WO2002013354A1

WO2002013354A1 - Brushless motor and method of manufacturing the brushless motor

Info

Publication number: WO2002013354A1
Application number: PCT/JP2001/006485
Authority: WO
Inventors: Shigeru Yoshida; Kodo Fukuoka; Masafumi Kumoi; Koji Kuyama
Original assignee: Matsushita Electric Industrial Co., Ltd.
Priority date: 2000-08-03
Filing date: 2001-07-26
Publication date: 2002-02-14
Also published as: WO2002013355A1; JP3578703B2; JP2002051520A; JP3578704B2; JP2002051519A

Abstract

A brushless motor, comprising a core (21) and terminals (31) formed of coils (22) and platy metal members, wherein a plurality of terminals (31) are disposed radially beforehand and connected to each other through connection members (32) on the inner or outer peripheral side thereof, each terminal (31) is stacked on the surface of each projected pole, each coil (22) is wound so as to bind each projected pole and each terminal (31), the ends of the coils (22) are connected to the terminals, and the connection members (32) are cut off for removal.

Description

Specification

Technical Field of the Invention

The present invention relates to a small brushless machine suitable for use in a portable electronic device and a method for manufacturing the same, and more particularly to a wire processing technique for a coil thereof. Background art

In the process of connecting the terminal of the coil to the external power supply terminal in a small brushless motor, it takes a lot of time to handle thin and soft wires. The tendency is more remarkable as the night becomes smaller. Therefore, various wire processing methods have been studied to facilitate assembly.

For example, J P—A—6—4 6 5 4 3 is a typical example. In this case, the core has a plurality of salient poles extending radially from the annular portion, and a coil is wound around the salient poles. A terminal is provided in the slot between the salient poles, and a coil terminal is wound around this terminal.

In this way, a terminal for holding the coil terminal is provided, and the terminal is placed in an empty space in the slot between the salient poles and wire-processed, so that the size of the motor is reduced. The soldering workability is improved without increasing the size. In addition, the evening terminal is integrally formed and held by a resin ring as a holding member to form a strong evening terminal assembly, and the terminal is prevented from being deformed or displaced by the terminal winding operation, and is connected to the external power supply terminal. Correctly soldered You. Such terminals are often used in small brushless rooms.

However, since this structure is provided with a terminal that protrudes from the ring to the slot, this terminal needs to be rigid and must be thick and strong. Therefore, this method cannot be applied to models that require a compact and high-density device that cannot provide a thick solid terminal in the slot. In addition, the resin ring must be thick and strong because the evening rim is formed and held integrally by the resin ring. Therefore, it cannot be applied to motors that require a small and thin design so that a resin ring cannot be placed on the annular part of the core.

Therefore, application of the invention disclosed in JP-A-4-193053, which is another known example, can be considered. Conventionally, a resin-molded insulator has been often arranged on the end face of the core to insulate the core from the coil. In this known invention, however, the salient pole in the insulation is provided. Yuichi Minal made of a thin metal plate is embedded in the area corresponding to. The coil is wound and held so as to bundle the salient poles and the terminal.

This is a structure in which the terminal is not arranged in the slot, so that it is suitable for a small and high-density motor so as not to take up an empty space in the slot. In addition, since the terminal is held in salient poles, the rigidity of this terminal is smaller than that of JP-A-6-465-43. Can be positioned correctly. In addition, the terminal holding member is placed in the annular part because the terminal is held on the core by the coil and the coil. There is no need to secure a space in which a bearing holding structure is provided. That is, the invention disclosed in JP-A-4-193053 solves the problem of the invention of JP-A-6-46553.

However, in this structure, the salient pole and the terminal overlap, so the thickness of the module increases by the total thickness of the terminal and its insulating layer. To eliminate this drawback, its thickness must be as thin as possible. However, when this resin insulating layer is formed by insert molding, the thickness of the resin in the portion to cover the resin insulating layer generally has to be about 0.2 mm or more due to restrictions due to molding fluidity. Therefore, when both sides are combined, a thickness of 0.4 mm is consumed for insulation, and this problem becomes a problem in the case where small size and thinness are strictly required. , JP—A—7—9557400. This is because a flexible printed circuit board (hereinafter, referred to as “: FPC”) is placed in contact with the annular portion on the end face of the core and the salient pole, and a coil is wound so as to bundle the salient pole and the FPC. After that, the coil terminal was directly connected to the external power supply terminal provided in the FPC. The thickness of the FPC including copper foil can be as thin as about 0.1 mm, so the thickness of the motor including this can be reduced, making it suitable for forming small and thin motors. . That is, here, the problem of the known technology disclosed in JP-A-.4-193053 has been solved.

