WO2019003553A1 - Motor manufacturing method, motor manufacturing device, and sensor magnet part positioning device - Google Patents

Abstract

This motor manufacturing method is a method for manufacturing a motor provided with: a stator 36 containing an excitation coil 32; a rotor 34 having a shaft 33 and a main magnet 35, and rotatably provided on the inside in the radial direction of the stator 36; and a sensor magnet part 31 for detecting the rotation position of the rotor 34. The method includes: a step for fixing the rotor 34 so that the main magnet 35 is at a prescribed rotation position; a step for using a positioning device that includes an external magnet 23 to position the sensor magnet part 31 at a magnetic pole position having a prescribed angle θ with respect to the prescribed rotation position of the main magnet 35; and a step for attaching the positioned sensor magnet part 31 to the shaft 33 while the rotor 34 fixed.

Description

Method of manufacturing motor, motor manufacturing device, and positioning device of sensor magnet unit

The present invention relates to a method of manufacturing a motor, a motor manufacturing apparatus, and a positioning apparatus for a sensor magnet unit.

The brushless motor comprises means for detecting the rotational position of the rotor. The means for detecting the rotational position of the rotor includes, for example, a sensor magnet unit fixed to a shaft that is a rotation shaft of the rotor, and a magnetic sensor arranged to face the sensor magnet unit. The detection means detects the rotational position of the rotor by detecting the change of the magnetic field of the sensor magnet unit rotating in synchronization with the rotor by the magnetic sensor.

Japanese Patent Application Laid-Open No. 11-289736

When current is applied to the coils of the stator to rotate the motor, current flows in the wire connecting the control board and the coil, and a magnetic field is formed around the wire. The influence of the magnetic field on the magnetic sensor disposed on the control substrate reduces the detection accuracy of the rotational position and increases the torque ripple. In order to prevent an increase in torque ripple, software may filter the detection signal to adjust the detected rotational position. However, when manufacturing the rotor, if there is a variation in the magnetized position in the circumferential direction (the position of the magnetic pole in the circumferential direction) of the sensor magnet with respect to the rotational position of the magnet of the rotor, the magnetic field affecting the magnetic sensor will also vary. As a result, adjustment of filtering software is required for each motor, which increases the manufacturing cost.

An object of the present invention is to provide a method of manufacturing a motor capable of manufacturing a motor capable of suppressing a torque ripple while maintaining detection accuracy of a rotational position of the motor, a manufacturing device, and a positioning device of a sensor magnet unit. Do.

A method of manufacturing a motor according to an exemplary embodiment of the present application includes a stator including an excitation coil, a shaft and a main magnet, a rotor rotatably provided radially inward of the stator, and a rotational position of the rotor And a sensor magnet unit for driving the motor. In the same manufacturing method, the step of fixing the rotor such that the main magnet is at a predetermined rotational position, and the positioning device including a magnetic field generating unit capable of generating a magnetic field, are used to Positioning the sensor magnet portion at an angled magnetic pole position, and attaching the positioned sensor magnet portion to the shaft with the rotor fixed.
In addition, the process of the said manufacturing method is not limited to performing in the described order.

According to the method of manufacturing the motor, the manufacturing apparatus, and the positioning device of the sensor magnet unit according to the exemplary embodiment of the present application, it is possible to manufacture the motor capable of suppressing the torque ripple while maintaining the detection accuracy of the rotational position of the motor. .

FIG. 1 is a cross-sectional view of a motor manufacturing apparatus according to a first embodiment. FIG. 2 is a top view of the motor manufacturing apparatus of FIG. FIG. 3 is a perspective view of the sensor magnet unit according to the first embodiment. FIG. 4A is a diagram showing one process for positioning the sensor magnet unit. FIG. 4B is a diagram showing one process for positioning the sensor magnet unit. FIG. 4C is a view showing a process for attaching the sensor magnet unit positioned in FIG. 4B to a shaft. FIG. 5 is a control block diagram of the motor manufacturing apparatus. FIG. 6 is a flowchart showing the positioning operation by the motor manufacturing apparatus. FIG. 7 is a diagram showing the positional relationship between the main magnet of the rotor and the sensor magnet unit. FIG. 8A is a view showing one process for positioning the sensor magnet unit according to the second embodiment. FIG. 8B is a view showing one process for positioning the sensor magnet unit according to the second embodiment. FIG. 8C is a view showing a process for attaching the sensor magnet unit positioned in FIG. 8B to a shaft. FIG. 9 is a diagram for explaining the position of the magnetized pole of the sensor magnet unit. FIG. 10 is a cross-sectional view showing a positioning device of a sensor magnet unit in another embodiment. FIG. 11 is a cross-sectional view showing a sensor magnet portion positioning device in another embodiment. FIG. 12 is a cross-sectional view showing a positioning device of a sensor magnet unit in another embodiment. FIG. 13A is a cross-sectional view of a sensor magnet unit and a positioning device according to another embodiment. 13B is a cross-sectional view showing a state in which the sensor magnet unit of FIG. 13A is attached to a shaft.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The scope of the present invention is not limited to the following embodiments, and can be arbitrarily changed within the scope of the technical idea of the present invention.

