JP2004260999A - Electric motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve motor performance and assemblability with an electric motor.
SOLUTION: A plurality of teeth 31a are arranged coaxially with respect to a rotor rotatably mounted on a housing and non-rotatably mounted on the housing, and are radially arranged around a rotation axis of the rotor. An electric motor having a circular yoke 31b connecting radial ends of each tooth 31a and a plurality of coils wound around each tooth 31a at a slot S formed between each tooth 31a is used as a stator yoke. 31b and the respective teeth 31a are integrally formed, and insulators disposed in the respective slots S and interposed between the respective teeth 31a and the respective coils are fitted into both ends of the respective slots S and the coil wires are inserted. A pair of end insulators, and an elastically deformable cylinder into which coil wires are inserted at both ends in these end insulators. It consisted of an intermediate insulator in the shape of a letter.
[Selection diagram] FIG.

Description

  The present invention relates to an electric motor including a rotor rotatably mounted on a housing and a stator arranged coaxially with the rotor and non-rotatably mounted on the housing.

In Patent Document 1 below, a stator is formed between a plurality of teeth radially arranged around a rotation axis of a rotor, a circular yoke connecting radial ends of these teeth, and the teeth. An electric motor (electric motor) having a plurality of coils wound around each of the teeth at the corresponding slots is shown.
JP-A-9-215230

  In the stator disclosed in the above-mentioned publication, a plurality of teeth are formed separately from the yoke, and after winding a coil around each tooth, each tooth is fixed to the yoke. For this reason, the characteristics of the teeth tend to vary, which tends to cause an increase in cogging torque, and may degrade motor performance. Further, it is necessary to fix each tooth to the yoke, and there is room for improvement in assemblability. Therefore, an object of the present invention is to improve the motor performance or the assemblability of an electric motor.

  In order to achieve the above object, according to the present invention, a rotor rotatably mounted on a housing and a stator coaxially disposed with respect to the rotor and non-rotatably mounted on the housing (an outer periphery of the rotor). The stator may be arranged on the inner periphery), and the stator connects a plurality of teeth radially arranged around the rotation axis of the rotor with radial ends of the teeth. In the electric motor having a circular yoke and a plurality of coils wound around the teeth at slots formed between the teeth, the yoke of the stator and the teeth are integrally formed. Insulators disposed in the respective slots and interposed between the respective teeth and the respective coils are respectively provided at both ends of the slots. A pair of end insulators which are fitted and through which a coil wire is inserted, and an elastically deformable cylindrical intermediate insulator which is fitted into the end insulators at both ends and through which a coil wire is inserted (claim) (Invention according to Item 1).

  In this case, the intermediate insulator may be formed by bending an elastically deformable thin plate-like material into a slot shape and overlapping the ends to form a cylinder (the invention according to claim 2). The overlapping portion of the intermediate insulator may be arranged at the center on the outer peripheral side of the slot (the invention according to claim 3). In each of the above cases, a pair of end insulators and an intermediate insulator are attached to each of the slots, a coil wire is inserted through these insulators to form a coil, and a resin for molding the coil is filled in the slot. (The invention according to claim 4) is also possible.

  In these electric motors (the electric motors of the inventions according to claims 1 to 4), since each tooth is formed integrally with the yoke, the characteristics of each tooth are less likely to vary, and an increase in cogging torque is prevented. Thus, the motor performance can be improved. Further, since the insulator provided in each slot and interposed between each tooth and each coil is constituted by the pair of end insulators and the intermediate insulator, the assemblability of the insulator into each slot can be improved. .

  Further, in the electric motor according to the fourth aspect of the present invention, after a pair of end insulators and an intermediate insulator are assembled in each slot, a coil wire is inserted through these insulators to form a coil, and the coil is made of resin. By molding, a stator is formed. By the way, since the insulator assembled to each slot is constituted by the pair of end insulators and the intermediate insulator, the insulator can be easily assembled to the slot. Further, when the coil is molded with resin, both ends of the intermediate insulator are elastically deformed by the molding pressure and are brought into close contact with the inner surface of the end insulator to prevent leakage of the resin. As a result, the resin does not leak to the peripheral surface of the stator, the gap between the rotor and the stator can be set narrow, and the motor performance can be improved.