However, in this structure, the FPC cannot function as a terminal. Because the FPC has a multilayer structure in which an insulator made of a resin film is laminated on the surface, the bent portion has a large springback and changes with time, and the bent shape cannot be maintained accurately. Because it is. In other words, it is not suitable for adopting a configuration in which the coil terminal connecting portion is bent and projected in the axial direction and connected to the external power supply terminal arranged on one side of the coil. Therefore, in the method described in JP-A-7-9.5.740, the FPC is superimposed on the end face of the core. The terminal of the coil is directly connected to the external power supply terminal provided on the FPC. ing.

However, the next issue is how to get rid of the FPC from the mouth, how to derive it from the outside, and how to connect it to equipment. In other words, even if it seems that the original purpose of improving the assemblability in the wire processing process has been achieved, new problems will be created in areas different from the wire processing.

As described above, none of these known technologies is satisfactory as a line processing technology in an extremely small and thin mobile phone. 'Disclosure of the invention'

Thus, the present invention provides a compact, high-density device that can not be obtained by these known technologies and that can connect a coil terminal to an external power supply terminal of a substrate disposed adjacent to one side of a coil and has no sufficient free space in a slot portion. The wire is suitable for a large motor, and it is not necessary to arrange a holding member in the annular part of the core, so that a space for the bearing holding structure etc. can be secured, and the wire can be made smaller and thinner. Provided is a small brushless camera having a processing structure and a method for manufacturing the same. The aim is to obtain a motor that is extremely small and thin but has high assembly productivity.

In order to achieve this object, a brushless motor according to the present invention includes a core, a coil, and an evening terminal made of a plate-shaped metal member, wherein the core is circular. It has an annular portion and a plurality of salient poles extending radially from the annular portion, and a plurality of evening terminals are held on the surface of the salient pole in a state of being separated from each other. The coils are wound so as to be bundled, and the terminal of each coil is connected to the terminal. '

Further, in the method of manufacturing a brushless model according to the present invention, a plurality of evening terminals are radially arranged in advance and connected by a connecting member on an inner peripheral side or an outer i side thereof, and an annular portion and the annular portion are formed. Each terminal is superimposed on the surface of each salient pole in a core having a plurality of salient poles extending radially from the portion, and a coil is wound so as to bundle these salient poles and the terminal, and the terminal of the coil is wound. The terminal is connected to the terminal, and the connecting member is cut and removed to achieve electrical insulation between the terminals.

Therefore, according to the present invention, without using a special terminal holding member, the core is kept electrically and mechanically separated from each other while maintaining its position by the core, and the coil has the function of holding the terminal on the salient pole surface. Fulfill. In this way, all of the functions of the known terminal holding member are replaced, and the terminal holding member is eliminated. In addition, this structure enables the use of thin and small terminal. <Therefore, the terminal can be made extremely small and thin with a terminal. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a sectional view showing a structure of a brushless camera according to a first embodiment of the present invention,

Fig. 2 shows the terminal in Fig. 1 connected by a connecting member. Figure,

FIG. 3 is a diagram showing a state in which the structure shown in FIG.

Fig. 4 is a diagram showing the state where the coil is wound around the one shown in Fig. 3,

FIG. 5 is a view showing a state in which the terminal and the coil terminal in FIG. 4 are joined by arc welding.

Fig. 6 is a diagram illustrating cutting and removing the connecting member in Fig. 5, and Fig. 7 is a diagram illustrating a state in which the arc welding joint in Fig. 6 is resistance-welded to a power supply terminal.

FIG. 8 is a view showing one example of a second embodiment of the present invention in which a brushless motor for manufacturing a brushless module is connected with a connecting member,

FIG. 9 is a view for explaining cutting and removing the connecting member after stacking the one shown in FIG. 8 on the core.

FIG. 10 is a diagram for explaining that the coil is wound around the one shown in FIG. 9 and the terminal and the coil end are joined by arc welding;

FIG. 11 is a diagram illustrating a motor stay assembly according to a first prior art, FIG. 12 is a diagram illustrating a motor setup according to a second prior art, and FIG.

