes a welding work space for connection. In this manner, the holder member 47 can draw the other end side of each motor side line sensor line ML to the outside of the motor case 41 via each controller side sensor line CL of the second engagement arm portion 47d. .

  Further, as shown in FIG. 7, a pair of engaging claws (holder member positioning portions) 47h are integrally provided on the bracket member 46 side of the disc-shaped main body portion 47a. Each engaging claw 47h is provided so as to protrude toward the bracket member 46, and is elastically deformed toward the radial direction of the disk-shaped main body 47a. Each engaging claw 47h enters the engaging hole 46f of the bracket member 46 while being elastically deformed when the holder member 47 is attached to the bracket member 46, and then each engaging claw 47h is released from the elastically deformed state. Returning to the original state, each engagement claw 47h is engaged with each engagement hole 46f to be prevented from coming off. That is, each engaging claw 47h has a function of positioning the holder member 47 with respect to the bracket member 46.

  As shown in FIG. 2, a resolver 48 as a rotation sensor that detects the rotation of the rotor 43 (rotating shaft 44) is provided in the motor case 41 and between the rotor 43 and the second bearing B <b> 2. . The resolver 48 includes a rotor 48a that is an exciting coil, and a stator (detection unit) 48b having a plurality of coils (detection coils) 48c. The rotor 48 a is fixed to the rotating shaft 44, and the sensor holder 47 e including the stator 48 b is held by the sensor holder mounting portion 47 i of the holder member 47. Thereby, the stator 48b generates a sinusoidal analog signal (detection signal) according to the rotation of the rotor 48a, and transmits the detection signal to the control device 18 (see FIG. 1), whereby the rotation of the rotor 43 is achieved. (Rotation speed, rotation angle, etc.) can be detected by the control device 18.

  Next, the assembly procedure of the brushless motor 20 formed as described above will be described in detail with reference to the drawings.

[Assembly of motor sub assembly]
As shown in FIG. 4, first, a motor case 41 is prepared, and a stator core 42 around which a coil 42 b is wound is fixed inside the motor case 41 by press-fitting or the like. Further, the first bearing B1 is fixed in the cylindrical space CS of the motor case 41 (see FIG. 2).

  Next, the bus bar unit 45 shown in FIG. 5 is prepared, and the bus bar unit 45 is stored on the opening 41 d side of the motor case 41. Here, the position of the other end side of each motor-side conductive plate MP protruding in the axial direction from the annular main body 45a and the position of the second notch 41h of the motor case 41 are predetermined with respect to the motor case 41. It arrange | positions so that it may become the circumferential direction. Thereafter, one end side of each motor-side conductive plate MP protruding outward in the radial direction of the annular main body 45a and the end portion of each coil 42b are electrically connected by welding or the like.

  Next, the rotor 43 (see FIG. 2) having the rotation shaft 44 is inserted inside the stator core 42, and the base end side of the rotation shaft 44 is supported by the first bearing B1. Thereby, the motor sub-assembly is completed.

[Assembly of holder sub assembly]
Next, a bracket member 46 shown in FIG. 6 and a holder member 47 shown in FIG. 7 are prepared. Here, in another assembly process, the sensor holder 47e of the holder member 47 is formed into a subunit by forming the cylinder portion 61 and the insulator portion 48b1 into the stator 48b by outsert molding, and the subunit, that is, the sensor holder 47e is attached. It is mounted on the sensor holder mounting portion 47 i of the holder member 47. Furthermore, the other end side of each motor-side sensor line ML embedded in the first arm portion 62 of the sensor holder 47e and one end side of each controller-side sensor line CL embedded in the second engagement arm portion 47d, The recesses 47g are electrically connected by welding or the like.

  Thereafter, the engaging claws 47 h side of the holder member 47 are made to face toward the motor case 41 side (back side) of the bracket member 46. At this time, each engaging claw 47h is made to face each engaging hole 46f while each controller side conductive plate CP on the holder member 47 side is positioned in the arc hole 46d of the bracket member 46. Then, by pressing the holder member 47 toward the bracket member 46, the respective engaging claws 47h enter the respective engaging holes 46f while being elastically deformed, and eventually the respective engaging claws 47h are changed from the elastically deformed state to the original state. Returning, the engagement of each engagement claw 47h with each engagement hole 46f is completed. As a result, the holder member 47 is fixed to the bracket member 46 with a single touch and with high accuracy, and the holder sub-assembly is completed.

