Position detection sensor unit and method for manufacturing the position detection sensor unit

Abstract

The present invention provides a position detection sensor unit and a method for manufacturing the position detection sensor unit, which can hold a circuit board with high precision and suppress the number of components. The position detection sensor unit (6) of the present invention includes a holder housing (45) and a sensor substrate holder (46). The sensor substrate holder (46) has a substrate insertion groove and a substrate holding portion that holds the side portion of the sensor wire connection portion. The holder housing (45) includes: a first substrate accommodation portion (81) that accommodates the tip (34a) of the insertion portion (34); and a second substrate accommodation portion (82) that accommodates the base (34b) of the insertion portion (34). The second substrate accommodation portion (82) is set to have a wider width in the radially inner side starting from the insertion portion (34) than the first substrate accommodation portion (81).

Description

Technical Field

[0001] The present invention relates to a position detection sensor unit and a method for manufacturing the position detection sensor unit. Background Art

[0002] Generally, as a rotary electric machine (starter generator) provided in an engine of an automatic two-wheeler, a rotary electric machine including the following parts is known: a stator; a rotor that rotates around the stator; and a position detection sensor unit that detects the rotational position of the rotor. The stator has, for example: a stator core having a tooth portion formed in a T shape; and a coil wound around the tooth portion. The rotor has: a rotor yoke formed in a bottomed cylindrical shape; and a plurality of magnets disposed at equal intervals in the circumferential direction on the inner peripheral surface of the rotor yoke.

[0003] The rotor yoke constituting the rotor also serves as a fly wheel. Particularly when the rotary electric machine is used as an engine starting device (stator motor), the rotary electric machine operates as a brushless motor. Therefore, a motor driver for driving the rotary electric machine as a brushless motor is connected to the rotary electric machine. Currents are supplied to the respective coils of the stator of the rotary electric machine based on a motor drive signal from the motor driver, and the rotor rotates. The motor driver generates a motor drive signal for driving the rotary electric machine as a brushless motor based on the rotational position signal of the rotor detected by the detection sensor.

[0004] The position detection sensor unit includes sensor elements (i.e., magnetic detection elements) such as a Hall integrated circuit (IC) disposed on the stator. Hereinafter, the sensor element will be referred to as a Hall IC. The Hall IC detects the switching of the magnetic flux of the magnet that is switched as the rotor rotates. When the rotary electric machine is used as an engine starting device, the position detection sensor unit detects not only the rotational position signal for generating the motor drive signal but also the absolute position information signal of the rotor. The position information signal is used to generate an ignition timing signal for the engine (see, for example, Patent Document 1).

[0005] Here, for the position detection sensor unit, the Hall IC is connected to a circuit board, and the circuit board and the Hall IC are housed inside a sensor housing. Moreover, in the sensor housing, for example, there is a sensor housing including the following parts: a sensor substrate holder that houses the circuit board to which the Hall IC is connected; a wire holder that is attached to the sensor substrate holder to prevent the circuit board from falling off; and a holder housing that supports the sensor substrate holder. Hereinafter, the sensor substrate holder will be referred to as a sensor substrate holder, and the wire holder will be referred to as a wire holder.

[0006] By housing a circuit board in a sensor substrate holder and using a wire holder to prevent the housed circuit board from falling off, the circuit board can be held by the sensor substrate holder in a state accurately positioned with high precision.

[0007] Prior Art Documents

[0008] Patent Documents

[0009] Patent Document 1: Japanese Patent Laid-Open No. 2009-89588 Summary of the Invention

[0010] Problems to be Solved by the Invention

[0011] However, for the sensor housing of the prior art, in order to hold the circuit board with high precision by the sensor substrate holder, it is necessary to additionally use a wire holder to prevent the circuit board from falling off. Therefore, the number of parts of the sensor housing increases, and this situation hinders cost reduction.

[0012] Therefore, the present invention provides a position detection sensor unit and a method for manufacturing the position detection sensor unit, which can hold a circuit board with high precision and suppress the number of parts.

[0013] Technical Means for Solving the Problems

[0014] To solve the above problems, the position detection sensor unit of the present invention detects the magnetic flux of a magnet provided on a rotor to detect the rotational position of the rotor, and is characterized by including: a holder housing that houses a substrate encapsulating a magnetic detection element, the magnetic detection element detecting the magnetic flux of the magnet; and a sensor substrate holder that is mounted on the holder housing and holds the substrate, the sensor substrate holder having: a groove opening provided at one end for inserting a first end portion of the substrate; a substrate insertion groove provided at the other end and having a contact surface; and a substrate holding portion that holds a side portion of the first end portion of the substrate inserted into the groove opening, the holder housing having: an outer frame member that houses the sensor substrate holder; and three feet integrally formed on the outer frame member, the three feet having inside: a substrate housing portion that houses a second end portion of the substrate opposite to the first end portion.

[0015] In the above structure, the substrate housing portion may also have: an opening for inserting the second end portion of the substrate; a first substrate housing portion that houses the second end portion of the substrate; and a second substrate housing portion that houses a portion of the substrate closer to the first end portion than the second end portion, and has a wider width in the radial inner side starting from the substrate compared to the first substrate housing portion.

[0016] In the above structure, a filler may also be filled inside the outer frame member to seal the opening.