FIG. 13 is a perspective view of a stay assembly of a motor according to a third conventional technique. BEST MODE FOR CARRYING OUT THE INVENTION

(Description of conventional technology)

Before describing embodiments of the present invention, an example of a known brushless machine will be described with reference to FIGS. 11 to 13 for reference φ.

FIG. 11 shows the one disclosed in JP-A-6-44653. In this case, as shown in the figure, the core 101 has a plurality of salient poles 103 radially extending from the central annular portion 102. Is wound. A slot 105 between the salient poles 103 is provided with an evening terminal 105, and a coil terminal 106 is wound and connected to the terminal 105. In the terminal 105, the coil terminal winding portion is formed to be bent in the axial direction of the core 101, and the external coil is disposed at a position on one side of the coil 104 along the axial direction of the core 101. The power supply terminal 107 (in this case, the land on the FPC 108) can be soldered. Although it is hidden in the figure and cannot be seen, the Yuichi Minor 105 is molded and held together by a resin ring provided behind (end face) the annular part 102 of the core 101. I have. The resin ring is press-fitted and fixed to the annular portion 102.

In this way, the terminal 105 for holding the coil terminal 106 is provided, and the terminal 105 is arranged in an empty space in the slot between the salient poles 103 to perform wire processing. As a result, the soldering workability is improved without increasing the motor dimensions. In addition, the terminal 一体 05 is integrally formed and held by a resin ring as a holding member to form a strong terminal assembly. Soldered correctly. Such terminals are often used in small brushless rooms.

However, since this structure is provided with a terminal 105 extending from the annular portion 102 to the slot, the terminal 105 needs rigidity and is thick and strong. There must be. Therefore, it is necessary to arrange a thick and strong terminal 105 in the slot. It cannot be applied to models that require a compact and high density that cannot be achieved.In addition, since the structure of this terminal 105 is integrally formed and held by a resin ring, the resin ring is also thick and strong. There must be. Therefore, it cannot be applied to motors that require a thin and thin wall because a resin ring cannot be arranged in the annular portion 102 of the core 101.

FIG. 12 shows an invention disclosed in JP-A-413-93 which has solved such a technical problem. FIG. 7A is a sectional view taken along the line in FIG. In the known technology, it is often practiced to dispose a resin molded insulator on the end face of the core for the purpose of insulating the core, the coil, and the G, but here, the insulator 11 is; LG Terminals 1 and 2 made of thin metal plates are embedded in the salient poles 1.14. Then, although not shown, the coils are wound so as to bundle the salient poles 1 14 and the evening 1 1 2 and the holding is performed. In addition, the terminal 1 1 2 has a coil end winding 1 13 at the tip thereof bent in the axial direction [ί], and the coil end winding 1 13 is disposed adjacent to the coil C on one side. It can be soldered to a printed wiring board (external power supply terminal on top, neither shown).

Since this is a structure in which the evening terminal 112 is not arranged in the slot portion, it is suitable for a small and high-density evening where no empty space can be taken up in the slot portion. Also, since the terminals 112 are held by the salient poles 114, the rigidity of this evening terminal 112 is smaller than that of Fig. 11 by / J, and it is thinner and smaller. However, it can be properly positioned to the external power supply terminal. Also, since the evening terminal 112 is held on the core by the insulator 111 and the tJ coil, there is no need to arrange an evening terminal holding member in the annular portion 115, and there is Bearing holding structure The space to be provided can be secured. That is, the known technique of FIG. 12 solves the problem of the known technique of FIG.

However, in this structure, since the salient poles 114 and the terminals 112 are connected, the total thickness of the terminals 112 and the insulating layer increases. To eliminate this disadvantage, its thickness must be as thin as possible. However, when this resin insulation layer is formed by insert molding, the thickness of the resin in such a portion generally has to be about 0.2 mm or more due to restrictions due to molding fluidity. Therefore, when both surfaces are aligned, a thickness of 0.4 mm is required for insulation, and this is a problem for motors that require strict miniaturization.