  In practicing the invention according to claim 4, it is also possible to form engagement portions at both ends in the axial direction of the insulator to engage with a tapered surface of a mold for molding (the invention according to claim 5). It is. In this case, it is possible to prevent the resin from leaking between the insulator and the mold for molding at the time of molding, to set a narrow gap between the rotor and the stator, and to improve the motor performance. Can be.

  In each of the above electric motors (the electric motor of each of the inventions according to claims 1 to 5), an insulator interposed between each of the teeth and each of the coils is disposed in each of the slots, and It is also possible to provide connecting portions for continuously connecting the front ends in the circumferential direction at predetermined axial intervals (the invention according to claim 6). In this case, since the connecting portions for continuously connecting the tips of the teeth in the circumferential direction are provided at predetermined axial intervals, the radial protrusion of the insulator interposed between each tooth and each coil ( It is possible to prevent radial protrusions through gaps formed between the tips of the respective teeth, thereby making it possible to narrow the gap between the rotor and the stator, thereby improving motor performance.

  In practicing the present invention, the housing and the stator are made unrotatable by key means, and a sensor mounted on the housing and detecting a rotation phase of the rotor with respect to the stator is positioned by the key means. The invention according to item 7) is also possible. In this case, the stator can be non-rotatably positioned and fixed to the housing by the key means, and a sensor for detecting the rotational phase of the rotor can be positioned and fixed to the housing using the key means. . Therefore, the sensor can be easily and inexpensively and accurately positioned with respect to the stator, the rotation phase of the rotor with respect to the stator can be accurately detected, and the motor performance can be sufficiently exhibited.

  In practicing the present invention, the electric motor is a vehicle steering system which applies an axial steering assisting force by rotation of the rotor to a steering rack shaft coaxially mounted in the rotor via a ball screw mechanism. An electric motor of the device, comprising a sensor for detecting a rotation phase of the rotor with respect to the stator, a notch provided in the protrusion by projecting one end of the rotor from the housing by a predetermined amount in the axial direction. (The invention according to claim 8) is also possible so as to be able to transmit torque to the test device. In this case, it is possible to evaluate the performance of the electric motor used in the vehicle steering device by itself, and to adjust the offset of a sensor that is attached to the housing and detects the rotation phase of the rotor with respect to the stator. It can be easily performed by itself and variations in motor performance can be suppressed.

  In practicing the present invention, it is also possible to connect the inner peripheral portions of the teeth at the boundaries between the phases (the invention according to claim 9). In this case, since the tips of the teeth are connected at the boundary between the coil units of each phase, that is, at a portion where the magnetic flux change is small and the back electromotive voltage is small, it is possible to suppress the generation of noise due to the back electromotive voltage and cogging. The torque can be reduced, and the motor performance can be improved.

  An embodiment of the present invention will be described below with reference to the drawings. 1 and 2 show an embodiment in which the electric motor according to the present invention is employed in a steering device for a vehicle. The electric motor according to this embodiment includes a cylindrical rotor 20 rotatably and axially immovably mounted on a housing 10 via ball bearings 91 and 92, and a housing arranged coaxially around the outer periphery of the rotor 20. The motor housing 11 includes a stator 30 that is non-rotatably (integrally) mounted to the motor housing 11, and a sensor 40 that detects the rotational phase of the rotor 20. ) And control signals (not shown) based on detection signals from the sensor 40 and the like.

  The housing 10 is composed of a motor housing 11 and a gear housing 12, and the gear housing 12 supports a pinion shaft and a steering rack shaft (not shown). The steering rack shaft is coaxially mounted in the rotor 20 via a ball screw mechanism (not shown) so that the rotation of the rotor 20 applies an axial steering assisting force. Has become.

  As shown in FIGS. 1 and 3, the rotor 20 has a shaft body 21 formed of a magnetic material in a stepped cylindrical shape, and 16 rotors 20 arranged and fixed at equal intervals on the outer periphery of the shaft body 21. A permanent magnet 22, a thin pipe 23 (a non-magnetic material such as stainless steel or aluminum) covering the permanent magnet 22 from the outer periphery, and a stepped cylindrical pipe fixed to the outer periphery of the shaft main body 21 to prevent the thin pipe 23 from coming off. The stopper 24 is formed of a metal, non-metal, magnetic material, or non-magnetic material. The pipe stopper 24 can also be used (substitute) by extending a part of the rotor-side member 42 of the sensor 40. In this case, the number of parts can be reduced.