[0017] In the manufacturing method of the position detection sensor unit of the present invention, the position detection sensor unit detects the magnetic flux of a magnet provided on a rotor to detect the rotational position of the rotor, and the manufacturing method of the position detection sensor unit is characterized by including: a first step of arranging a plurality of substrates encapsulating magnetic detection elements on a jig, assembling wires to the substrates, the magnetic detection elements detecting the magnetic flux of the magnet; a second step of holding the substrates and the wires by a sensor substrate holder, and connecting the wires to the substrates; a third step of assembling sensor wires to the substrates, and connecting the assembled sensor wires to the substrates and thus to the magnetic detection elements; and a fourth step of removing the sensor substrate holder and the substrates from the jig and housing them in a holder housing, and filling a filler inside the holder housing.

[0018] Effects of the Invention

[0019] According to the present invention, a circuit board can be held with high precision and the number of parts can be suppressed. Description of the Drawings

[0020] Figure 1 A perspective view of a rotating electric machine according to an embodiment of the present invention.

[0021] Figure 2 A top view of a rotating electric machine according to an embodiment of the present invention with the rotor removed.

[0022] Figure 3 A cross-sectional side view of a rotor of a rotating electric machine according to an embodiment of the present invention.

[0023] Figure 4 A perspective view of a stator according to an embodiment of the present invention.

[0024] Figure 5 A view showing the inner peripheral side of a rotor according to an embodiment of the present invention developed.

[0025] Figure 6 A perspective view showing a state where a main part of a position detection sensor unit according to an embodiment of the present invention is cut off.

[0026] Figure 7 An exploded perspective view of a position detection sensor unit according to an embodiment of the present invention.

[0027] Figure 8 A perspective view showing a state where a circuit board according to an embodiment of the present invention is held by a sensor substrate holder.

[0028] Figure 9Exploded perspective view showing the state of disassembling the circuit board from the sensor board holder of an embodiment of the present invention.

[0029] Figure 10 Plan view showing the position detection sensor unit of an embodiment of the present invention.

[0030] Figure 11 Explanatory drawing of the manufacturing method of the position detection sensor unit of an embodiment of the present invention, Figure 11 where (a) shows the process of connecting wires to each circuit board, Figure 11 and (b) shows the process of connecting sensor wires to each circuit board.

[0031] Figure 12 Perspective view explaining the process of filling the filler inside the holder housing of an embodiment of the present invention.

[0032] [Explanation of symbols]

[0033] 1: Rotating motor

[0034] 4: Rotor

[0035] 6: Position detection sensor unit

[0036] 16: Magnet

[0037] 21b: Sensor wire

[0038] 30: Sensor housing

[0039] 31A to 31C: First to third circuit boards (boards)

[0040] 34: Insertion part (second end part of the board)

[0041] 34a: Tip of the insertion part (second end part of the board)

[0042] 34b: Base of the insertion part (side closer to the root than the tip of the board)

[0043] 35: Sensor wire connection part (first end part of the board)

[0044] 35a: Side part of the sensor wire connection part (side part of the root)

[0045] 38a to 38d: First to fourth Hall ICs (magnetic detection elements)

[0046] 41: Wire

[0047] 45: Holder housing

[0048] 46: Sensor board holder

[0049] 51: Substrate insertion groove

[0050] 52: Groove opening

[0051] 54: Substrate holding part

[0052] 60: Outer frame member

[0053] 75: Opening

[0054] 80: Substrate housing part

[0055] 61a: First leg part (leg part)

[0056] 61b: Second leg part (leg part)

[0057] 61c: Third leg part (leg part)

[0058] 81: First substrate housing part

[0059] 82: Second substrate housing part

[0060] 90: Filler

[0061] 100: Fixture Detailed implementation mode

[0062] Next, based on the accompanying drawings, the position detection sensor unit of the embodiment of the present invention and the manufacturing method of the position detection sensor unit will be described.

[0063] <Rotary electric machine>

[0064] Figure 1 is a perspective view of the rotary electric machine 1. Figure 2 is a top view of the rotary electric machine 1 with the rotor 4 removed. Figure 3 is a cross-sectional side view of the rotor 4 of the rotary electric machine 1.

[0065] As Figures 1 to 3 shown, the rotary electric machine 1 can be used as a starting generator for an engine of a vehicle such as a motorcycle, and is a three-phase brushless type rotary electric machine. The rotary electric machine 1 includes: a stator 2 fixed to an engine block (not shown); a rotor 4 fixed to a crank shaft (not shown) of the engine; and a position detection sensor unit 6 that detects the rotational position of the rotor 4.

[0066] A wire 21a is connected to a coil 10 (described later) wound around the stator 2 and extends from the position detection sensor unit 6 to the sensor wire 21b.

[0067] In addition, in the following description, the rotational axis direction of the rotor 4 of the rotating electric machine 1 is referred to as the axial direction. The side of the rotating electric machine 1 around which the sensor wire 21b and the lead wire 21a are wound is referred to as the outer side in the axial direction. The side of the rotating electric machine 1 opposite to the outer side in the axial direction, that is, the side where the crankshaft extends and the rotor 4 is fixed to this crankshaft, is referred to as the inner side in the axial direction.

[0068] Figure 4 is a perspective view of the stator 2.