[Assembly of each sub assembly]
Next, the completed motor sub-assembly and holder sub-assembly are prepared, and the holder member 47 side faces the opening 41d side of the motor case 41. At this time, the positioning engagement portion 47b, the first engagement arm portion 47c, and the second engagement arm portion 47d of the holder member 47 are respectively connected to the first cutout portion 41g, the second cutout portion 41h, and the third cutout portion of the motor case 41. It is made to engage with the part 41i. Then, the motor sub-assembly (motor case 41) and the holder sub-assembly (bracket member 46 / holder member 47) are positioned in the circumferential direction, whereby each flange portion 41e (motor case side screw hole 41f) of the motor case 41 is positioned. The flange portions 46g (bracket member side screw holes 46h) of the bracket member 46 automatically face each other in the axial direction.

  Thereafter, the outer peripheral wall 46 i forming the holder fixing portion 46 e of the bracket member 46 is press-fitted into the opening 41 d of the motor case 41. As a result, the motor sub-assembly and the holder sub-assembly are positioned in the axial direction, the distal end side of the rotating shaft 44 is inserted into the second bearing B2, and each motor-side conductive plate MP protruding in the axial direction from the annular main body 45a. The other end of each enters the circular arc hole 46d of the bracket member 46, and comes into contact with one end side of each controller side conductive plate CP (see FIG. 8).

  And in arc hole 46d, the other end side of each motor side conductive plate MP and one end side of each controller side conductive plate CP are electrically connected by welding etc. by using welding tool T shown in FIG. 3 places in total). Thereafter, a cover CO (see FIG. 3) is further attached to the arc hole 46d. Thereby, the assembly of the bracket member 46 to the motor case 41, that is, the fixing of the motor sub-assembly and the holder sub-assembly is completed, and the brushless motor 20 is completed. Here, since the motor case 41 and the bracket member 46 are fixed (temporarily fixed) to each other by press-fitting, the bracket member 46 is detached from the motor case 41 due to vibration or the like when the brushless motor 20 is transported. There is nothing.

[Attachment to Deceleration Mechanism 30]
In order to attach the brushless motor 20 to the speed reduction mechanism 30, first, as shown in FIG. 1, the connecting member CN is fitted and fixed to the tip portion of the rotating shaft 44. Next, the tip end side of the rotation shaft 44 of the brushless motor 20 is caused to face the speed reducer case 33 of the speed reduction mechanism 30. Then, the connection member CN and the worm shaft 31a are serrated.

  Then, as shown in FIG. 2, each fixing screw S is inserted into each motor case side screw hole 41f and each bracket member side screw hole 46h, and each fixing screw S is screwed into the reduction gear case 33 using a fastening tool (not shown). Join. Thereby, the main fixing of the motor case 41 and the bracket member 46 and the attachment of the brushless motor 20 to the speed reducer case 33 (the speed reduction mechanism 30) are completed.

  As described above in detail, the brushless motor 20 according to the first embodiment includes the motor case 41 formed in a cylindrical shape, and in the motor case 41, the end of the coil 42b is connected to the motor side. A bus bar unit 45 having a conductive plate MP and a resolver 48 having a stator 48b to which the end of the motor side sensor line ML is connected to detect the rotation of the rotor 43 are provided. Is covered with a bracket member 46 formed into a disk shape, and the bracket member 46 holds the stator 48b, and a holder for pulling out the motor-side conductive plate MP and the motor-side sensor wire ML to the outside. A member 47 was attached.

  Thus, the bus bar unit 45 having the motor-side conductive plate MP and the stator 48b to which the motor-side sensor wire ML is connected can be collectively arranged inside the motor case 41 of the bracket member 46, and the holder member 47 can be disposed. The motor side conductive plate MP and the motor side sensor line ML can be collectively pulled out to the outside of the motor case. Accordingly, the motor case 41 and the bracket member 46 are formed by using steel plates to reduce the manufacturing cost and reduce the size and weight, while simplifying the drawing operation of the motor side conductive plate MP and the motor side sensor line ML, which has been conventionally required. The cover plate can be eliminated, and as a result, assembly workability can be greatly improved.