In the drawings, an XYZ coordinate system is shown as a three-dimensional orthogonal coordinate system as appropriate. In the XYZ coordinate system, the Z-axis direction is the vertical direction. The X-axis direction is the right-left direction in FIG. 1 among the directions orthogonal to the Z-axis direction. The Y-axis direction is orthogonal to both the X-axis direction and the Z-axis direction. Further, unless otherwise specified, in the following description, a radial direction centered on a central axis (shaft axis) extending in the vertical direction (Z-axis direction) is referred to as “radial direction” and a circumference centered on the central axis The direction is called "circumferential direction". The side radially away from the central axis is called the radially outer side, and the opposite side is called the radially inner side.

(Embodiment 1)
[1-1. Constitution]
<Motor>
The motor 30 according to the first embodiment shown in FIG. 1 is, for example, a brushless motor. The motor 30 includes a shaft 33, a rotor 34, a main magnet 35, a stator 36, a bus bar 37, an external connection terminal 38, a housing 39, and the like.

The shaft 33 is disposed at the position of the central axis of the motor 30, and is inserted into the cylindrical rotor core 34a. As shown in FIG. 4C, a recess 33a extending in the Z-axis direction is formed at the tip of the shaft 33 on one side in the axial direction. The pin part 31b of the sensor magnet part 31 mentioned later is attached to the recessed part 33a.

The rotor 34 has a rotor core 34 a and a main magnet 35 mounted radially outward of the rotor core 34 a. As shown in FIG. 7, the main magnet 35 is provided with N poles and S poles alternately in the circumferential direction. The number of poles of the main magnet 35 is eight. Although the main magnet 35 of the rotor shown in the present embodiment is SPM (Surface Permanent Magnet) fixed to the surface of the rotor core, the present invention is not limited to this. The main magnet 35 may be replaced by an IPM (Interior Permanent Magnet) fixed inside the rotor core.

The stator 36 is disposed close to the radially outer side of the rotor 34. The stator 36 is an annular member, and has a ring-shaped stator core 36a having teeth portions (not shown) provided at equal intervals in the circumferential direction and a core back portion (not shown) connecting the teeth. . The teeth extend radially inward from the core back portion. On the teeth portion of the stator core 36a, for example, a three-phase exciting coil 32 composed of a U-phase, a V-phase, and a W-phase is wound.

The bus bar 37 is a conductive member. In the present embodiment, the bus bar 37 is a plate-like member made of metal. The bus bar 37 is a wire that connects the exciting coil 32 and the external connection terminal 38 and supplies a current. The external connection terminal 38 is electrically connected to an external power supply (not shown) and supplies a current to the exciting coil 32 through the bus bar 37. The shape, material, and the like of the bus bar 37 are not limited to the above. In addition, the bus bar 37 may be connected to the exciting coil 32, the external connection terminal 38, and the like via a control board described later.

The housing 39 is provided on the radially outer side of the stator core 36a. The housing 39 is cylindrical, and one side in the Z-axis direction is open. In the present embodiment, the housing 39 has a cylindrical shape. The shape of the housing may not be limited to a cylinder, but may be a rectangular parallelepiped, a shape combining a rectangular parallelepiped and a cylinder, or the like, and is not particularly limited. The housing 39 is made of, for example, aluminum and is formed by die-casting, but may also be formed by other methods such as cutting and forging. In addition to aluminum, the material of the housing 39 may be another metal material such as iron, and is not particularly limited.

Although not shown, the motor 30 further includes a control board. The control board has a magnetic sensor (not shown) facing the sensor magnet unit 31 attached to the shaft 33. In the present embodiment, the magnetic sensor is an MR sensor, but may be a Hall element or the like. The magnetic sensor detects the magnetic field of the sensor magnet unit 31 that rotates with the shaft 33. Thereby, the rotational position of the rotor 34 can be detected.