[0069] As Figure 4 shown, the stator 2 includes, for example, a stator core 2A formed by laminating electromagnetic steel sheets, and a plurality of coils 10 wound around the stator core 2A. The stator core 2A has: a main body portion 2a formed in an annular shape; and a plurality of tooth portions 2b radially protruding outward in the radial direction from the outer peripheral surface of the main body portion 2a. At the tip portions of the respective tooth portions 2b, for example, claw pieces 3 protruding in a substantially T shape to both sides in the circumferential direction are provided.

[0070] Here, the shape of the claw piece 3 of each tooth portion 2b is not a fixed shape, and in the claw piece 3 of a part of the tooth portions 2b, a notch portion 7 is formed, for example, between a position slightly more outward than the axial center to the outer end in the axial direction. The notch portion 7 is used, for example, to receive the leg portions (first leg portion) 61a, leg portions (second leg portion) 61b, and leg portions (third leg portion) 61c for holding the sensor of the position detection sensor unit 6 described later (refer to Figure 3 ). The notch portion 7 is formed in such a manner as to form a substantially rectangular fitting groove straddling two claw pieces 3 adjacent in the circumferential direction. The pairs of notch portions 7 forming this fitting groove are continuously arranged at a total of three positions in the circumferential direction.

[0071] Hereinafter, in order to distinguish the four tooth portions 2b in which the notch portion 7 is formed in the claw piece 3 from the other tooth portions 2b, they are referred to as specific tooth portions 2B.

[0072] According to this structure, the respective leg portions 61a, 61b, 61c of the position detection sensor unit 6 are inserted and arranged in the pairs of respective notch portions 7 formed in the adjacent specific tooth portions 2B.

[0073] Moreover, an insulator (not shown) is installed on the outer surface of the stator core 2A so as to cover the circumferential regions of the respective tooth portions 2b, and the coils 10 are wound around the respective tooth portions 2b from the insulator.

[0074] Figure 5 The inner peripheral side of the rotor 4 is shown in an unfolded manner.

[0075] As Figure 1 , Figure 3 , Figure 5As shown, the rotor 4 includes: a bottomed cylindrical rotor yoke 12 made of a magnetic material; and a support portion 14 coaxially fixed to the bottom wall 12a of the rotor yoke 12. The crankshaft of the engine is integrally rotatably coupled to the support portion 14.

[0076] On the inner peripheral surface of the rotor 4, a plurality of magnets 16 are circumferentially equally spaced. Each of these magnets 16 is formed in a rectangular shape that is long in the axial direction of the rotor 4. Except for one, the surfaces (inner surfaces) of all other magnets 16 facing the center of the rotor 4 are magnetized to either an N pole or an S pole. One magnet 16c has a short secondary magnetic pole portion 19 magnetized to an S pole on the inner surface at one end side (one end side in the long strip direction) of the main magnetic pole portion 18 magnetized to an N pole on the inner surface.

[0077] In addition, in the following description, Figure 5 the magnet 16 magnetized to an N pole over the entire inner surface is referred to as the N - pole magnet 16a, and the magnet 16 magnetized to an S pole over the entire inner surface is referred to as the S - pole magnet 16b. Also, the magnet 16 including the main magnetic pole portion 18 and the secondary magnetic pole portion 19 is referred to as the bipolar magnet 16c.

[0078] Here, in the rotor 4, the bipolar magnet 16c is disposed between a specific set of adjacent N - pole magnets 16a, 16a. The S - pole magnet 16b is disposed between other adjacent N - pole magnets 16a, 16a.

[0079] Therefore, on the inner peripheral side of the rotor 4, except for one axial end side ( Figure 5 the upper end side in the figure), the N pole and the S pole appear alternately. On the other hand, at one axial end side, the three N poles of the secondary magnetic pole portion 19 of the bipolar magnet 16c and the magnets before and after it (before and after in the circumferential direction) appear continuously.

[0080] The region at one axial end side of the magnet 16 is used as a target for detecting the ignition timing of the engine, and the remaining axial regions of the magnet 16 are mainly used as targets for detecting the commutation timing of the coil 10.

[0081] The end portion of the coil 10 wound around the tooth portion 2b of the stator core 2A is connected to one end of a wire 21a. The wire 21a is bundled by a protective tube 22a and is arranged in an arc shape along the circumferential direction of the stator 2 at the outer axial end of the stator 2. The other end of the wire 21a extends outside the engine body via a grommet 23 provided in the engine body (not shown) and is connected to a control device (not shown).

[0082] At the outer axial end of the stator 2, a sensor wire 21b extending from a sensor housing 30 described later (refer to Figure 2)It is bundled by the protective tube 22b and extends in an arc shape along the circumferential direction of the stator 2. The sensor wire 21b extends outside the engine body through a grommet 24 provided in the engine body (not shown) and is connected to a control device (not shown).

[0083] According to such a structure, the control device (not shown) supplies current to the coil 10 at a predetermined timing when the engine is started, thereby rotating the rotor 4 and the crankshaft. Moreover, after the engine is started, the generated electric power accompanying the rotation of the rotor 4 is used to charge a battery (not shown) or directly used.

[0084] Here, the lead wire 21a and the sensor wire 21b disposed at the axially outer end of the stator 2 are held at the axially outer end of the stator core 2A via a clip 25.