  Further, according to the brushless motor 20 according to the first embodiment, the bracket member 46 includes the bearing holding portion 46a that holds the second bearing B2 that rotatably supports the rotating shaft 44 that is fixed to the rotor 43, and the bracket. A holder fixing portion 46e for positioning the member 46 with respect to the motor case 41 and an engagement hole 46f for positioning the holder member 47 with respect to the bracket member 46 are provided. As a result, the bracket member 46 can position the second bearing B2, the motor case 41, the bus bar unit 45, the holder member 47, and the stator 48b in a state in which the respective shaft cores coincide with each other. It becomes possible to suppress generation | occurrence | production of a vibration and abnormal noise reliably. In addition, since the stator 48b forming the resolver 48 is disposed inside the motor case 41 with respect to the second bearing B2, the dustproof / drip-proof property of the stator 48b can be further improved.

  Furthermore, according to the brushless motor 20 according to the first embodiment, the outer peripheral wall portion 46i of the holder fixing portion 46e is an annular wall portion protruding toward the motor case 41, and the outer peripheral wall portion 46i is formed into the opening portion 41d. Since the bracket member 46 is fixed to the motor case 41 by the press-fitting, it is not necessary to temporarily fix both using the fixing screw S or the like. Accordingly, for example, when the brushless motor 20 is transported in a temporarily assembled state, the size and weight can be reduced by the amount that the fixing screw S or the like is unnecessary. Therefore, it becomes possible to improve the conveyance efficiency of the brushless motor 20 in the temporarily assembled state.

  Further, according to the brushless motor 20 according to the first embodiment, as the holder member positioning portion, the engagement hole 46f provided in the bracket member 46 and the engagement provided in the holder member 47 and engaged with the engagement hole 46f. Since the claw 47h is provided, the holder member 47 can be attached to the bracket member 46 with one touch, and assembling workability can be further improved.

  Furthermore, according to the brushless motor 20 according to the first embodiment, the flange 41e is provided on the opening 41d side along the axial direction of the motor case 41 and extends radially outward of the motor case 41. Is provided with a motor case side screw hole 41f penetrating in the axial direction of the motor case 41, and the bracket member 46 is provided with a bracket member side screw hole 46h opposed to the motor case side screw hole 41f. The brushless motor 20 was fixed to the speed reducer case 33 by a fixing screw S penetrating the member side screw hole 46h. Thus, the main fixing of the motor case 41 and the bracket member 46 and the fixing of the brushless motor 20 to the speed reducer case 33 can be performed with one fixing screw S, and as a result, the assembly workability can be further improved. It becomes possible.

  In addition, according to the brushless motor 20 according to the first embodiment, since the brushless motor 20 is used as a drive source of the electric power steering apparatus 10, the electric power steering is required to have low noise, low vibration, low cost, and light weight. It is also possible to support the device. As a result, it can be easily mounted on a light vehicle or the like that requires low cost and low fuel consumption.

  Next, a second embodiment of the present invention will be described in detail with reference to the drawings. In addition, the same code | symbol is attached | subjected about the part which has the same function as 1st Embodiment mentioned above, and the detailed description is abbreviate | omitted.

  9 is a cross-sectional view for explaining the internal structure of the brushless motor according to the second embodiment, FIG. 10 is a perspective view showing the holder member (with a signal conductive member and a detection portion) in FIG. 9, and FIG. 1 is a perspective view showing a stator core (with a current collector and a driving conductive member).

  As shown in FIG. 9, the brushless motor 50 according to the second embodiment is different from the first embodiment in that the holder member 60 is attached by being fitted to a bracket member 70. Further, the bus bar unit (current collector) 80 is integrated with the stator core 42, and the motor side conductive plate MP of the bus bar unit 80 is directly pulled out of the motor case 41 without the holder member 60. Is different.