Therefore, as another publicly known example, there is the one of JP-A-7-975740. This is because, as shown in Fig. 13, F P..C 124 is arranged in contact with the annular portion 122 on the end face of the core 122 and the salient pole 123, and the salient pole 123 is formed. After winding the coil 1 2 5, the terminal 1 2 7 of the cell is directly connected to the external power supply terminal 1 2 6 provided on the FPC 1 2 4 It is. Since the thickness of the FPC 1 and 2 including the copper foil can be as thin as about 0.1 mm, the thickness of the motor including the FPC 1 and 2 can be reduced, making it suitable for configuring a small and thin motor. is there. In other words, the configuration shown in FIG. 13 solves the problem of the known technology shown in FIG.

However, in this structure, the FPC 124 cannot function as an overnight terminal. (Because the FPC 124 has a multilayer structure in which insulators made of grease film are stacked on the surface.) Bending: The springback of the part and the change with time are large, and the bending shape can be precisely controlled. Because it cannot be maintained. In other words, it is not suitable for adopting a configuration in which the coil terminal connecting portion is bent and projected in the axial direction and connected to an external power supply terminal arranged on one side of the coil. Therefore, in this known technology, the FPC 124 is superimposed on the end face of the core 122, and the terminal 127 of the coil is directly connected to the external power supply terminal 126 provided on the FPC 124. Have been. '

Then, the next problem is how to escape the FPC 124 from the mouth, how to lead it out of the motor, and how to connect it to the equipment. In other words, even if it seems to have achieved the original purpose of improving the assemblability in the wire processing process, new technical issues will arise in areas different from wire processing. (Description of Example of the Present Invention)

The present invention has solved such a problem in the related art, and an embodiment thereof will be described below with reference to the drawings. (First embodiment)

The motors shown in Figs. 1 to 7 are brushless motors that have an extremely small and thin shape with an outer diameter of about 10 mm, for example, and are used for vibration notification in mobile phones and the like. is there. In FIG. 1, this mode is composed of a stay (non-rotating part) 1, a mouth (rotating part) 2, and a cover 18. The mouth-to-mouth frame 2 is mainly composed of the mouth-to-mouth frame 11, and a ring-shaped magnet 12 is mounted inside. An eccentric weight 13 is attached to the mouth frame 11. The mouth frame 11 rotates about a shaft 14 attached to the center thereof. Station 1 mainly consists of a motor pace 15, and a winding assembly consisting of a core 21, a coil 22, and a terminal 31 is attached to this motor pace 5, and further supports a shaft 14. For metal 16 mounted on the center of the Morning Base 15. The coil terminal 2 is connected to the power supply terminal 17 of the mobile base 15. The power supply terminal 7 is provided at a position adjacent to one side of the coil 22 along the axial direction of the motor. Then, as described above, the mouth 14 is rotatably fitted with the metal 16 in a rotatable state, and is covered with the cap-shaped bar 18. A power supply terminal 17 is exposed on the lower surface of the motor, so that the motor can be reflow-connected to a device board (not shown).

The completed motor is connected to the board of the equipment (mobile phone) as described above, and the coil 22 is energized via the metal power supply terminal 17 on the lower surface, thereby rotating the contactor 2. I do. Then, vibration is generated by the eccentric weight 13 attached to the mouth 2 to vibrate the equipment.

Since the present invention relates to the structure of the stay 1, the stay 1 will be described in detail below.

Figure 2 shows the shape of the terminal. Here, six evening terminals 1 are arranged radially, and they are connected together by a connecting member 32 placed at the center. The connecting member 32 has a positioning hole 32a in the center thereof in a penetrating state.

In each terminal 31, the holding portion 31 a overlaps the salient pole of the base core, which is made wider, and the distal end side is the coil terminal connection portion lb. Then, as described above, the connecting member is Terminals 31 are interconnected by 2 and maintain their positions with each other. In each terminal 31, there are two bent portions 31c and 31c that are bent in a Z-shape in the middle portion between the holding portion 31a and the coil terminal connecting portion 31b. The coil terminal connection 3 lb is shifted from the holder 31 a in the motor axial direction. In the middle part from the holding part 3 1 ab to the connecting member 32, a member 31 f extends to the body in the rotation direction of the motor, and furthermore, the tip of the material 31 f It is bent in the axial direction to form the guide part 31 d of the crossover.

Yuichi Minal 31 is made of a non-magnetic metal, that is, a copper alloy plate such as a phosphor bronze plate having a thickness of about 80 / m. An insulating film made of UV-curable resin, thermosetting resin, etc.