[0085] <Position Detection Sensor Unit>

[0086] Figure 6 FIG. is a perspective view showing a state in which the main part of the position detection sensor unit 6 is cut off. Figure 7 FIG. is an exploded perspective view of the position detection sensor unit 6. In addition, Figure 6 in, in order to easily understand the structure of the position detection sensor unit 6, it is shown in a state where the filler is removed.

[0087] As Figure 1 、 Figure 6 、 Figure 7 shown, the position detection sensor unit 6 includes: a resin sensor housing 30 disposed on the axially outer side of the stator core 2A; and three circuit boards (substrates) 31A, 31B, 31C (first circuit board 31A, second circuit board 31B, third circuit board 31C), which are housed inside the sensor housing 30.

[0088] In addition, in the following description, in the state where the position detection sensor unit 6 (sensor housing 30) is mounted on the stator 2, the radial direction of the stator 2 in the position detection sensor unit 6 is referred to as the radial direction, the axial direction of the stator 2 is referred to as the axial direction, and the circumferential direction of the stator 2 is referred to as the circumferential direction for explanation.

[0089] <Circuit Board>

[0090] Figure 8 FIG. is a perspective view showing a state in which the first circuit board to the third circuit boards 31A, 31B, 31C are held by the sensor board holder 46.

[0091] As Figure 7 、 Figure 8As shown, with respect to each of the circuit boards 31A, 31B, and 31C, the first circuit board 31A, the second circuit board 31B, and the third circuit board 31C are arranged in sequence along the circumferential direction. Each of the circuit boards 31A, 31B, and 31C is formed in a substantially T shape, for example, and includes: an insertion portion 34 formed long along the axial direction; and a sensor wire connection portion (the first end portion of the substrate) 35 integrally formed at the axially outer end of the insertion portion 34 and formed long along the circumferential direction.

[0092] On the insertion portion 34 of the first circuit board 31A, a first Hall IC 38a and a second Hall IC 38b are surface-mounted by soldering. These first Hall IC 38a and second Hall IC 38b are arranged along the axial direction with the first Hall IC 38a located on the axially outer side.

[0093] On the insertion portion 34 of the second circuit board 31B, a third Hall IC 38c is surface-mounted, and on the insertion portion 34 of the third circuit board 31C, a fourth Hall IC 38d is surface-mounted. The Hall ICs 38b, 38c, and 38d of each of the circuit boards 31A, 31B, and 31C are surface-mounted in the following manner, that is: the distance from the axially inner end edge (top edge) 34c of the insertion portion 34 is the same distance. Each of the Hall ICs 38a to 38d is a magnetic detection element and is constituted by a so-called chip Hall IC, for example.

[0094] At the sensor wire connection portion 35 of each of the circuit boards 31A, 31B, and 31C, two through-holes 39a for sensor wires are respectively formed at substantially the center in the circumferential direction. One end of a sensor wire 21b (refer to Figure 2 ) is inserted into these through-holes 39a for sensor wires and is connected to each of the circuit boards 31A, 31B, and 31C by soldering or the like. The sensor wire 21b is connected to each of the Hall ICs 38a to 38d via each of the circuit boards 31A, 31B, and 31C.

[0095] At the sensor wire connection portion 35 of the first circuit board 31A, two through-holes 39b for wires are formed at the end portion on the side of the second circuit board 31B in the circumferential direction. At the sensor wire connection portion 35 of the second circuit board 31B, two through-holes 39b for wires are respectively formed at both end portions in the circumferential direction. At the sensor wire connection portion 35 of the third circuit board 31C, two through-holes 39b for wires are formed at the end portion on the side of the second circuit board 31B in the circumferential direction.

[0096] According to this structure, the end portions of the wire 41 are inserted into the wire through-holes 39b of the first circuit board 31A and the second circuit board 31B. The end portions of the wire 41 are inserted into the wire through-holes 39b of the second circuit board 31B and the third circuit board 31C. By connecting each of the circuit boards 31A, 31B, 31C to the end portion of the wire 41 by soldering or the like, the first circuit board 31A, the second circuit board 31B, and the third circuit board 31C are connected in series in sequence.

[0097] <Sensor housing>

[0098] As Figure 6 , Figure 7 shown, the sensor housing 30 includes: a holder housing 45 that houses each of the circuit boards 31A, 31B, 31C; and a sensor board holder 46 that is mounted on the holder housing 45 and holds each of the circuit boards 31A, 31B, 31C.

[0099] <Sensor board holder>

[0100] Figure 9 FIG. is an exploded perspective view showing a state in which the first circuit board to the third circuit boards 31A, 31B, 31C are disassembled from the sensor board holder 46.

[0101] As Figure 8 , Figure 9 shown, the sensor board holder 46 has: a pair of board insertion grooves 51 into which the sensor wire connection portions 35 of the first circuit board 31A are inserted, a pair of board insertion grooves 51 into which the sensor wire connection portions 35 of the second circuit board 31B are inserted, and a pair of board insertion grooves 51 into which the sensor wire connection portions 35 of the third circuit board 31C are inserted.

[0102] The pair of board insertion grooves 51 are formed at intervals in the circumferential direction so as to accommodate both side portions in the circumferential direction in the sensor wire connection portion 35.