The control board further includes a microcontroller including a control circuit and the like. The microcontroller can calculate the rotational position of the rotor 34 based on the output of the magnetic sensor. Thereby, the drive of the motor 30 can be controlled based on the instruction of the microcontroller or the like. In other words, the rotation and stop of the rotor 34 can be controlled. Therefore, for example, by controlling energization of the excitation coil 32 of three phases, the rotor 34 is rotated to a predetermined position, and the magnetic pole of the main magnet 35 is referred to as a predetermined rotational position (hereinafter referred to as a rotor fixed position). can do. Although not shown, the control substrate includes other circuits such as a drive circuit and electronic components.

The motor 30 further includes a sensor magnet unit 31.

<Sensor magnet section>
The sensor magnet unit 31 is attached to the end of the shaft 33 as described later.

As shown in FIG. 3, the sensor magnet unit 31 includes a columnar magnet unit 31 a and a columnar pin unit 31 b whose outer diameter is smaller than that of the magnet unit 31 a. The pin portion 31 b includes a grip portion 31 e. The magnet portion 31 a is a permanent magnet that has two poles of N and S. The end portion on one side in the axial direction of the pin portion 31 b is attached to the inner peripheral surface of the magnet portion 31 a. More specifically, the magnet portion 31 a has a through hole that penetrates in the axial direction. At least a part of the pin portion 31 b is fixed in the through hole by press fitting, adhesion, or the like. The end of the pin 31b on the one side in the axial direction is located on one side in the axial direction of the opening on the one side in the axial direction of the through hole of the magnet 31a. The end of the pin portion 31 b on the other side in the axial direction is positioned on the other side in the axial direction with respect to the through hole on the other side in the axial direction of the magnet portion 31 a. The gripping portion 31e is an end portion located on the other side in the axial direction of the magnet portion 31a. The gripping portion 31e is gripped by an operation unit 15 shown in FIG. 1 described later. The sensor magnet unit 31 is positioned at a predetermined position (hereinafter, referred to as “sensor magnet magnetic pole position”) as described later.

<Manufacturing device of motor>
As shown in FIGS. 1 and 2, the motor manufacturing apparatus 10 includes an arm portion 11, a support member 13 for supporting one end of the arm portion 11, an operation portion 15, a shaft holding portion 18 and a base portion 19. Prepare. The base portion 19 supports the motor 30 and the support member 13 to be manufactured.

The arm unit 11 moves in the X axis direction, the Y axis direction, and the Z axis direction together with the operation unit 15 under the control of the control unit 50 shown in FIG. 5 described later. The operation unit 15 is provided at the other end of the arm unit 11. The operation unit 15 grips the grip 31e of the sensor magnet 31 shown in FIG. The shaft holder 18 holds the other end of the shaft 33 from below. Thus, when the sensor magnet 31 is attached to one end of the shaft 33 of the motor 30 placed on the base 19, the shaft 33 can be prevented from being lowered.

<Positioning device>
The positioning device included in the motor manufacturing device 10 includes an operation unit 15 and a position adjustment unit 20, as shown in FIGS. 1 and 2.

As shown in FIG. 4A, the position adjustment unit 20 has a main body 21, an external magnet 23, and a recess 25.

The main body portion 21 may be provided to protrude on the base portion 19 of the motor manufacturing apparatus 10, or may be provided by forming the concave portion 25 directly in the base portion 19. The external magnet 23 is disposed above the main body 21 and includes a permanent magnet magnetized in two poles.

As shown in FIG. 4A, the recess 25 is formed at the center of the main body 21. The recess 25 extends in the axial direction of the shaft 33. The inner diameter of the recess 25 is formed to such an extent that the inserted pin portion 31 b can rotate. As shown in FIG. 4B, when the pin portion 31 b is inserted into the recess 25, the magnet portion 31 a of the sensor magnet portion 31 radially faces the external magnet 23. At this time, the operation unit 15 releases the sensor magnet unit 31. Thus, the sensor magnet unit 31 is rotatably supported by the position adjustment unit 20. The sensor magnet unit 31 is rotated to the sensor magnet magnetic pole position and stopped by the repulsive force of the magnetic force between the magnet unit 31 a and the external magnet 23 and the attraction force.