  A bearing holding portion 46a for holding the second bearing B2 is provided at the center portion of the bracket member 70, and the inner diameter dimension of the bearing holding portion 46a is provided on the motor case 41 side (lower side in the drawing) of the bearing holding portion 46a. An annular holding portion 71 having a larger inner diameter is provided. Further, an outer peripheral wall portion 46 i that is press-fitted into the opening 41 d of the motor case 41 is provided on the radially outer side of the annular holding portion 71 of the bracket member 70. However, in FIG. 9, the flange portion 41 e and the motor case side screw hole 41 f of the motor case 41, and the flange portion 46 g and the bracket member side screw hole 46 h of the bracket member 70 are on the front side and the rear side in the drawing. Not shown for placement.

  The annular holding portion 71 constitutes a holder member positioning portion in the present invention, and the fitting portion 48 d of the holder member 60 is press-fitted into the annular holding portion 71. Thereby, the holder member 60 is positioned with respect to the bracket member 70. Here, in order to assemble the bracket member 70, first, the second bearing B2 may be attached to the bearing holding portion 46a, and then the cylinder portion 61 (fitting portion 48d) may be attached to the annular holding portion 71. Thus, in the present embodiment, the holder member 60 is attached to the annular holding portion 71 so that the holder member 60 is reduced in size and weight.

  As shown in FIG. 10, the holder member 60 is made of an insulating material such as plastic, and is provided integrally with a cylindrical portion 61 formed in a substantially cylindrical shape and extending radially outward of the cylindrical portion 61. A first arm portion 62 and a second arm portion 63 having a base end portion connected to the distal end portion of the first arm portion 62 are provided.

  A plurality of teeth portions are provided on the inner peripheral side of the stator 48b forming the resolver 48, and insulator portions (not shown) are provided so as to cover the peripheral surfaces of the respective tooth portions. The insulator portion is formed integrally with the cylindrical portion 61, and a coil 48c is wound around each tooth portion via the insulator portion.

  A plurality of fitting portions 48d are integrally provided on the outer peripheral portion of the stator 48b so as to protrude radially outward of the cylindrical portion 61 on the radially outer side of the cylindrical portion 61. Each fitting portion 48d is adapted to be fitted into the annular holding portion 71 by press fitting. Also in the present embodiment, the cylindrical portion 61 and the insulator portion are configured by outsert molding a resin material on the stator 48b.

  Thus, the holder member 60 has a function of positioning the resolver 48 at a predetermined position of the bracket member 70 in addition to the function as a sensor holder that holds the stator 48b. The axial length of each fitting portion 48d is set to be shorter than the axial length of the cylindrical portion 61. Therefore, the cylindrical portion 61 is easily mounted in the annular holding portion 71.

  A plurality of motor-side sensor wires (not shown), one end of which is electrically connected to the coil 48c of the stator 48b, are embedded in the first arm portion 62 by insert molding. The proximal end portion of the second arm portion 63 is connected to the distal end portion of the first arm portion 62 where the other end side is exposed. A plurality of controller-side sensor lines CL are embedded in the second arm portion 63 by insert molding, whereby one end side of each controller line CL is connected to the other end side of each motor-side sensor line. ing. Further, the other end side of each controller line CL is exposed from the second arm portion 63 as shown in the figure. Here, the distal end side (the side where each controller line CL is exposed) of the second arm portion 63 is disposed outside the motor case 41 via a notch (not shown) provided in the motor case 41. It has become.

  As shown in FIGS. 9 and 11, a bus bar unit 80 formed in an annular shape is provided between the stator core 42 and the holder member 60 along the axial direction of the rotating shaft 44, similarly to the stator core 42. The bus bar unit 80 is formed in a substantially disk shape by an insulating material such as plastic, and is integrally connected to the stator core 42 by a plurality of claw portions 81. The bus bar unit 80 is provided with three motor side conductive plates (drive conductive members) MP each having a substantially L-shaped cross section, and each motor side conductive plate MP has U, V and W phases, respectively. Provided corresponding to the coil 42b. Lead wires of the coils 42 b are routed in a plurality of guide grooves 82 provided in the bus bar unit 80. The base end portion of each motor side conductive plate MP is attached to the bus bar unit 80 and connected to the lead wire of each coil 42b, and the front end portion of each motor side conductive plate MP is connected to the holder member 60 from the motor case 41. It is directly drawn out of the motor case 41 without being interposed.