3 1 e is formed. In FIG. 2 (a), the region represented by the dotted-line hatching is the insulating film 31e. As shown in the drawing, the insulating film 31e is formed radially inward of the bent portion 31c and radially outward of the connecting member 32. In other words, the bent portion 31c and the coil terminal connecting portion 3.1b are not insulated.

The insulating film 31e can be formed, for example, by vapor deposition of a polyimide-based material when thinness is given the highest priority. According to this, a thickness of several meters can be used practically, but 3 m must be considered as the limit of thickness in order to give a withstand voltage of about 30 QV to the insulating film. In the example shown in Fig. 2, with emphasis on productivity, a method of applying a liquid thermosetting resin by a screen printing method and curing it, and a thickness of 10 to 30 m was used. A film is formed. If priority is given to the pressure resistance and heat resistance reliability including burrs, the thickness of the mask screen should be increased or the viscosity of the liquid should be controlled, etc. It may be a thickness. Therefore, the thickness of the insulating film 31e is preferably 3 m or more and 100 m or less.

FIG. 3 shows a state in which the evening terminal 31 is overlaid on the surface of the core 21. The core 21 has an annular portion 21a near the center, and six salient poles 21b radially extending outward from the annular portion 21a. The terminal 31 is arranged in contact with the salient pole 2 lb of the core, and is temporarily fixed using an adhesive or the like. At this time, the thickness of the terminal 31 is about 0.1 mm including the insulation film, and the increase in the thickness of the terminal is small.

The structure of the terminal 31 will be described again in relation to the core 21.The coil terminal connection part 3 1b of the terminal 31 is bent from the surface of the core 21 by the bent part 31c. It is axially separated and extends radially parallel to the core surface. The bent portion 31c is located near the outer peripheral surface 2lc of the core, and does not project radially outward from the outer peripheral surface 2.lc. The connecting member 32 is inside the annular portion 21a of the core. The member 3 Γ f extends from the holding portion 31 a of the evening terminal 31 along the surface of the annular portion 21 a, and the crossover guide portion 31 d is just between the salient poles 21 b. At the center between them, it protrudes in the axial direction of the motor. <FIG. 4 shows a state where the coil 22 is wound around the one shown in FIG. 3. Here Mo Mo is a three-phase brushless Mo and has three sets of coils 22 (and salient poles 2 lb). In FIG. 4 (a), the coil 22 is wound around, for example, the rightmost salient pole 21b in FIG. 4 (a), and the crossover 24 is guided to a plurality of crossover guides 31d. It is wound counterclockwise while being wound, and wound around the leftmost salient pole 21b. The coil terminals 23 are located near the tip of each salient pole 21b. It is wound around a coil terminal connection part 31b. This is repeated three times at three locations, completing the assembly as shown in the figure.

At this time, the insulation film 31 e of the evening terminal was applied so as to cover the portion in contact with the coil 22 and the portion in contact with the crossover 24 in the evening terminal 31, and the terminal 31 and the coil 2 2 is kept insulated. Evening Minal 3 1 is in contact not only with coil 2 2 but also with core 21, but by forming an insulating film on core 21, insulation can be similarly secured. Therefore, in this case, it is not always necessary to insulate the portion of the terminal 31 in contact with the core 21. Next, the coil end 23 is joined to the coil end connecting portion 31b by arc welding. To this end, as shown in FIG. 4 (b), first, the ground electrode 71 of the welding machine is electrically connected to the central connecting member 32 of the evening terminal 31. Specifically, the ground electrode 71 is pressed against the positioning hole 32 a at the center of the connecting member 32. The welding electrode 72 is arranged so as to face the tip of the coil terminal connecting portion 31b. Then, “arc discharge” is generated, and the coil terminal 23 and the coil terminal connecting portion 31b are fusion-bonded. This operation is performed six times while rotating the core 21 by 60 °, and the welding is completed. A non-consumable electrode such as tungsten is used as the welding electrode 72, and the periphery of the molten portion is covered with an inert gas such as argon which is jetted from a gap 77 around the outer periphery of the contact electrode 72. Oxidation is prevented. Figure 5 shows the state where welding has been completed. The base material of the coil terminal connection part 31b is melted and joined so as to wrap the coil terminal 23. 3 1 h is the beam arc welded joint. Next, the connecting member 32 in the center is cut and removed by the cutting tool 73 as shown in FIG. In Fig. 6, the cut part 31g is the annular part Slightly protrudes inside 2 1a. The cutting tool 73 is operated while being guided in the vicinity of the annular portion 21a of the core, so that the remaining projecting portion is made as small as possible. Alternatively, depending on the size of the motor, there may be an application in which the cut portion 31g is protruded to be engaged with the motor pace 15 and held in the axial or rotational direction.