  The shaft main body 21 protrudes from the left end of the motor housing 11 by a predetermined amount in the axial direction, and transmits a torque to a rotating shaft of a test device (a motor performance evaluation test device (not shown)) through a notch 21b provided in the protrusion 21a. It is configured to be connected as possible. The mounting surface of the electric motor shown in FIG. 1 to the test apparatus is the left end surface of the motor housing 11 in FIG.

  Each of the permanent magnets 22 has a shape that is long in the axial direction, is formed in an arc shape in which an inner peripheral side (one of the S poles) is convex toward the inner periphery, and has an outer peripheral side (one side). The N poles are alternately formed) and are formed in an arc shape centered on the rotation center of the rotor 20. The thin pipe 23 is a pipe for preventing magnet scattering, and is fixed to the outer periphery of the permanent magnet 22 by caulking a part between the permanent magnets 22. Note that the thin pipe 23 and the pipe stopper 24 may have an integrated structure molded with resin.

  As shown in FIGS. 1 and 4, the stator 30 includes a cylindrical core 31, a plurality of (18) coils 32 wound around the core 31, and an insulator 33 interposed between the core 31 and the coil 32. And a coil connection tool (bus bar) 34 for connecting the ends of the coils 32, and a current-carrying terminal 35 connected to the coil connection tool 34, which has adhesiveness and electrical insulation to the motor housing 11. Molded at 36 and integrated.

  As shown in FIGS. 5 to 7, the core 31 is formed by punching out an electromagnetic steel sheet into a predetermined shape (the shape shown in FIG. 5) and then laminating the steel sheet in the axial direction to form an integral structure. 18 teeth 31a radially arranged about the rotation axis of the teeth 31a, and a circular yoke 31b connecting the radially outer ends of the teeth 31a. The teeth 31a and the yoke 31b are integrally formed. Is formed. Each tooth 31a has a magnetic pole portion 31a1 extending in the circumferential direction on the inner peripheral side, and forms a slot S extending in the axial direction for winding the coil 32. In addition, circular concave and convex fitting portions 31c and 31d are formed at the base end and the distal end portion of each tooth 31a, and by fitting these, electromagnetic steel plates are integrally laminated. .

  As shown in FIGS. 8 to 11, the coil 32 has three coils continuous in the circumferential direction as one coil unit (U1-phase, V1-phase, W1-phase, U2-phase, V2-phase, and W2-phase). It is formed continuously with wires, and the 18 coils 32 are composed of 6 coil wires. In addition, it is desirable that the tip of each coil wire is sharply sharpened in order to improve the winding property, assembling property, and reliability on the core 31 and the coil connection tool 34, and at that time, the tip is sharply sharpened using a special jig. Alternatively, the coil wire may be thinned by being pulled in the axial direction, and then cut and sharpened.

  As illustrated in FIG. 11, each coil unit is wound in the order of 1 to 8 from the outer circumference of the left tooth 31a to the inner circumference, and then wound in the order of 9 to 15 from the inner circumference to the outer circumference of the central tooth 31a. Finally, the right teeth 31a are formed by being wound from the inner circumference to the outer circumference in the order of 16 to 24. If the outer periphery 15 of the center tooth 31a is wound around the outer periphery 24 of the right tooth 31a, it cannot be wound next on the outer periphery 22 of the right tooth 31a, and the number of turns of the coil 32 is reduced. I will.

  As shown in FIGS. 8 and 12 to 16, the insulator 33 is fitted to a pair of end insulators 33 a attached to the axial end of the core 31, and fitted into the end insulators 33 a at both ends. The intermediate insulator 33b is formed into three parts in the motor axis direction. As shown in FIGS. 12 to 15, each end insulator 33 a includes a through hole 33 a 1 through which a coil wire is inserted, a protrusion 33 a 2 fitted into a cutout 31 e formed at an end of the core 31, and a coil 33 a 2. A guide groove 33a3 for guiding the nozzle 32 and three notches 33a4 are formed, and a cylindrical portion 33a5 is formed corresponding to the through hole 33a1. As shown in FIG. 16, the intermediate insulator 33b is formed by bending an elastically deformable thin plate-shaped insulator material into a shape of a slot S (a shape through which a coil wire is inserted) to form a cylinder. The portion is located at the center on the outer peripheral side of the slot S.