  As described above in detail, the brushless motor 50 according to the second embodiment can achieve substantially the same operational effects as those of the first embodiment described above. In addition, in the second embodiment, since the holder member 60 is attached to the annular holding portion 71 of the bracket member 70 by press fitting, the assembly workability can be further improved, and the holder member 60 can be It becomes possible to reduce the size and weight. Further, since the front end portion of each motor-side conductive plate MP is directly pulled out of the motor case 41 without passing through the holder member, the three controller-side conductive plates CP (see FIG. 7) can be omitted. The welding operation (see FIG. 8) between each controller side conductive plate CP and each motor side conductive plate MP is not required.

  Next, a third embodiment of the present invention will be described in detail with reference to the drawings. Note that portions having the same functions as those of the second embodiment described above are denoted by the same reference numerals, and detailed description thereof is omitted.

  12 is a sectional view for explaining the internal structure of the brushless motor according to the third embodiment, FIG. 13 is a perspective view showing the first holder member (with signal conductive member) in FIG. 12, and FIG. 14 is shown in FIG. The perspective view which shows the 2nd holder member (with a conductive member for a signal and a detection part) is each represented.

  As shown in FIG. 12, the brushless motor 90 according to the third embodiment is different in the shapes of the bracket member 100 and the holder member 110 compared to the second embodiment.

  The bracket member 100 is provided with a bearing holding portion 46a and an annular holding portion 71, and further, a holder fixing portion 46e similar to that of the first embodiment is provided outside the annular holding portion 71 in the radial direction. The holder fixing portion 46e is provided with a pair of engagement holes 46f (only one is shown in the drawing). Each engagement hole 46f is engaged with a pair of engagement claws 47h (see FIG. 13) provided in a disk-shaped member 111 of the holder member 110 described later.

  Thus, in the brushless motor 90 according to the third embodiment, the holder member 110 (disk-shaped member 111) is held by the holder fixing portion 46e as in the first embodiment, and further the second embodiment. The holder member 110 (cylinder part 61) is held by the annular holding part 71 as in the form. With such a holding structure, the holder member 110 is more stably held with respect to the bracket member 100, and as a result, the detection accuracy of the resolver 48 can be further improved.

  On the further radially outer side of the holder fixing portion 46e of the bracket member 100, an annular convex portion 101 protruding toward the side opposite to the motor case 41 side (upper side in the figure) is provided. A bracket member supporting convex portion 112 provided on the disk-shaped member 111 is fitted in the annular convex portion 101. That is, the outer peripheral wall portion 101a forming the annular convex portion 101 constitutes the motor case positioning portion in the present invention. Specifically, the bracket member 100 is positioned with respect to the motor case 41 via a disk-shaped member 111 fixed to the motor case 41.

  As shown in FIG. 13, the holder member 110 includes a disk-shaped member 111 made of an insulating material such as plastic, and a support cylinder portion 113 is integrally provided at the center of the disk-shaped member 111. ing. This support cylinder part 113 removes the 2nd arm part 63 from the cylinder part 61 shown in FIG. 14 which forms the holder member 110 with the disk shaped member 111, ie, the holder member 60 in 2nd Embodiment shown in FIG. The cylindrical portion 61 in a state (omitted) is supported. As described above, the support tube portion 113 is configured to hold the tube portion 61 in the annular holding portion 71 so as not to rattle.

  The outer peripheral portion of the disk-shaped member 111, that is, the fitting cylinder that protrudes on the outer side in the radial direction from the bracket member support convex portion 112 on the side opposite to the side from which the bracket member support convex portion 112 protrudes (the lower side in the figure). The part 114 is provided integrally. The fitting cylinder portion 114 is formed thinner than the bracket member support convex portion 112 and is set to a dimension higher than the protruding height of the bracket member support convex portion 112. Thereby, as shown in FIG. 12, the fitting cylinder portion 114 enters the gap between the motor case 41 and the bus bar unit 80 and is fitted into the opening 41 d of the motor case 41.

  Further, as shown in FIG. 13, the notch 114a is formed in the fitting cylinder 114, and each motor-side conductive plate MP (see FIG. 12) is arranged in each notch 114a. It has become so. That is, each notch 114 a is configured to pull out the tip of each motor side conductive plate MP to the outside of the motor case 41.