As a result of applying the magnetic force to the sensor magnet unit 31, the external magnet 23 rotates the sensor magnet unit 31 to the position shown in FIG. The position shown in FIG. 7 is a position where the sensor magnet magnetic pole position has a predetermined angle θ with respect to the rotor fixed position.

The sensor magnet unit 31 is attached to the shaft 33 while maintaining the positioned state. Thereby, the magnetized position of the sensor magnet unit 31 with respect to the main magnet 35 becomes constant.

Although a permanent magnet is used as the external magnet 23 in the illustrated example, an electromagnet may be used.

<Control unit>
The positioning operation of the sensor magnet unit 31 by the motor manufacturing apparatus 10 is executed by the control unit 50 shown in FIG. The control unit 50 includes, for example, a microcontroller, a ROM, a processor, a RAM, and the like. The microcontroller is provided, for example, on a control substrate and includes a control circuit and the like. The ROM stores, for example, a control program for positioning operation. The processor controls the positioning operation based on, for example, a control program. The RAM temporarily stores, for example, various data under control.

As shown in FIG. 5, the control unit 50 generates and outputs control signal commands to the movement drive unit 51 and the rotor rotation control unit 53.

The movement drive unit 51 is a drive mechanism that moves the arm unit 11 in the X-axis direction, the Y-axis direction, and the Z-axis direction shown in FIGS. 1 and 2 in accordance with a control signal command from the control unit 50. As shown in FIGS. 4A, 4B, and 4C, the movement drive unit 51 can move the operation unit 15 provided at one end of the arm unit 11 to the position adjustment unit 20 or the shaft 33.

The rotor rotation control unit 53 is provided on a control substrate of the motor 30 and controls energization of the stator 36, that is, rotation of the rotor 34 via a microcontroller or the like. For example, as described above, by controlling the energization of the exciting coil 32, the rotor 34 is rotated and stopped so that the magnetic pole of the main magnet 35 has a predetermined rotational position.

[1-2. Operation]
FIG. 6 is a flowchart showing a positioning operation mainly performed by the control unit 50 of the motor manufacturing apparatus 10.

As described above, first, the rotational position of the rotor 34 is previously fixed to a predetermined rotational position (step S101). Next, the arm unit 11 is moved, and the target sensor magnet unit 31 is gripped by the operation unit 15 (step S102). The arm unit 11 is moved, and the operation unit 15 is moved to the position adjustment unit 20 (step S103). The pin portion 31 b of the sensor magnet portion 31 is inserted into the recess 25 of the main body portion 21, and the sensor magnet portion 31 is positioned in the axial direction of the shaft 33. The grip by the operation unit 15 is released, and the sensor magnet unit is released (step S104). At this time, the sensor magnet unit 31 is rotated until it reaches the sensor magnet magnetic pole position by the attraction force and the repulsion force of the magnet unit 31a with respect to the external magnet 23, and stops. As a result, the sensor magnet unit 31 is positioned. If the positioning of the sensor magnet unit 31 is completed, the process proceeds to step S106 (step S105). The sensor magnet unit 31 positioned by the operation unit 15 is gripped (step S106). The arm unit 11 is raised and moved, and the operation unit 15 is moved to the end of the shaft 33 of the motor 30 as shown in FIG. 4C (step S107). The arm portion 11 is lowered, and the pin portion 31b is attached to the recess 33a of the shaft 33 by press-fitting while holding the sensor magnet 31 by the operation unit 15 (step S108).

The step of fixing the rotor 34 (S101) may be performed any time before the sensor magnet portion 231 is attached to the shaft 33. For example, the step of fixing the rotor 34 (S101) may be performed in parallel with the positioning step of the sensor magnet 31 or may be performed after the positioning step of the sensor magnet 31.

By the above operation, the sensor magnet unit 31 is positioned at a magnetic pole position having a predetermined angle θ with respect to the main magnet 35 of the rotor 34 fixed at a predetermined rotational position, and is attached to the shaft 33.

According to the first embodiment, in the manufacturing process of the motor, the sensor magnet unit 31 is positioned at the sensor magnet magnetic pole position having a predetermined angle θ with respect to the rotor fixed rotational position using the positioning device including the magnetic field generating unit capable of generating the magnetic field. Is positioned, and the positioned sensor magnet 31 is attached to the shaft 33. Therefore, positioning with respect to the main magnet 35 of the sensor magnet part 31 can be performed easily. Thereby, the variation in the magnetic pole position of the sensor magnet portion 31 with respect to the main magnet 35 of the rotor 34 can be suppressed.