  As shown in FIG. 1, FIG. 4, FIG. 8, and FIG. 9, the coil connection tool 34 includes a holder 34a made of an insulating resin and connection pieces 34b connecting ends of the coil units. Is formed with a leg portion 34a1 that fits into the notch 33a4 of the end insulator 33a, and a flat plate portion 34b1 is formed on each connection piece 34b to which each connection piece 35a of the energization terminal 35 is connected. The flat plate portion 34b1 of each connection piece 34b and each connection piece 35a of the energization terminal 35 are joined by resistance welding before being molded with the resin 36.

  The current-carrying terminals 35 are screwed and fixed to the housing 10 in advance (see FIG. 2), and the core 31, the coil 32, the insulator 33, and the coil connector 34 of the stator 30 are shown in FIGS. As shown in (1), each flat plate portion 34b1 of the coil connector 34 comes into contact with each connection piece 35a of the energizing terminal 35 by being incorporated in the motor housing 11. At this time, a key 50 shown by a virtual line in FIG. 1 is used for positioning the stator 30 with respect to the motor housing 11 (positioning in the circumferential direction). The key 50 can be used as a reference when assembling the housing-side member 41 (see FIGS. 1 and 17) of the sensor 40 to the motor housing 11. When positioning the stator 30 and the housing-side member 41 of the sensor 40 with respect to the motor housing 11 in this manner, the positioning of the sensor 40 with respect to the rotor 20 with respect to the rotor 20 is performed by using a non-magnetic key ( It is desirable to perform the same in the same manner (not shown).

  As shown in FIG. 18, the resin 36 is filled and solidified in a state in which a mold 60 for molding is fitted on the inner periphery of the stator 30, and as shown in FIG. Then, the stator 30 is integrated with the motor housing 11. The mold 60 for molding has a tapered surface 61 at both ends in the axial direction of the insulator 33, that is, a portion engaging with the inner periphery of the end of the end insulator 33a. To prevent leakage to the inner peripheral side. The injection port (gate not shown) of the resin 36 is desirably disposed at a position where the molding pressure does not directly act on the core 31, and at a position substantially in the center of the slot S where the coil 32 does not hinder the resin injection. Is desirable.

  The sensor 40 includes a housing-side member 41 positioned and fixed to the motor housing 11 and a rotor-side member 42 positioned and fixed to the rotor 20. The phase of the rotor 20 and the stator 30 ( The rotation phase of the rotor 20 with respect to the stator 30 is detected, and a detection signal is output to a control device (not shown).

  If an offset value of the sensor 40 with respect to the motor unit is detected in advance and is written in the sensor 40 in the form of a trimming resistor or the like, the offset value is obtained from the sensor 40 at a voltage level by a control device (illustrated in FIG. (Omitted). In this case, there is no need to write the offset value in the control device (not shown), and even if the control device (not shown) changes, the offset value is accurately sent to the control device (not shown), and the predetermined torque is obtained. Can be generated.

  The electric motor configured as described above performs the following steps, that is, a step of winding each coil 32 around the core 31, a step of assembling the coil connector 34 to each coil 32, and a step of attaching the stator 30 to the motor housing 11. , A process of assembling the housing side member 41 of the sensor 40 to the motor housing 11, a process of assembling the rotor 20 to the housing 10, and the like.

  In the step of winding each coil 32 around the core 31, prior to winding each coil 32, each end insulator 33a is attached to both ends in the axial direction of the core 31, and then both ends of each intermediate insulator 33b are attached. Eighteen intermediate insulators 33b are assembled so as to fit into the cylindrical portions 33a5 of the end insulators 33a, and then the coils 32 are sequentially wound in the order shown in FIG. 11 to form a coil unit. Is done.

  In the process of assembling the coil connection tool 34 to each coil 32, the coil connection tool 34 fits each leg 34a1 into each notch 33a4 of the end insulator 33a in accordance with each coil unit wound around the core 31. Thereby, the ends (coil wires) of the respective coil units are caulked and fixed to the corresponding portions of the respective connection pieces 34b, and the stator sub-assembly shown in FIGS. 8 to 10 is formed. You.