The winding assembly completed in this way is attached to the module 15 overnight. This is shown in FIG. Evening minal 31 Arc welding Joint 3 1 h is superimposed on feed terminal 17 of motor pace 15, this part is sandwiched by resistance welding head 76, and Joule heat is generated when current flows. It produces heat. When heated and pressed to just before melting, the arc welded joint, ie, the melted coil terminal connection 3 lb, and the power supply terminal 17 are welded. After that, as described at the beginning, the assembly is performed, and the moo is completed.

By removing the connecting members 3 2. for holding the evening miners 3 1 in this way, the evening miners 3 1 are separated from each other and overlap the surfaces of the salient poles 21 b. The coil 22 is wound so as to bundle the salient pole 2 1b and the Yuichi Minaru 3 1 while maintaining the position. Therefore, the motor can be configured to be extremely small and thin while having the terminal 31.

A plurality of terminals 31 are arranged radially in advance, and the inner peripheral side thereof is connected by a connecting member 32. After connecting the terminal 31 to the end face of the salient pole 21b, the connecting member 32 is held. Is cut and removed to provide electrical insulation between the evening mina 31.This eliminates the need for a member that holds a plurality of evening mina 31 and improves the workability of assembly. ing. Also, salient pole 2 1b is connected to terminal 3 by connecting member 3 2. A plurality of terminals 31 can be handled while maintaining the mutual position until 1 is maintained, which also improves the assembly workability. Therefore, good assemblability can be realized in a small and thin motor.

In the terminal 31, a cut portion 3 lg which is an inner peripheral end thereof protrudes more inward than the annular portion 21 a of the core 21. That is, cutting can be performed in a state of protruding inward from the contour of the core 21. Therefore, when the method of cutting and removing the connecting member 32 after holding the terminal 31 superimposed on the surface of the salient pole 21b is adopted, the cutting tool 73 can be easily inserted and the workability is good.

The terminal 31 is superposed and held on the surface of the salient pole 21b, and the portion in contact with the core 21 or the coil 22 is formed with an insulating film 31e, which is much thinner than a known one, and is electrically operated. Insulation is achieved. This eliminates the need for a member to hold the evening minal, and at the same time minimizes the increase in the thickness of the motor due to the terminal 31 overlapping the salient pole 21b. .

The external power supply terminal 17 is arranged on a flat board (motor pad 15), and is provided at a position adjacent to one side of the coil 22 along the motor axis direction. Then, the electrical terminal 17 of the module is placed on the lowermost surface of the board (base 15), which provides good connectivity with the equipment. When assembling, it is possible to assemble simply by stacking the parts, so that the assembling performance is excellent.

The evening terminal 31 has an axial bent portion 31c in the middle between the holding portion 31a and the terminal connection portion 31b of the coil. 3 1 b is away from core 21 in the axial direction of motor As a result, the contact with the magnet 12 can be avoided, and the coil terminal holding portion 31b can be provided at a position where the external power supply terminal 17 can be easily arranged and connected. In other words, in general, the outer perimeter of the salient pole and the magnet are close to each other, and the evening mina held by the salient pole is also close to the magnet in the mode of the night and evening type. On the other hand, in the present invention, the terminal 31 is bent to avoid contact between them. In addition, the terminal connection portion 31b of the coil is led to a position where the external power supply terminal 17 can be easily arranged and connected, thereby improving ease of assembly and use. Therefore, it is possible to make the module excellent in assemblability and easy to use for equipment manufacturers. · Terminal 31 is made of a copper-based alloy as a non-magnetic metal, which is a metal of the same type as coil 22. And good joining quality can be obtained. Also, it is possible to prevent an unnecessary magnetic loop from being created between the terminal 31 and the magnet 12 which are arranged close to each other.

The terminal 31 has a guide portion 31d that regulates the position of the crossover 24 in the annular portion 21a, so that the crossover can be easily performed while suppressing an increase in cost-up space. 24 position control can be performed.