[0103] The board insertion groove 51 has: a groove opening 52 that opens at one end on the inner side in the axial direction; and a contact portion (contact surface) 53 that is formed at the other end on the outer side in the axial direction. The board insertion groove 51 has a board holding portion 54 provided on the side portion. The board holding portion 54 extends in the circumferential direction so as to hold the side portion 35a of the sensor wire connection portion 35. That is, the board insertion groove 51 is formed in a U-shaped cross section that opens in the circumferential direction so as to clamp the side portion 35a of the sensor wire connection portion 35.

[0104] Insert the side portions 35a on both sides of the sensor wire connection portion 35 into the substrate insertion grooves 51 through the groove openings 52 of the pair of substrate insertion grooves 51. Among the sensor wire connection portions 35 inserted into the substrate insertion grooves 51, the axially outer ends 35b come into contact with the contact portions 53. Thus, the contact portions 53 can be used to prevent the sensor wire connection portions 35 from coming out of the substrate insertion grooves 51 axially outward.

[0105] For the sensor wire connection portion 35 disposed in the substrate insertion groove 51, the circumferential side portions 35a are held by the substrate holding portions 54. Thus, the circuit boards 31A, 31B, and 31C are held at the specified positions of the sensor substrate holder 46 in a state of being highly accurately positioned.

[0106] The sensor substrate holder 46 is mounted on the holder housing 45.

[0107] <Holder Housing>

[0108] Figure 10 It is a plan view showing the position detection sensor unit 6.

[0109] As Figure 6 、 Figure 7 、 Figure 10 shown, the holder housing 45 has an outer frame member 60 and three legs 61a, 61b, and 61c integrally formed on the outer frame member 60.

[0110] The outer frame member 60 is formed in a shape corresponding to that of the sensor substrate holder 46 and in an oval shape when viewed axially, and has a cylindrical peripheral wall 63 formed by bending along the outer periphery of the stator core 2A (refer to Figure 2 ). More specifically, the peripheral wall 63 is integrally formed with: an outer peripheral wall portion 63a, which constitutes the radially outer wall; an inner peripheral wall portion 63b, which constitutes the radially inner wall; and side wall portions 63c and 63d, which connect the outer peripheral wall portion 63a and the inner peripheral wall portion 63b. The sensor substrate holder 46 is press-fitted into the peripheral wall 63 by insertion. By fitting the outer peripheral wall 65 of the sensor substrate holder 46 into the peripheral wall 63 of the outer frame member 60, the outer frame member 60 and the sensor substrate holder 46 are integrated.

[0111] As Figure 2 、 Figure 7 shown, in the peripheral wall 63, a wiring guide 68 extending radially inward is integrally formed at the center of the inner peripheral wall portion 63b. The wiring guide 68 is formed to gather a plurality of sensor wires 21b extending from the outer frame member 60 and extend them laterally.

[0112] In the wiring guide member 68, a bolt seat 69 is integrally formed at the radially inner top end. The bolt seat 69 is the part for fixing the outer frame member 60 to the stator core 2A. By inserting a bolt 71 into the bolt seat 69 and screwing the bolt 71 into the internal thread portion of the stator core 2A, the outer frame member 60 is fixedly fastened to the stator core 2A.

[0113] On the outer peripheral wall portion 63a of the peripheral wall 63, at a position closer to the circumferential direction end than the approximate center in the circumferential direction, a thick-walled plate-like tongue portion 73 protrudes radially outward. The tongue portion 73 is the part for fixedly fastening the position detection sensor unit 6 to an engine body (not shown), and a bolt insertion hole 73a for inserting a bolt (not shown) is formed.

[0114] As Figure 3 , Figure 6 , Figure 7 As shown, on the base portion 60a of the outer frame member 60, foot portions 61a, 61b, 61c adjacent in the circumferential direction protrude toward the axially inner side.

[0115] The three foot portions 61a, 61b, 61c are formed in a substantially bottomed square tube shape with an opening 75 on the base portion 60a side. The cross-sectional shape of the three foot portions 61a, 61b, 61c perpendicular to the axial direction is formed in a rectangular shape long in the circumferential direction so as to be insertable between the pairs of notches 7 of the specific tooth portions 2B of the stator 2 (also refer to Figure 4 ).

[0116] In a state where the holder housing 45 is mounted on the axially outer end of the stator core 2A (refer to Figure 2 ), the foot portions 61a, 61b, 61c are respectively inserted between the pairs of notches 7 of the specific tooth portions 2B. The radially outer surfaces of the respective foot portions 61a, 61b, 61c are arranged on the same plane as the radially outer surfaces of the claw pieces 3 of the stator 2.

[0117] At the axially inner ends (top ends) of the respective foot portions 61a, 61b, 61c, holding portions 77 are formed to extend along the axial direction. The holding portions 77 are used to suppress the swaying of the respective foot portions 61a, 61b, 61c within the notches 7 and to increase the rigidity of the respective foot portions 61a, 61b, 61c. The holding portions 77 include: a protruding portion 77a that protrudes from the radially inner surface of the respective foot portions 61a, 61b, 61c; and a rib portion 77b that protrudes from the radially outer surface of the protruding portion 77a.