  In the step of molding the stator 30 into the motor housing 11, prior to molding, the stator sub-assembly shown in FIGS. Is attached to the motor housing 11 from the outer periphery, and thereafter, the flat plate portion 34b1 of each connection piece 34b of the coil connection tool 34 and each connection piece 35a of the energizing terminal 35 are joined by resistance welding. And molded with resin 36. The injection of the resin 36 is performed from the right side to the left side in FIG. 1 and from the inner circumference to the outer circumference.

  In the process of assembling the housing-side member 41 to the motor housing 11 in the sensor 40, the housing-side member 41 is connected to the motor housing 11 with reference to the key 50 (see the phantom line in FIG. 1) in which the stator subassembly is positioned on the motor housing 11. 11 and assembled. Before or after this step, the ball bearing 91 is mounted on the motor housing 11.

  In the process of assembling the rotor 20 to the housing 10, the rotor 20 is positioned via the ball bearing 92 while the rotor side member 42 of the sensor 40 is positioned and assembled at the right end of the rotor 20 and the ball bearing 92 is assembled. Then, the motor housing 11 to which the stator 30 and the like are assembled is inserted into the rotor 20 from left to right, and the motor housing 11 and the gear housing 12 are connected using bolts (not shown). .

  In the electric motor of the present embodiment manufactured as described above, since each tooth 31a is formed integrally with the yoke 31b, the characteristics of each tooth 31a are less likely to vary, and an increase in cogging torque is suppressed. As a result, the motor performance can be improved.

  An insulator 33 disposed in each slot S and interposed between each tooth 31a and each coil 32 is combined with a pair of end insulators 33a mounted on both ends of the core 31 and assembled in each slot S. Since it is constituted by 18 intermediate insulators 33b to be attached and is divided and formed in the axial direction of the motor, it is possible to easily assemble the insulator 33 into each slot S.

  When the coils 32 and the like are molded with the resin 36, both ends of the intermediate insulator 33b are elastically deformed by the molding pressure, so that the intermediate insulator 33b comes into close contact with the inner surface of the end insulator 33a to prevent leakage of the resin. Thereby, the resin 36 does not leak to the inner peripheral surface of the stator 30, the gap between the rotor 20 and the stator 30 can be set narrow, and the motor performance can be improved. In addition, the overlapping portion of the intermediate insulator 33b is pressed against each other by the molding pressure to prevent resin leakage.

  Further, in the electric motor of the present embodiment, since the guide groove 33a3 for guiding the coil 32 is formed in the end insulator 33a of the insulator 33 attached to each slot S, the coil 32 can be stably wound. Thus, the assemblability can be improved. In addition, since the engaging portions for engaging with the mold 60 for molding are formed at both ends in the axial direction of the insulator 33, the resin 36 leaks to the inner peripheral side through the space between the insulator 33 and the mold 60 for molding during molding. Can be prevented, the gap between the rotor 20 and the stator 30 can be set narrow, and the motor performance can be improved.

  Further, in the electric motor of the present embodiment, when the coil 32 is continuously wound around the three teeth 31a, as shown in FIG. Since the center tooth 31a is wound from the inner circumference to the outer circumference and finally wound from the inner circumference to the outer circumference of the other tooth 31a, the outer circumference portion between the teeth 31a (the space is larger than the inner circumference portion). Can be effectively used to increase the number of turns of the coil 32, and the motor performance can be improved.

  In the electric motor of the present embodiment, the thin pipe 23 covering the surface of the plurality of permanent magnets 22 attached to the outer peripheral surface of the rotor 20 is fixed by caulking a part between the magnets. The management can be easily performed by the thickness of the permanent magnet 22 and the thickness of the thin pipe 23, the gap between the rotor 20 and the stator 30 can be easily managed, and the motor performance can be stabilized.

  Further, in the electric motor of the present embodiment, the motor housing 11 and the stator 30 are non-rotatably positioned by the key 50, and the housing of the sensor 40 which is attached to the motor housing 11 and detects the rotation phase of the rotor 20 with respect to the stator 30. Since the side member 41 is positioned by the key 50, the stator 30 can be non-rotatably positioned and fixed to the motor housing 11 by the key 50, and the housing side member 41 of the sensor 40 is attached to the motor housing 11 using the key 50. Positioning can be fixed. Therefore, the sensor 40 can be easily and inexpensively and accurately positioned with respect to the stator 30, the rotation phase of the rotor 20 with respect to the stator 30 can be accurately detected, and the motor performance can be sufficiently exhibited. It is possible.