Since the coil terminal connection part 3 lb of the terminal 31 is located on the outer peripheral side of the salient pole 21 b of the core 21, that is, the core 21 and the coil 22 are viewed from the axial direction of the motor. Since it is located radially outside of the contour, a tool for connecting this coil terminal connecting portion 31b to the external power supply terminal 17 such as the resistance welding head shown in FIG. , And the work of making the connection easy.

After overlapping and holding the terminal 31 on the surface of the salient pole 2 1b, the coil 22 is wound so that the salient pole 2 lb and the Yuichi Minar 3 1 are bundled. It is not necessary to hold the evening terminal 31 by other means until the end, and handling becomes easier, and when the evening terminal 31 is connected, the connecting portion is separated before winding. The degree of freedom of the process increases, such as separation.

At terminal 31, bend 3 1 c and coil terminal connection

Since no insulating film 31e is formed on 31b, there is no springback due to the resin material or the like, and the bent shape can be accurately maintained. In addition, when joining with the coil end 23, no organic matter is interposed, and a good joining state is obtained.

By applying and curing an ultraviolet curable resin or a thermosetting resin to form the insulating film 31e, an insulating film 31 高い having high heat resistance can be formed with high productivity. Specifically, since these resins can be selectively applied in the manufacturing process and quickly cured and dried, the insulation treatment can be performed with high productivity. According to this method, the thickness of the film can be easily controlled, and an insulating film having a thickness suitable for various required characteristics such as thinness, productivity, pressure resistance and heat resistance can be easily obtained.

(Second embodiment)

A second embodiment of the present invention will be described with reference to FIGS. The second embodiment is different from the first embodiment in that the connection structure of Yuichi Minaru 51 is changed and the manufacturing process is changed accordingly. In the following, it seems that there is no change or redundancy compared to the first embodiment. Parts and illustrations are omitted from illustration and description.

Figure 8 shows the shape of terminal 51. This is one in which six evening terminals 51 are arranged radially, and each terminal 51 is integrally connected by a frame-shaped connecting member 52 placed outside these terminals 51. . At each evening 51, at the inner part along the radial direction (the holding part 51a whose base overlaps the salient pole of the core, the tip part formed at the outer part along the radial direction) Are the coil terminal connecting portions 5 1 b. As described above, the coil terminal connecting portions 5 1 b are connected to each other by the connecting member 52. The holding portion 51 a and the coil terminal connecting portion 5 There are two bends 51c in the middle part of 1b, whereby the coil terminal connection 51b is shifted in the axial direction of the motor. It is a guide part for the wire and is formed at the tip of the member 5 If The insulating film 51 e is formed on a part of the surface of the terminal 51. The broken line in Fig. 8 (a) The area represented by the hatched area is the insulating film 51 e. In the evening terminal 51, the annular portion 41 a of the core 41 (Fig. 9) No inner peripheral end portion 5 1 g in the insulating film is formed to overlap, and has a left exposed metal surface.

FIG. 9 shows a state where the terminal 51 is overlaid on the surface of the core 41. As shown in the figure, the terminal 51 is arranged in contact with the salient pole 41b of the core 41, and is fixed using an adhesive or the like. Next, the connecting member 52 is cut off from the evening terminal 51. 'At this time, cutting is performed using a cutting tool 74 as shown in the drawing at the tip end 51 h of the coil terminal connecting portion 51 b.

FIG. 10 shows the coil after the connecting member 52 is cut and removed. 22 indicates a wound state. The winding operation is completed by repeating the process three times in the same manner as in the first embodiment. Next, the coil terminal connection portion 5 1 b and the coil terminal 23 are joined by arc welding. First, the ground electrode 75 ′ of the welding machine is connected to the metal exposed surface at the innermost periphery of the terminal, that is, the inner periphery 51. electrically connected to g. For this purpose, a ground electrode 75 as shown in FIG. 10 (b) is used. The ground electrode 75 is formed by fitting a ring-shaped electrode 75b to a guide rod 75a fitted into the innermost positioning hole 41c of the core 41. This is pressed against the exposed metal surface of the evening 51, that is, the inner peripheral portion 51g. The welding electrode 72 is arranged so as to face the tip of the coil terminal connecting portion 51b. Then, arc discharge is caused to fuse and join the coil terminal connecting portion 51b and the coil terminal 23. This operation is performed 6 times while rotating the core 41 by 60 ° to complete the welding. , ..

The winding assembly completed in this manner is mounted on the motor and pedestal in the same manner as in the first embodiment, and the coil terminal connecting portion 51b of the evening terminal 51 is connected to the power supply terminal. The motor is completed.