Moreover, since the manufactured motor can maintain the detection accuracy of the rotational position of the rotor, it is possible to effectively suppress the torque ripple. More specifically, the arrangement of the sensor magnet 31 affects the detection accuracy of the magnetic sensor. Therefore, by making the rotational positions of the sensor magnet unit 31 and the rotor 34 constant and improving the positional accuracy of the sensor magnet unit, it is possible to increase the accuracy of calculation of the rotational position based on the output of the magnetic sensor by software. Therefore, at the time of driving of the motor, torque ripple can be suppressed more effectively. Further, since it is not necessary to adjust software for each of the assembled motors 30, the manufacturing process of the motor can be simplified, and the manufacturing cost of the motor 30 can be suppressed.

According to the first embodiment, positioning of the sensor magnet unit 31 is performed by rotating the sensor magnet unit 31 by the magnetic field of the external magnet 23. For this reason, positioning with respect to the main magnet 35 of the sensor magnet part 31 can be performed easily.

According to the first embodiment, since the position adjustment unit 20 of the positioning device can support the sensor magnet unit 31 in the axial direction of the shaft 33, the sensor magnet unit 31 can be easily attached to the shaft 33.

According to the first embodiment, since the process from positioning of the sensor magnet unit 31 to attachment to the shaft 33 can be performed by one motor manufacturing apparatus 10, the working time required for assembly, movement of members, etc. can be shortened. .

According to the first embodiment, the sensor magnet unit 31 includes a magnet unit 31a having a magnetic pole and a pin unit 31b attached to the magnet unit 31a. The shaft 33 includes an axially extending recess 33a therein. The pin portion 31 b of the sensor magnet portion 31 is attached to the recess 33 a of the shaft 33. Therefore, the outer diameter of the sensor magnet portion 31 can be made smaller than the outer diameter of the shaft, and the sensor magnet portion 31 can be attached to the shaft 33 before the motor 30 is attached. It will be easier.

Second Embodiment
[2-1. Constitution]
In the second embodiment, the positioning device is implemented in that the magnetizing coil 225 is used instead of the external magnet 23 as the magnetism generating portion, and the magnet portion 231a of the sensor magnet portion 231 is not magnetized before positioning. Different from Form 1. Hereinafter, differences from the first embodiment will be mainly described.

The positioning device realized in the motor manufacturing apparatus 10 includes the operation unit 15 shown in FIG. 1 and the position adjustment unit 220 shown in FIGS. 8A and 8B.

The position adjustment unit 220 is provided on the base unit 19. The position adjustment part 220 has the main-body part 21, the magnetizing coil 225, and the recessed part 25 as shown to FIG. 8A.

As shown in FIG. 8B, when the pin portion 31b of the sensor magnet portion 231 is inserted into the recess 25, the magnetizing coil 225 radially faces the magnet portion 231a. While holding the sensor magnet unit 231 by the operation unit 15, a current is supplied to the magnetizing coil 225, and the magnetizing coil 225 is magnetized in a predetermined direction.

Specifically, the magnetizing coil 225 generates a magnetic field in a predetermined direction MD as shown in FIG. The rotational position of the rotor 34 shown in FIG. 9 is the same as the position shown in FIG. By the generation of the magnetic field, the positions of the two poles of the magnet portion 231a are magnetized to a predetermined position. The magnetic pole position of the magnetized sensor magnet portion 231 has a predetermined angle θ with respect to the rotational position of the rotor 34.

The sensor magnet unit 231 is attached to the shaft 33 in a state where the magnetic pole position after magnetization is held. Thereby, the magnetization position of the sensor magnet unit 231 with respect to the main magnet 35 becomes constant.

In the above example, instead of the magnetizing coil 225, a magnetizing yoke may be used.

[2-2. Operation]
As in the first embodiment, positioning of the sensor magnet unit 231 and attachment to the shaft 33 are performed under control of the control unit 50.

The rotor 34 is fixed. The operation unit 15 grips the target sensor magnet unit 231. The sensor magnet unit 231 gripped by the operation unit 15 is moved to the position adjustment unit 220 as shown in FIG. 8A. The pin portion 31 b of the sensor magnet portion 231 is inserted into the recess 25 of the position adjustment portion 220. Thus, the sensor magnet unit 231 is positioned in the axial direction of the shaft 33. A current flows through the magnetizing coil 225 to generate a magnetic field of a predetermined magnetization direction MD as shown in FIG. As a result, the sensor magnet unit 231 is magnetized in a predetermined direction, and is positioned at a position having a predetermined angle θ with respect to the fixed rotational position of the rotor 34. The predetermined angle θ is a constant angle in all the motors 30 manufactured in the motor manufacturing apparatus 10.