[0118] The protruding portion 77a abuts against the inner circumferential surface of the claw piece 3 of the specific tooth portion 2B. The rib portion 77b is inserted between the claw pieces 3 of the specific tooth portion 2B adjacent in the circumferential direction and closer to the axially inner side than the notch 7.

[0119] As Figure 6 ,Figure 7 As shown, inside each of the legs 61a, 61b, and 61c of the holder housing 45, there is a substrate receiving portion 80 that receives the insertion portions (the second ends of the substrates) 34 of the respective circuit boards 31A, 31B, and 31C. The substrate receiving portion 80 has: a first substrate receiving portion 81 that receives the tip (the second end of the substrate) 34a of the insertion portion 34; a second substrate receiving portion 82 that receives the base (the side closer to the first end than the second end) 34b of the insertion portion 34 closer to the sensor wire connection portion 35 than the tip 34a; and an opening 75 that opens the base 60a of the second substrate receiving portion 82.

[0120] The first substrate receiving portion 81 opens axially outward from the axially inner end 82d of the second substrate receiving portion 82. The first substrate receiving portion 81 has, for example, a first outer wall 81a, a first inner wall 81b, a first bottom 81c, and a first inclined wall 81d.

[0121] The first outer wall 81a is provided on the radially outer side of each of the legs 61a, 61b, and 61c. The first inner wall 81b is provided at a spaced interval radially inward with respect to the first outer wall 81a. The first bottom 81c extends radially outward from the axially inner end of the first inner wall 81b. The first inclined wall 81d extends in an inclined manner from the radially outer end of the first bottom 81c to the axially inner end of the first outer wall 81a. The second substrate receiving portion 82 opens axially outward from the axially outer end of the first substrate receiving portion 81 to the base 60a.

[0122] The second substrate receiving portion 82 has, for example, a second outer wall 82a, a second inclined wall 82b, and a second inner wall 82c. The second outer wall 82a is provided on the radially outer side that is on the extension line of the first outer wall 81a. The second inclined wall 82b extends in an inclined manner radially inward and axially outward from the axially outer end of the first inner wall 81b. The second inner wall 82c extends from the axially outer end of the second inclined wall 82b to the base 60a and is provided at a spaced interval radially inward with respect to the second outer wall 82a. The outer wall 80a of the substrate receiving portion 80 is formed by the first outer wall 81a and the second outer wall 82a.

[0123] According to such a structure, by inserting the insertion portion 34 through the opening 75 of the substrate receiving portion 80 of each of the legs 61a, 61b, and 61c, the insertion portion 34 is received in the substrate receiving portion 80. Specifically, the tip 34a of the insertion portion 34 is received in the first substrate receiving portion 81, and the base 34b of the insertion portion 34 is received in the second substrate receiving portion 82.

[0124] In this state, for the tip 34a of the insertion portion 34, the tip edge 34c is disposed facing the first bottom 81c. The tip 34a of the insertion portion 34 is disposed closer to the first inner wall 81b side and is spaced apart from the first outer wall 81a by a width W1 to a certain extent. The base 34b of the insertion portion 34 is disposed spaced apart from the second inner wall 82c by a width W2 to a certain extent and is also disposed spaced apart from the second outer wall 82a by a width W1 to a certain extent.

[0125] That is, on the radially inner side with the base 34b of the insertion portion 34 as the starting point, the second inner wall 82c is disposed with a width W2 extended compared to the first inner wall 81b. On the radially outer side with the insertion portion 34 (the tip 34a and the base 34b) as the starting point, the second outer wall 82a and the first outer wall 81a (i.e., the outer wall 80a) are disposed with a width W1 extended.

[0126] In a state where the insertion portions 34 of the respective circuit boards 31A, 31B, and 31C are housed in the board housing portion 80, the sensor wire connection portions 35 of the respective circuit boards 31A, 31B, and 31C are in contact with the base portion 60a of the holder housing 45. As a result, the sensor wire connection portions 35 are disposed in a state of protruding on the base portion 60a.

[0127] Here, in a state where the sensor wire connection portions 35 are disposed on the base portion 60a, the positions of the through holes 39a for sensor wires of the sensor wire connection portions 35 (refer to Figure 8 ) are disposed at positions corresponding to the recesses of the guide walls 85 erected on the base portion 60a.

[0128] The insertion portions 34 of the respective circuit boards 31A, 31B, and 31C housed in the legs 61a, 61b, and 61c are respectively disposed such that the surface-mounted Hall ICs 38a to 38d face radially outward. That is, in a state where the respective circuit boards 31A, 31B, and 31C are disposed at the axially outer end of the stator core 2A (refer to Figure 2 ), the legs 61a, 61b, and 61c are respectively inserted between the pairs of the notches 7 of the specific tooth portions 2B (refer to Figure 3 ). As a result, the Hall ICs 38a to 38d are disposed to face the magnets 16 of the rotor 4.

[0129] In this state, a filler 90 (refer to Figure 10 ) is filled in the interior of the peripheral wall 63 and the board housing portion 80. As a result, the interior space of the peripheral wall 63 and the board housing portion 80 are sealed by the filler 90.