  Further, in the electric motor of the present embodiment, one end of the rotor 20 is protruded from the housing 10 in the axial direction by a predetermined amount, and torque can be transmitted to the rotating shaft of the test device through the notch 21b provided in the protruding portion 21a. , It is possible to evaluate the performance of the motor alone, and easily adjust the offset of the sensor 40 attached to the housing 10 and detecting the rotation phase of the rotor 20 with respect to the stator 30 by the motor alone. And variations in motor performance can be suppressed.

  In the above embodiment, as shown in FIGS. 5 and 7, the tips (inner peripheral ends) of the respective teeth 31 a are formed discontinuously in the circumferential direction, and the respective slots S are formed on the inner peripheral side. Although they are continuously open, as shown by the imaginary line in FIG. 7, when connecting portions 31a2 for continuously connecting the tips of the teeth 31a in the circumferential direction are provided at predetermined axial intervals ( In the case where the connecting portions 31a2 are provided on the electromagnetic steel sheets laminated every predetermined number of sheets), the intermediate insulator 33b interposed between each tooth 31a and each coil 32 projects in the radial direction (between the tip of each tooth 31a). (Protruding inwardly through the gap formed through the gap) can be prevented, the gap between the rotor 20 and the stator 30 can be set narrow, and the motor performance can be improved.

  Further, in the above embodiment, the insulator 33 is constituted by a pair of end insulators 33a attached to both ends of the core 31 and 18 intermediate insulators 33b assembled in each slot S (two types of 20 insulators). However, as shown in FIG. 19, the cylindrical portion 33a5 of the end insulator 33a is formed to be longer in the axial direction by a predetermined amount (formed to be approximately half the axial length of the core 31). It is also possible to alternately form the distal end portion as a solid line shape oblique in the radial direction and a virtual line shape (alternately oblique shape in the circumferential direction). In this case, when assembling the pair of end insulators 33a to the core 31, the phases are shifted vertically by one slot, so that the insulators 33 can be constituted by one kind and two pieces, so that the number of parts is reduced. Thus, cost reduction and productivity improvement can be achieved.

  Further, in the above embodiment, the coil connector 34 is used to connect the end of each coil 32 and each connection piece 35a of the current-carrying terminal 35. However, as shown in FIG. It is also possible to connect the terminal terminals 39 directly to the ends of the power supply terminals 35 so that the terminal terminals 39 are connected to the respective connection pieces 35 a of the energizing terminals 35. In this case, by bending the end of the coil 32, the position of the terminal terminal 39 can be arbitrarily changed, the degree of freedom in setting the terminal terminal 39 can be improved, and the assembling property can be improved. Can be done.

  Further, when the present invention is carried out, the boundaries (C1, C2, C3, C4, C5, C6 in FIG. 10) of the coil units of the respective phases (U1, V1, W1, U2, V2, W2). That is, when the tip of the tooth 31a is connected to a portion where the magnetic flux change is small and the back electromotive voltage is small, it is possible to suppress the generation of noise due to the back electromotive voltage and to reduce the cogging torque. Thus, the motor performance can be improved.

  In practicing the present invention, in addition to the sensor 40, a back electromotive force sensor (not shown) for detecting a back electromotive force of the electric motor, and a calculating means for calculating an offset amount based on outputs from both of these sensors When (not shown) is provided, the offset of the sensor 40 can be easily obtained electrically, and the detection value of the sensor 40 can be electrically corrected based on this. Therefore, in this case, there is no need to mechanically adjust the offset of the sensor 40 with respect to the motor housing 11, and the assembly workability can be improved.

  In practicing the present invention, it is also possible to employ the magnetic encoder 140 shown in FIGS. 21 to 23 instead of the sensor 40. The encoder 140 includes a housing-side member 141 mounted on the motor housing 11 and a rotor-side member 142 (comprising a drum 142a and a magnet 142b) mounted on the rotor 20 side. As shown in FIG. 23, the incremental phase 142b includes an incremental phase (an INC phase having 108 poles each of N and S poles) and an absolute phase (a U phase, a V phase having 8 poles each of N and S poles / phase, W phase) are axially displaced and magnetized.