The sensor magnet unit 231 is held by the recess 25 of the position adjustment unit 220 and the operation unit 15 during magnetization so that the sensor magnet unit 231 does not move due to the impact of magnetization.

When the magnetization of the magnet unit 231a is completed, that is, when the positioning is completed, the arm unit 11 is raised and moved in a state in which the sensor magnet unit 231 is gripped by the operation unit 15. Then, the operation unit 15 is moved to the end of the shaft 33 of the motor 30 as shown in FIG. 8C. With the position of the sensor magnet 231 fixed by the operation unit 15, the arm 11 is lowered to press-fit the pin 31 b into the recess 33 a of the shaft 33. As a result, the sensor magnet unit 231 is attached to the shaft 33.

According to the second embodiment, positioning of the sensor magnet unit 231 is performed by magnetizing the sensor magnet unit 231 with a magnetizing unit. Here, from the positioning of the sensor magnet unit 231 to the attachment to the shaft 33, the operation can be performed in a state where the sensor magnet unit 231 is gripped. For this reason, positioning with respect to the main magnet 35 of the sensor magnet part 231 can be performed easily.

(Other embodiments)
As mentioned above, the above-mentioned embodiment was described as an illustration of art indicated in this application. However, the technology in the present disclosure is not limited to this, and it is possible to appropriately change, replace, add, omit, etc. as follows.

[1]
In the first and second embodiments, the operation unit 15 grips the sensor magnets 31 and 231, but the present invention is not limited to this. For example, as shown in FIG. 10, the operation unit 151 may have an air suction unit 151a. The sensor magnet units 31, 231 are attracted and held by the operation unit 151 by the air suction unit 151a.

[2]
In the said Embodiment 1, although the external magnet 23 is provided in the position adjustment part 20, it is not limited to this. The operation unit 15 may be provided with a magnetism generation unit such as the external magnet 23 or the like.

For example, as shown in FIG. 11, the positioning apparatus includes an operation unit 152 and a position adjustment unit 320.

The operation unit 152 is made of a magnetic material and has an external magnet 153 attached at a predetermined rotational position at an end. The predetermined rotational position is the same position as the external magnet 23 of the first embodiment. The operation unit 152 grips the grip 31e of the sensor magnet 31 at the end. The position adjustment unit 320 does not have an external magnet.

At the time of the positioning operation, the operation unit 152 is lowered together with the gripped sensor magnet 31 and the external magnet 153. Then, the pin portion 31 b of the sensor magnet portion 31 is inserted into the recess 25 of the position adjustment portion 320. At this time, the operation unit 152 releases the gripping unit 31 e so that the sensor magnet unit 31 can rotate. Thus, as in the first embodiment, the sensor magnet unit 31 is rotated by the magnetic force of the external magnet 153.

The same configuration can be applied to the second embodiment. That is, the operation unit has a magnetizing coil or a magnetizing yoke attached so as to magnetize the sensor magnet unit 231 in a predetermined direction. During the positioning operation, the operation unit 152 descends together with the gripped sensor magnet unit 231 and the magnetizing coil or the magnetizing yoke. The pin portion 31 b of the sensor magnet portion 31 is inserted into the recess 25 of the position adjustment portion 220 and held. A current is supplied to the magnetizing coil to magnetize the sensor magnet portion 231, thereby completing the positioning.

[3]
FIG. 12 shows a modification of the positioning device of FIG. In the same modification, the operation unit 154 has an air suction unit 154a, and holds the sensor magnet unit 31 by fixing the sensor magnet unit 31 by air suction. Others are the same as the example of the said Embodiment 1 and FIG.

Further, as in the example of FIG. 10, the operation unit 154 may include a magnetizing coil or a magnetizing yoke instead of the external magnet 153.

[4]
13A and 13B show an example of attaching another form of sensor magnet unit 331 to the motor 30. FIG. The sensor magnet unit 331 includes a magnet unit 331a having two magnetic poles and a holder unit 331b for holding the magnet unit 331a. The holder portion 331 b includes a cylindrical portion for press-fitting the shaft 233. The sensor magnet portion 331 further includes a flange portion 331 f that protrudes outward in the radial direction. The flange portion 331 f is gripped by the operation portion 155 and attached to the shaft 233 as shown in FIG. 13B.