[0130] Here, on the radially inner side starting from the base portion 34b of the insertion portion 34, the second inner wall 82c is arranged so as to extend the width W2 compared to the first inner wall 81b. Further, on the radially outer side starting from the insertion portion 34, the outer wall 80a is arranged so as to extend the width W1. Therefore, the space on the radially inner side of the base portion 34b of the insertion portion 34 and the space on the radially outer side of the insertion portion 34 are substantially uniformly filled with the filler 90 (refer to Figure 10 ). Thus, the insertion portion 34 can be firmly fixed by the filler 90.

[0131] By substantially uniformly filling the space on the radially inner side of the insertion portion 34 and the space on the radially outer side of the insertion portion 34 with the filler 90, when the filler 90 is heated and cooled, the filler 90 can expand and contract substantially equally. Thus, the stress acting on the insertion portion 34 can be alleviated (reduced), and the thermal toughness of the insertion portion 34 can be improved.

[0132] <Control of Ignition Timing and Fuel Injection Timing>

[0133] As Figure 3 , Figure 5 shown, the first Hall IC 38a detects the switching of the magnetic flux of each of the pole magnets 16a, 16b, 16c by the height of the sub-pole portion 19 of the bipolar magnet 16c. The second Hall IC 38b, the third Hall IC 38c, and the fourth Hall IC 38d detect the switching of the magnetic flux of each of the pole magnets 16a, 16b, 16c by the height of the main pole portion 18 of the bipolar magnet 16c.

[0134] The second Hall IC 38b, the third Hall IC 38c, and the fourth Hall IC 38d output the signals detected at the position M2 on the central side of the rotor 4 as the rotation position signals of the rotor 4 to the control device. The first Hall IC 38a outputs the signals detected at the position M1 on the axial one end side of the rotor 4 as the absolute position information signals on the circumference of the rotor 4 to the control device.

[0135] The control device receives the output signals of the second Hall IC 38b, the third Hall IC 38c, and the fourth Hall IC 38d, and controls the commutation timing of the three-phase coil 10. At the same time, it receives the output signal of the first Hall IC 38a and the output signals of the second Hall IC 38b, the third Hall IC 38c, and the fourth Hall IC 38d, and controls the ignition timing and the fuel injection timing of the engine.

[0136] As described above, according to the position detection sensor unit 6, the sensor housing 30 can hold each of the circuit boards 31A, 31B, and 31C in a state accurately positioned at a specified position by using the sensor substrate holder 46. Moreover, the sensor housing 30 can accommodate each of the held circuit boards 31A, 31B, and 31C in the holder housing 45. That is, the sensor housing 30 can hold each of the circuit boards 31A, 31B, and 31C with high precision by using the two members of the holder housing 45 and the sensor substrate holder 46.

[0137] In contrast, a conventional sensor housing includes, for example, the following three members: a sensor substrate holder that houses each circuit board; a wire holder that is attached to the sensor substrate holder to prevent the circuit board from falling off; and a holder housing that supports the sensor substrate holder. That is, compared with the conventional sensor housing, the sensor housing 30 of the embodiment can reduce the number of parts from three members to two members.

[0138] Thus, according to the position detection sensor unit 6 of the embodiment, each of the circuit boards 31A, 31B, and 31C can be held with high precision, and the cost can be reduced by reducing the number of parts of the sensor housing 30.

[0139] Moreover, according to the sensor housing 30, the filler 90 can be filled substantially uniformly in the space radially inside the insertion portion 34 and the space radially outside the insertion portion 34 of each of the circuit boards 31A, 31B, and 31C. Therefore, when the filler 90 is heated and cooled, the filler 90 can expand and contract substantially evenly. Therefore, the stress acting on the insertion portion 34 can be alleviated (reduced), and the thermal shock resistance of the insertion portion 34 can be improved.

[0140] In contrast, for a conventional sensor housing, for example, the space radially inside the insertion portion of each circuit board is narrow, and it is difficult to fill the filler in the space radially inside the insertion portion. Therefore, it is difficult to fill the filler uniformly in the space radially inside the insertion portion and the space radially outside the insertion portion. As a result, it is conceivable that when the filler is heated and cooled, stress is generated in the insertion portion due to the expansion and contraction caused by the linear expansion of the filler, and cracks are generated by applying stress to, for example, solder or a Hall IC.

[0141] Moreover, it is conceivable that it is difficult to fill the filler in the space radially inside the insertion portion, and the insertion portions of the respective circuit boards float with respect to the holder housing. Therefore, it is conceivable that the stress tolerance of the insertion portions of the respective circuit boards is reduced.

[0142] <Manufacturing method of the position detection sensor unit>

[0143] Based on Figure 11 , Figure 12A method for manufacturing the position detection sensor unit 6 will be described.

[0144] Figure 11 FIG. 4 is an explanatory diagram of the manufacturing method of the position detection sensor unit 6. Figure 11 In FIG. 4(a), the process of connecting the wires 41 to the respective circuit boards 31A, 31B, and 31C arranged in the jig 100 is shown. Figure 11 In FIG. 4(b), the process of connecting the sensor wires 21b to the respective circuit boards 31A, 31B, and 31C arranged in the jig 100 is shown. Figure 12 FIG. 5 is a perspective view for explaining the process of filling the filler 90 inside the holder housing 45.