  A second arm portion 115 whose base end portion is connected to the distal end portion of the first arm portion 62 provided in the cylindrical portion 61 is integrally provided on the outer peripheral portion of the disk-shaped member 111. A plurality of controller-side sensor lines CL are embedded in the second arm portion 115 by insert molding, whereby one end side of each controller line CL is the other end side of each motor-side sensor line of the first arm portion 62. It is designed to be connected electrically. Here, the distal end side (the side where each controller line CL is exposed) of the second arm portion 115 is arranged outside the motor case 41 via a notch (not shown) provided in the motor case 41. It has become.

  As described above in detail, the brushless motor 90 according to the third embodiment can achieve substantially the same operational effects as those of the second embodiment described above. In addition to this, in the third embodiment, the fitting cylinder portion 114 is arranged in the gap between the motor case 41 and the bus bar unit 80 so as to be fitted into the opening 41d of the motor case 41, And the bracket member 100 is positioned by the bracket member support convex part 112. Thereby, the outer peripheral wall part 46i (refer FIG. 9) which protrudes in the motor case side can be omitted, and the length dimension L3 on the motor case side is larger than the length dimension L1 on the motor case side in the second embodiment. Can also be shortened (L3 <L1). Therefore, the brushless motor 90 can be further downsized (shortened).

  Next, a fourth embodiment of the present invention will be described in detail with reference to the drawings. Note that portions having the same functions as those of the second embodiment described above are denoted by the same reference numerals, and detailed description thereof is omitted.

  FIG. 15 is a cross-sectional view illustrating the internal structure of the brushless motor according to the fourth embodiment, and FIG. 16 is a perspective view illustrating the holder member (with a signal conductive member and a detection unit) in FIG.

  As shown in FIG. 15, the brushless motor 120 according to the fourth embodiment is different in the shapes of the bracket member 130 and the holder member 140 compared to the second embodiment.

  The bracket member 130 is provided with a bearing holding portion 46a, and a holder fixing portion 46e similar to that of the first embodiment is provided outside the bearing holding portion 46a in the radial direction. In addition, an outer peripheral wall 46i that is press-fitted into the opening 41d of the motor case 41 is provided outside the holder fixing portion 46e in the radial direction. Thus, in the bracket member 130, the annular holding portion 71 (see FIG. 9) in the second embodiment is omitted. Therefore, the thickness of the bracket member 130 (dimension along the vertical direction in the figure) is reduced as compared with the second embodiment.

  The holder fixing portion 46e is provided with three engagement holes 46f (only one is shown in the drawing). Each engagement hole 46f is provided at equal intervals (120 ° interval) along the circumferential direction of the holder fixing portion 46e, and each engagement hole 46f is provided with 3 provided in a cylindrical holder 141 of a holder member 140 described later. One engaging claw 47h (see FIG. 16) is engaged. Accordingly, the holder member 140 can be firmly fixed without rattling with respect to the holder fixing portion 46e.

  As shown in FIG. 16, the holder member 140 is formed of a cylindrical holder 141 and a holder member 60 that is substantially the same as that shown in FIG. As described above, the holder member 140 according to the fourth embodiment employs a structure in which the cylindrical holder 141 is added to the holder member 60 according to the second embodiment. However, as shown in FIG. 10, in the second embodiment, the position of the first arm portion 62 is on the lower end side (lower side in the figure) of the cylindrical portion 61, whereas the fourth embodiment , The position of the first arm portion 62 is the upper end side (upper side in the drawing) of the cylindrical portion 61.

  As shown in FIG. 15, the outer diameter R1 of the cylindrical holder 141 is set to be smaller than the inner diameter R2 of the bus bar unit 80, and the bottom side (lower side in the figure) of the cylindrical holder 141 is As shown in the figure, it enters the inside of the bus bar unit 80 in the radial direction. Further, a through hole 141a through which the rotating shaft 44 passes is provided on the bottom side of the cylindrical holder 141, and a fitting part 48d of the holder member 60 is fitted in the vicinity of the through hole 141a. Yes. That is, the holder member 60 is mounted on the bottom side in the cylindrical holder 141.