  Therefore, when an electric motor is configured by employing the encoder 140 described above, an absolute phase (U phase, V phase, W phase) functioning as an absolute sensor and an incremental phase (INC phase) functioning as an incremental sensor are included. Since they are arranged substantially linearly in the axial direction, it is possible to easily adjust the detection sensitivity of the sensor.

  When the present invention is carried out, as shown in FIG. 24, when a part of the yoke 31b located between the teeth 31a is protruded by a predetermined amount in the extending direction (inner circumferential direction) of the teeth 31a, the winding is performed. The rigidity of the yoke 31b can be increased by suppressing the reduction of the space of the wire (reduction of the space for winding the coil 32).

  In practicing the present invention, the rotor includes a rotor rotatably mounted on the housing, and a stator coaxially disposed with respect to the rotor and non-rotatably mounted on the housing, wherein the stator is configured to rotate the rotor. A plurality of teeth radially arranged around the axis, a circular yoke connecting the radial ends of the teeth, and a slot formed between the teeth are wound around the teeth. In an electric motor having a plurality of coils, an insulator disposed in each of the slots and interposed between each of the teeth and each of the coils is engaged with a tapered surface of a mold for molding at both axial ends of the insulator. It is also possible to form an engaging part.

  In practicing the present invention, the rotor includes a rotor rotatably mounted on the housing, and a stator coaxially disposed with respect to the rotor and non-rotatably mounted on the housing, wherein the stator is configured to rotate the rotor. A plurality of teeth radially arranged around the axis, a circular yoke connecting the radial ends of the teeth, and a slot formed between the teeth are wound around the teeth. In the electric motor having a plurality of coils, the housing and the stator may not be rotatable by key means, and a sensor attached to the housing and detecting a rotation phase of the rotor with respect to the stator may be positioned by the key means. It is possible.

  In practicing the present invention, a rotor rotatably mounted on the housing, a stator coaxially disposed with respect to the rotor and non-rotatably mounted on the housing, and a rotational phase of the rotor with respect to the stator. In the electric motor provided with a sensor for detecting the position of the rotor, one end of the rotor is protruded from the housing by a predetermined amount in the axial direction, and the rotor is connected to the test device through a cutout provided in the protrusion so as to be capable of transmitting torque. It is also possible to configure. In this case, the electric motor is an electric motor for a vehicle steering device that applies an axial steering assisting force by rotation of the rotor to a steering rack shaft that is coaxially mounted in the rotor via a ball screw mechanism. It may be.

  In practicing the present invention, the rotor includes a rotor rotatably mounted on the housing, and a stator coaxially disposed with respect to the rotor and non-rotatably mounted on the housing, wherein the stator is configured to rotate the rotor. A plurality of teeth radially arranged around the axis, a circular yoke connecting the radial ends of the teeth, and a slot formed between the teeth are wound around the teeth. In an electric motor having a plurality of coils, the tips of the teeth may be connected at the boundary between the coil units of each phase.

It is a longitudinal section showing one embodiment of an electric motor by the present invention. FIG. 2 is a plan view of the electric motor shown in FIG. 1. FIG. 2 is a vertical sectional side view of a main part of the rotor shown in FIG. 1. FIG. 2 is a longitudinal sectional view of a motor housing and a stator shown in FIG. 1. FIG. 5 is a front view of the core alone shown in FIGS. 1 and 4. FIG. 5 is a side view of the core alone shown in FIGS. 1 and 4. It is the front view which expanded and showed a part of FIG. FIG. 10 is a cross-sectional view along a line AA of FIG. 9 illustrating a relationship among a core, a coil, an insulator, and a coil connector in the stator illustrated in FIGS. 1 and 4. FIG. 9 is a left side view of the assembly shown in FIG. 8. FIG. 9 is an enlarged cross-sectional view of the assembly shown in FIG. 8 taken along line BB. It is the enlarged view which showed the winding order of the coil shown in FIG. FIG. 9 is a front view of the end insulator alone shown in FIG. 8. FIG. 9 is a rear view of the end insulator alone shown in FIG. 8. It is the front view which expanded and showed a part of FIG. It is the rear view which expanded and showed a part of FIG. FIG. 9 is a view showing an intermediate insulator assembled between both end insulators shown in FIG. 8. FIG. 2 is a front view of the sensor shown in FIG. 1. It is process explanatory drawing at the time of resin-molding a stator component to a motor housing. It is a fragmentary sectional view showing a modification of an insulator. It is a figure showing an embodiment in which a terminal terminal is directly connected to an end of a coil. FIG. 2 is a side view of a magnetic encoder that can be used instead of the sensor shown in FIG. 1. FIG. 22 is a plan view of the magnetic encoder shown in FIG. 21. FIG. 22 is a diagram showing a positional relationship of magnetized tracks provided on an outer peripheral surface of a rotor side member of the magnetic encoder shown in FIG. 21. FIG. 9 is a partial view showing a modified embodiment of the yoke in the core.