[0145] As Figure 11 shown in FIG. 5(a), in the first step, the respective circuit boards 31A, 31B, and 31C encapsulating the first Hall IC 38a to the fourth Hall IC 38d are arranged in the jig 100. In a state where the respective circuit boards 31A, 31B, and 31C are arranged in the jig 100, the wires 41 are assembled to the via holes 39b for the wires of the respective circuit boards 31A, 31B, and 31C (both are referred to Figure 8 ).

[0146] In the second step, the sensor substrate holder 46 is arranged in the jig 100. Thus, the respective circuit boards 31A, 31B, and 31C and the wires 41 are held (supported) by the sensor substrate holder 46. In this state, the wires 41 are connected to the respective circuit boards 31A, 31B, and 31C by, for example, soldering.

[0147] As Figure 11 shown in FIG. 5(b), in the third step, the sensor wires 21b are assembled to the via holes 39a for the sensor wires of the respective circuit boards 31A, 31B, and 31C. After assembling the sensor wires 21b, the sensor wires 21b are connected to the respective circuit boards 31A, 31B, and 31C by, for example, soldering. Thus, the sensor wires 21b are connected to the respective Hall ICs 38a to 38d via the respective circuit boards 31A, 31B, and 31C (refer to Figure 11 FIG. 5(a)).

[0148] As Figure 12 shown in FIG. 6, in the fourth step, the sensor substrate holder 46 and the respective circuit boards 31A, 31B, and 31C are removed from the jig 100 (refer to Figure 11 FIG. 5(b)) and housed in the holder housing 45. Specifically, the sensor substrate holder 46 is pressed into the outer frame member 60 of the holder housing 45. Moreover, the respective circuit boards 31A, 31B, and 31C are housed in the substrate housing portions 80 of the respective legs 61a, 61b, and 61c included in the holder housing 45.

[0149] In this state, a filler 90 (see Figure 6 ) is filled inside the outer frame member 60 of the holder housing 45 and the substrate accommodating portions 80 of the respective leg portions 61a, 61b, 61c (see Figure 10 ). Thus, the first to fourth processes of the manufacturing method of the position detection sensor unit 6 are completed.

[0150] As described above, according to the position detection sensor unit 6, in a state where the sensor substrate holder 46 and the respective circuit boards 31A, 31B, 31C are arranged in the jig 100, the lead wires 41 are connected to the respective circuit boards 31A, 31B, 31C. Further, in this state, the sensor wires 21b are connected to the respective circuit boards 31A, 31B, 31C.

[0151] Therefore, the respective leg portions 61a, 61b, 61c for accommodating the respective circuit boards 31A, 31B, 31C can be formed integrally with the holder housing 45. Therefore, the number of parts of the position detection sensor unit 6 can be reduced to two, and the cost of the position detection sensor unit 6 can be suppressed.

[0152] In addition, the present invention is not limited to the above-described embodiments, and includes embodiments obtained by making various changes to the above-described embodiments without departing from the gist of the present invention.

[0153] For example, in the above-described embodiment, the case where the rotary electric machine 1 is used as a starting generator for an engine of a vehicle such as a motorcycle has been described. However, it is not limited thereto, and the rotary electric machine 1 can be applied to various uses. For example, the rotary electric machine 1 can also be used only as a generator or only as an electric motor.

Claims

1. A position detection sensor unit that detects the magnetic flux of a magnet provided on a rotor to detect the rotational position of the rotor, characterized in that Comprising: A holder housing that houses a substrate encapsulating a magnetic detection element, the magnetic detection element detecting the magnetic flux of the magnet; And A sensor substrate holder that is mounted on the holder housing and holds the substrate, The sensor substrate holder having: A groove opening provided at one end for inserting a first end portion of the substrate; A substrate insertion groove provided at the other end and having a contact surface; and A substrate gripping portion that grips a side portion of the first end portion of the substrate inserted into the groove opening, The holder housing having: An outer frame member that houses the sensor substrate holder; and Three legs integrally formed on the outer frame member, The three legs having inside thereof: a substrate accommodating portion that accommodates a second end portion of the substrate opposite to the first end portion.

2. The position detection sensor unit according to claim 1, characterized in that The substrate accommodating portion has: An opening for inserting the second end portion of the substrate; A first substrate accommodating portion that accommodates the second end portion of the substrate; and A second substrate accommodating portion that accommodates a portion of the substrate closer to the first end portion than the second end portion, and has a wider width in the radial inner side starting from the substrate compared to the first substrate accommodating portion.

3. The position detection sensor unit according to claim 2, characterized in that A filler is filled inside the outer frame member to seal the opening.

4. A manufacturing method of a position detection sensor unit that detects the magnetic flux of a magnet provided on a rotor to detect the rotational position of the rotor, and the manufacturing method of the position detection sensor unit is characterized by including: A first step of arranging a plurality of substrates encapsulating magnetic detection elements on a jig and assembling wires to the substrates, the magnetic detection elements detecting the magnetic flux of the magnet; A second step of using a sensor substrate holder to hold the substrate and the wires and connecting the wires to the substrate; A third step of assembling sensor wires to the substrate and connecting the assembled sensor wires to the substrate and thus to the magnetic detection element; And A fourth step of removing the sensor substrate holder and the substrate from the jig and housing them in a holder housing, and filling a filler inside the holder housing.

Images