  As shown in FIG. 16, a cutout portion 141b cut out from the opening side to the bottom side of the cylindrical holder 141 is formed on the side wall of the cylindrical holder 141. From the cutout portion 141b, the holder The first arm portion 62 and the second arm portion 63 of the member 60 are pulled out to the outside. In addition, the tip end side (the side where each controller line CL is exposed) of the second arm portion 63 of the holder member 60 is interposed through a notch portion (not shown) provided in the motor case 41 as in the second embodiment. It is arranged outside the motor case 41. Since the position of the first arm portion 62 is the upper end side of the fixed main body portion 61, the position where the first arm portion 62 and the second arm portion 63 are pulled out is between the bus bar unit 80 and the bracket member 130. It becomes.

  As described in detail above, the brushless motor 120 according to the fourth embodiment can achieve substantially the same operational effects as those of the second embodiment described above. In addition, in the fourth embodiment, the bracket member 130 is made thin, and the bottom side (fixed main body portion 61) of the cylindrical holder 141 is inserted into the inside of the bus bar unit 80 in the radial direction. The length dimension L4 of the entire casing of the motor 120 can be made shorter than the length dimension L2 of the entire casing in the second embodiment (L4 <L2). Therefore, the brushless motor 120 can be further downsized (shortened).

  It goes without saying that the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the invention. For example, in each of the above embodiments, the sensor holder 47e and the holder members 60, 110, and 140 are formed by outsert-molding the cylindrical portion 61 and the insulator portion with a resin material on the stator 48b. However, the present invention is not limited to this, and an insulator member may be previously formed of an insulating material, and the insulator member may be attached so as to cover the stator 48b.

  In each of the above embodiments, the brushless motors 20, 50, 90, 120 are applied to the column assist type electric power steering apparatus 10 provided in the middle of the steering shaft 12. However, the present invention is not limited thereto. Not limited to this, the present invention can also be applied to an electric power steering device that assists the pinion 15 (see FIG. 1) or assists the tie rod 16 (see FIG. 1).

  Further, in each of the above-described embodiments, the case where the brushless motors 20, 50, 90, 120 are used as the drive source of the electric power steering apparatus 10 is shown, but the present invention is not limited to this, for example, an oil pump motor or the like It can also be used as a drive source for other engine accessories.

  In each of the above embodiments, the resolver 48 is used as the rotation sensor in the present invention. However, the present invention is not limited to this, and other types of rotation can be used as long as the rotation of the rotor 43 can be detected. A sensor such as an encoder can also be employed.

  The brushless motor is used, for example, as a drive source of an electric power steering device mounted on a vehicle such as an automobile, and assists the steering of the steering wheel by the driver.

[0003]
A rotation sensor having a disk shape formed by pressing a steel plate, a bracket member that contacts the opening of the motor case and covers the opening, and is mounted on the motor case side of the bracket member, and the detection And a holder member for pulling out the signal conductive member to the outside through a notch between the motor case and the bracket member.
[0008]
In the brushless motor of the present invention, the bracket member includes a bearing holding portion that holds a bearing member that rotatably supports a rotating shaft fixed to the rotor, and a motor case positioning that positions the bracket member with respect to the motor case. And a holder member positioning portion that positions the holder member with respect to the bracket member.
[0009]
In the brushless motor of the present invention, the holder member pulls out the driving conductive member to the outside.
[0010]
In the brushless motor of the present invention, the motor case positioning portion is an annular wall portion protruding toward the motor case side, and the bracket member is attached to the motor case by press-fitting the annular wall portion into the opening. It is characterized by being fixed to.
[0011]
In the brushless motor of the present invention, the holder member positioning portion includes an engagement hole provided in the bracket member, and an engagement claw provided in the holder member and engaged with the engagement hole. And
[0012]
The brushless motor according to the present invention is characterized in that the holder member positioning portion includes an annular holding portion having an inner diameter larger than an inner diameter of the bearing holding portion.
[0013]
The brushless motor of the present invention is provided with a flange portion extending radially outward of the motor case on the opening side along the axial direction of the motor case, and the flange portion penetrates in the axial direction of the motor case. A case side screw hole is provided, a bracket member side screw hole facing the motor case side screw hole is provided in the bracket member, and a fixing screw penetrating the motor case side screw hole and the bracket member side screw hole is used. The brushless motor is fixed to an object to be attached.