As described above, in the second embodiment, the terminals 51 are preliminarily arranged radially and integrally connected to the frame-shaped connecting member 52 on the outer peripheral side, and the salient poles 4 1b After the terminal 51 is superimposed and held on the surface of the terminal 51, the connecting member 52 is cut and removed, so that electrical insulation between the terminal 51 is achieved. This eliminates the need for a member that holds the evening light and improves workability in assembly.

In the Yuichi Minar 51, the coil terminal connecting portion 51b protrudes more outward than the salient poles 41b of the core 41. That is, the contour of core 4 1 Protruding outward. Therefore, when a method of cutting and removing the connecting member 52 after holding the evening light 51 on the end face of the salient pole 41b is used, the cutting tool is easy to handle and workability is good.

Although several embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various applications and developments are possible within the scope of the present invention. is there.

Claims

The scope of the claims

1. A brushless motor, comprising: a core, a coil, and a terminal made of a plate-shaped metal member, wherein the core has an annular portion and a plurality of salient poles extending radially from the annular portion, A plurality of evening terminals are held on the surface of the salient pole in a state of being separated from each other, a coil is wound so as to bundle each salient pole and the terminal, and a terminal of each coil is connected to the evening terminal. It is connected to the.

2. The brushless motor according to claim 1, wherein the first and second terminals are radially arranged in advance and connected by a connecting member on an inner peripheral side or an outer peripheral side thereof. In this configuration, the connection member is cut and removed after being held on the surface of the pole so as to achieve electrical insulation with another terminal. .

3. The brushless motor according to claim 1 or 2, wherein the tip of the evening terminal projects radially outward from the core contour when viewed from the axial direction of the motor.

4. The brushless motor according to claim 1 or 2, wherein an insulating film is formed on a portion contacting the core and / or a portion contacting the coil, and between the core and the core. Or electrical insulation between the coils.

5. A brushless brush according to claim 1 or 2, which is located adjacent to one side of the coil along an axial direction of the motor and the brushless. —The power supply terminal is located at the position corresponding to the part where the coil terminal of the terminal is connected.

6. The brushless motor according to claim 1 or 2, wherein the evening terminal is a shaft of the motor between a portion that is overlapped and held on the surface of the salient pole and a portion that connects the coil terminal. Direction bending part. .

7. The brushless motor according to claim 1 or 2, wherein the terminal is formed of a non-magnetic metal.

8. The brushless motor according to claim 1 or 2, wherein the coil has a crossover passing near the annular portion between the salient poles of the core, and the evening terminal is the annular shape. It has a guide in the motor axis direction that regulates the position of the crossover in the section.

9. The brushless motor according to claim 1 or 2, wherein the connection portion of the coil terminal at the terminal of the motor is in a radial direction rather than a contour of the core and the coil when viewed from the axial direction of the motor. It is arranged outside.

10. The brushless model according to claim 1, wherein the evening minimum is:

An insulating film is formed on a portion in contact with the core and a portion in contact with the coil to provide electrical insulation between the core and the coil. An axial bending portion of the motor between the terminal connecting portion and the terminal; and An insulating film is not formed on the bent portion and the portion connecting the coil terminal.

11. The brushless motor according to claim 4, wherein the insulating film is formed by applying an ultraviolet curable resin or a thermosetting resin to the terminal and curing the resin.

12. The brushless motor according to claim 11, wherein the thickness of the insulating film is 3 m or more and 100 / m or less.

1 3. A method of manufacturing brushless motors,

A plurality of evening terminals are radially arranged in advance and connected integrally by connecting members on the inner peripheral side or the outer peripheral side thereof.

In a core having an annular portion and a plurality of salient poles extending radially from the annular portion, the surface of each salient pole is superimposed on each evening terminal, and a coil is formed so as to bundle these salient poles and evening terminal. Is wound,

Connect the terminal of the coil to the terminal,

The connection member is cut and removed to achieve electrical insulation between the terminals.

14. The method for manufacturing a brushless motor according to claim 13, wherein each of the salient poles is bonded and held on the surface of each salient pole.

15. The method for manufacturing a brushless motor according to claim 13 or 14, wherein instead of winding the coil and then cutting the connecting member, each terminal is provided on the surface of each salient pole. Cut the connecting member while holding the And then wind the coil.