Explanation of reference numerals

DESCRIPTION OF SYMBOLS 10 ... Housing, 11 ... Motor housing, 12 ... Gear housing, 20 ... Rotor, 21 ... Shaft main body, 21a ... Projection part, 21b ... Notch part, 22 ... Permanent magnet, 23 ... Thin pipe, 24 ... Pipe stopper, 30 ... Stator, 31 ... core, 31a ... teeth, 31a2 ... connecting portions provided on the teeth, 31b ... yokes, 32 ... coils, 33 ... insulators, 33a ... end insulators, 33a3 ... guide grooves provided on the end insulators, 33b ... Intermediate insulator, 34 coil connection tool, 35 energizing terminal, 36 resin for molding, 39 terminal terminal, 40 sensor, 41 member on housing side, 42 member on rotor side, 50 key, 60 molding Mold, 61 ... tapered surface, 91, 92 ... ball bearing, S ... slot.

Claims (9)

A rotor rotatably mounted on the housing, and a stator coaxially disposed with respect to the rotor and non-rotatably mounted on the housing, wherein the stator is radially disposed about a rotation axis of the rotor; In the electric motor having a plurality of teeth, a circular yoke connecting radial ends of these teeth, and a plurality of coils wound around each of the teeth at a slot formed between each of the teeth, The yoke of the stator and the teeth are integrally formed, and insulators disposed in the slots and interposed between the teeth and the coils are fitted to both ends of the slots, respectively. A pair of end insulators into which the coil wire is inserted, and a coil fitted at both ends into the end insulators. Electric motor, wherein the line is constituted by the intermediate insulator elastically deformable tubular to be inserted. 2. The electric motor according to claim 1, wherein the intermediate insulator is formed in a tubular shape by bending an elastically deformable thin plate-shaped material into a slot shape and overlapping ends thereof. 3. The electric motor according to claim 2, wherein the overlapping portion of the intermediate insulator is disposed at a center of an outer peripheral side of the slot. 4. The electric motor according to claim 1, 2 or 3, wherein a pair of end insulators and an intermediate insulator are assembled in each of the slots, a coil wire is inserted through these insulators to form a coil, and the coil is molded. An electric motor characterized in that the slot is filled with resin. 5. The electric motor according to claim 4, wherein engaging portions are formed at both axial ends of the insulator so as to engage with a tapered surface of a mold for molding. The electric motor according to any one of claims 1 to 5, wherein an insulator interposed between each of the teeth and each of the coils is disposed in each of the slots, and a tip of each of the teeth is arranged in a circumferential direction. An electric motor characterized in that connecting portions for continuous connection are provided at predetermined axial intervals. 2. The electric motor according to claim 1, wherein the housing and the stator are made non-rotatable by key means, and a sensor attached to the housing and detecting a rotation phase of the rotor with respect to the stator is positioned by the key means. Features electric motor. 2. The electric motor according to claim 1, wherein the electric motor applies a steering assisting force in an axial direction by rotation of the rotor to a steering rack shaft coaxially mounted in the rotor via a ball screw mechanism. An electric motor for a steering device, comprising a sensor for detecting a rotation phase of the rotor with respect to the stator, a notch provided in the protrusion by projecting one end of the rotor axially from the housing by a predetermined amount; An electric motor characterized in that the electric motor is configured to be connected to a test device so as to be capable of transmitting a torque. 2. The electric motor according to claim 1, wherein the tips of the teeth are connected at a boundary between the coil units of each phase.

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