[0004]
[0014]
The brushless motor of the present invention is characterized in that the brushless motor is a drive source of an electric power steering device.
Effect of the Invention [0015]
According to the brushless motor of the present invention, a motor case formed in a cylindrical shape is provided, and in the motor case, a current collector having a driving conductive member to which an end of a coil is connected, and an end of the signal conductive member And a rotation sensor having a detection unit for detecting the rotation of the rotor. The bracket member formed in a disk shape by pressing a steel plate into the opening of the motor case is brought into contact with the opening. A holder member is mounted on the motor case side of the bracket member to hold the detection portion and to pull out the signal conductive member to the outside through a notch portion between the motor case and the bracket member. . As a result, the current collecting device having the drive conductive member and the detection unit connected to the signal conductive member can be collectively arranged inside the motor case of the bracket member, and the signal conductive member can be disposed via the holder member. Can be pulled out of the motor case. Therefore, the motor case and bracket members are formed using steel plates to reduce the manufacturing cost and reduce the size and weight, while simplifying the pulling out of each conductive member, eliminating the cover plate that was required in the past, and assembling work. It is possible to greatly improve the performance.
[0016]
According to the brushless motor of the present invention, the bracket member includes a bearing holding portion that holds the bearing member that rotatably supports the rotating shaft fixed to the rotor, and a motor case positioning portion that positions the bracket member with respect to the motor case. And a holder member positioning portion for positioning the holder member with respect to the bracket member. As a result, the bracket member can position the bearing member, the motor case, the current collector, the holder member, and the detection unit in a state where the respective shaft cores coincide with each other. It is possible to reliably suppress the generation of sound. Moreover, since the detection part which forms a rotation sensor can be arrange | positioned inside a motor case rather than a bearing member, it becomes possible to improve the dust resistance / drip-proof property of a detection part more.
[0017]
According to the brushless motor of the present invention, the holder member removes the driving conductive member.

Claims (8)

A brushless motor comprising a stator core and a rotor that rotates within the stator core,
A motor case that is formed in a cylindrical shape and in which the stator core is fixed;
A coil wound around the stator core;
A current collector provided in the motor case and having a driving conductive member to which an end of the coil is connected;
A rotation sensor provided in the motor case and having a detection unit for detecting rotation of the rotor by connecting an end of the signal conductive member;
A bracket member that is formed in a disk shape by pressing a steel plate and covers the opening of the motor case;
A brushless motor, comprising: a holder member mounted on the bracket member, holding the detection unit, and pulling out the signal conductive member to the outside.   2. The brushless motor according to claim 1, wherein the bracket member includes a bearing holding portion that holds a bearing member that rotatably supports a rotating shaft fixed to the rotor, and a motor that positions the bracket member with respect to the motor case. A brushless motor comprising a case positioning portion and a holder member positioning portion for positioning the holder member with respect to the bracket member.   2. The brushless motor according to claim 1, wherein the holder member pulls out the driving conductive member to the outside.   3. The brushless motor according to claim 2, wherein the motor case positioning portion is an annular wall portion protruding toward the motor case, and the bracket member is inserted into the opening portion by press-fitting the annular wall portion. A brushless motor characterized by being fixed to a motor case.   3. The brushless motor according to claim 2, wherein the holder member positioning portion includes an engagement hole provided in the bracket member and an engagement claw provided in the holder member and engaged with the engagement hole. Brushless motor characterized by   3. The brushless motor according to claim 2, wherein the holder member positioning portion is an annular holding portion having an inner diameter larger than an inner diameter of the bearing holding portion.   2. The brushless motor according to claim 1, wherein a flange portion extending radially outward of the motor case is provided on the opening side along the axial direction of the motor case, and the flange portion penetrates in the axial direction of the motor case. A motor case side screw hole is provided, the bracket member is provided with a bracket member side screw hole facing the motor case side screw hole, and a fixing screw penetrating the motor case side screw hole and the bracket member side screw hole is provided. A brushless motor, wherein the brushless motor is fixed to an object to be attached.   The brushless motor according to claim 1, wherein the brushless motor is a drive source of an electric power steering apparatus.

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