The positioning device includes an operation unit 155 and a position adjustment unit 420 provided on the base unit 19 shown in FIG. The position adjustment unit 420 includes an external magnet 423, a main body 421, and a holder support 427 protruding from the main body 421. Similar to the first embodiment, the external magnet 423 applies a magnetic force such that the sensor magnet 331 is in the rotational position shown in FIG. 7.

The holder support portion 427 has an outer diameter smaller than the inner diameter of the cylindrical portion of the holder portion 331 b of the sensor magnet portion 331. The holder support 427 extends in the axial direction of the shaft 233. As in the first embodiment, the main body portion 421 is provided so as to protrude on the base portion 19 of the motor manufacturing apparatus 10. Alternatively, the main body 421 may directly form the holder support 427 on a part of the base 19.

During the positioning operation, the holder support portion 427 of the position adjustment portion 420 is inserted into the cylindrical portion of the holder portion 331 b of the sensor magnet portion 331. Thus, the sensor magnet 331 is positioned in the axial direction of the shaft 233. Then, the operation unit 155 releases the sensor magnet unit 331. Thus, as in the first embodiment, the sensor magnet unit 331 is rotated by the magnetic force of the external magnet 423 and positioned at the above-described predetermined rotational position. The operation unit 155 moves to the shaft 233 while holding the positioned sensor magnet 331, and attaches it to the end of the shaft 233 as shown in FIG. 13B.

Also in this example, the positioning device may include a magnetizing coil or a magnetizing yoke instead of the external magnet 423 as in the second embodiment. Further, as in the example of the above [2], the operation part 155 may be provided with the external magnet 423 or the magnetizing coil or the magnetizing yoke. Further, as in the case of the above [1] or [3], the operation unit 155 may hold the sensor magnet unit 331 by air suction.

[5]
In the above embodiment, the sensor magnet unit is mainly held by the operation unit at the time of positioning operation, but the present invention is not limited to this. The position adjustment unit may be provided with a releasable holding function to hold the sensor magnet unit.

[6]
In the above embodiment, the fixing of the rotor 34 is performed electrically, but is not limited thereto. For example, it is also possible to lock and fix the rotor 34 by a physical fixing portion.

[7]
In the above embodiment, the number of poles of the main magnet 35 is eight, but it may be more or less. Moreover, in said embodiment, although it is a three-phase motor, the motor of other numbers of phases, such as five phases and seven phases, may be sufficient.

[8]
The order of execution of the positioning operation in the above embodiment is not necessarily limited to the description of the above first and second embodiments, and can be executed in parallel or the order of execution can be changed without departing from the scope of the invention. can do.

The motor manufactured by the above manufacturing method can be used, for example, in various applications such as electric power steering and a compressor.

DESCRIPTION OF SYMBOLS 10 ... Motor manufacturing apparatus, 11 ... Arm part, 13 ... Support member, 15, 151, 152, 154, 155 ... Operation part, 20, 220, 320, 420 ... Position adjustment part, 23, 153, 423 ... External magnet, DESCRIPTION OF SYMBOLS 25 ... Recess, 30 ... Motor, 31, 231, 331 ... Sensor magnet part, 31a, 231a, 331a ... Magnet part, 31b ... Pin part, 32 ... Excitation coil, 33, 233 ... Shaft, 33a ... Recess, 34 ... Rotor , 35: main magnet, 36: stator, 50: control unit, 225: magnetizing coil, 331b: holder portion, 331f: flange portion, 427: holder support portion

Claims (15)

A stator including an exciting coil;
A rotor having a shaft and a main magnet and rotatably provided radially inward of the stator;
A sensor magnet unit for detecting the rotational position of the rotor;
A method of manufacturing a motor comprising
Securing the rotor such that the main magnet is at a predetermined rotational position;
Positioning the sensor magnet portion at a magnetic pole position having a predetermined angle with respect to a predetermined rotational position of the main magnet using a positioning device including a magnetic field generating portion capable of generating a magnetic field;
And mounting the sensor magnet unit positioned on the shaft with the rotor fixed. The sensor magnet unit has at least two magnetic poles,
In the process of positioning the sensor magnet unit,
Supporting the sensor magnet portion rotatably by the positioning device;
The method according to claim 1, further comprising the step of rotating the sensor magnet unit by the magnetic field of the magnetic field generation unit to position the sensor magnet unit at the magnetic pole position. The magnetic field generating unit is a magnetizing unit,
In the process of positioning the sensor magnet unit,
Supporting the sensor magnet unit by the positioning device;
The method according to claim 1, further comprising the step of positioning the sensor magnet unit by magnetizing the supported sensor magnet unit to the magnetic pole position by the magnetizing unit. The method for manufacturing a motor according to any one of claims 1 to 3, wherein the rotor is fixed at the predetermined rotation position by energization of the excitation coil. The sensor magnet unit includes a magnetized magnet unit or a non-magnetized magnet unit, and a pin unit to which the magnet unit is attached.
The shaft includes an axially extending recess therein;
The method of manufacturing a motor according to any one of claims 1 to 4, wherein the step of attaching the sensor magnet portion to the shaft includes a step of press-fitting a pin portion of the sensor magnet portion into the recess of the shaft. The sensor magnet unit includes a holder unit,
The holder portion includes a tubular portion,
5. The method according to claim 1, wherein attaching the sensor magnet unit to the shaft includes pressing an axial end of the shaft into the cylindrical portion of the holder unit of the sensor magnet unit. The manufacturing method of the motor as described. The positioning device includes the magnetic field generation unit, and includes a position adjustment unit capable of supporting the sensor magnet unit along an axis parallel to the axis of the shaft, and an operation unit for holding and moving the sensor magnet unit. ,
Moving the sensor magnet unit to the position adjustment unit by the operation unit;
Positioning the sensor magnet unit at the magnetic pole position by the magnetic field generation unit;
The method according to claim 1, wherein the sensor magnet unit is attached to the shaft while holding the sensor magnet unit positioned by the operation unit. A stator including an exciting coil;
A rotor having a shaft and a main magnet, and rotatably provided radially inward of the stator;
A sensor magnet unit for detecting the rotational position of the rotor;
A motor manufacturing apparatus comprising:
A rotor fixing portion for fixing the rotor so that the main magnet is at a predetermined rotational position;
A position adjusting unit that includes a magnetic field generating unit capable of generating a magnetic field, and positions the sensor magnet unit at a magnetic pole position having a predetermined angle with respect to a predetermined rotational position of the main magnet;
An operation unit which holds the positioned sensor magnet unit and attaches the held sensor magnet unit to the shaft in a state where the rotor is fixed;
A control unit that controls the operation of the operation unit. The sensor magnet unit has at least two magnetic poles,
The motor manufacturing apparatus according to claim 8, wherein the position adjustment unit rotatably supports the sensor magnet unit, and rotates the sensor magnet unit by a magnetic field of the magnetic field generation unit. The motor manufacturing apparatus according to claim 8, wherein the magnetic field generation unit is a magnetizing unit disposed to magnetize the sensor magnet unit. The motor manufacturing apparatus according to any one of claims 8 to 10, wherein the rotor fixing unit energizes the excitation coil according to a command of the control unit to fix the rotor at the predetermined rotation position. The sensor magnet unit includes a magnetized magnet unit or a non-magnetized magnet unit, and a pin unit extending from the center of the magnet unit.
The shaft includes an axially extending recess therein;
The motor manufacturing apparatus according to any one of claims 8 to 11, wherein the operation unit attaches the sensor magnet unit to the shaft by press-fitting a pin unit of the sensor magnet unit into the recess of the shaft. The sensor magnet unit includes a holder unit,
The holder portion includes a tubular portion,
12. The sensor magnet unit according to any one of claims 8 to 11, wherein the operation unit attaches the sensor magnet unit to the shaft by press-fitting an axial end of the shaft into the cylindrical portion of the holder unit of the sensor magnet unit. The motor manufacturing apparatus according to claim 1. The motor manufacturing apparatus according to any one of claims 8 to 13, wherein the position adjustment unit supports the sensor magnet unit along an axis parallel to an axis of the shaft. A stator including an exciting coil;
A rotor having a shaft and a main magnet and rotatably provided radially inward of the stator;
A sensor magnet unit for detecting the rotational position of the rotor;
A positioning device for a sensor magnet unit for manufacturing a motor comprising:
A position adjustment unit that includes a magnetic field generation unit capable of generating a magnetic field, and positions the sensor magnet unit at a predetermined magnetic pole position;
An operation unit for holding the sensor magnet unit in a state of being positioned by the position adjustment unit and attaching the sensor magnet unit to the shaft;

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