Rotating electrical machine

Abstract

A rotating electric machine (1) of an embodiment includes a cylindrical stator (2), a rotor (3) disposed in an inner space of the stator (2), a bottomed cylindrical housing (4) that houses the stator (2), an end cover (5) attached to an open end (41) of one side of the housing (4), and a circuit board (7) that controls driving of the rotating electric machine (1). The stator (2) includes a stator core (20) having a plurality of protrusions (20b) that protrude toward a center of the stator (2), an insulator (21, 22) fitted to the stator core (20), and a coil (23) in which the plurality of protrusions (20b) are wound with a winding (24) via the insulator (21, 22). The circuit board (7) is disposed at a position that is inward of an axial outer end of the housing (4) and between the stator (2) and the end cover (5). The rotating electric machine (1) further includes a first insulating sheet (8) disposed between the circuit board (7) and the stator (2) to insulate the circuit board (7) and the coil (23), and a second insulating sheet (9) disposed between the circuit board (7) and the end cover (5) to insulate the circuit board (7) and the end cover (5).

Description

Technical Field

[0001] This invention relates to rotary electric motors. Background Technology

[0002] Previously, brushless DC motors with an internal rotor type were known in rotating electrical machines (see, for example, Patent Documents 1 and 2).

[0003] For example, Patent Document 1 discloses a structure in which resin is injected into the housing of an electric motor. The resin has a central space for the rotor to be inserted and is filled between the stator and the housing.

[0004] For example, Patent Document 2 discloses a structure for housing a circuit board within a housing. The housing includes a metal cylinder assembled around the outer periphery of the stator, a resin-molded portion formed by molding the cylinder and the stator with resin, a metal cover connected to the front end of the cylinder, and a cover member mounted at the base end of the resin-molded portion.

[0005] Prior art literature

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent No. 3318531

[0008] Patent Document 2: Japanese Patent No. 3612715 Summary of the Invention

[0009] Summary of the invention

[0010] The problem that the invention aims to solve

[0011] However, there is room for improvement in terms of internally constructing a circuit board for controlling the motor's operation and simultaneously miniaturizing the motor in the axial direction.

[0012] Therefore, the object of the present invention is to internally form a circuit board and simultaneously miniaturize the rotary motor in the axial direction.

[0013] Solution for solving the problem

[0014] As a solution to the aforementioned problems, the present invention has the following structure.

[0015] (1) The rotary motor of the present invention comprises: a cylindrical stator; a rotor disposed in the internal space of the stator; a cylindrical or bottomed cylindrical housing housing the stator; an end cap mounted on an open end of one side of the housing; and a circuit board for controlling the drive of the rotary motor, the stator comprising: a stator core having a plurality of protrusions protruding toward the center of the stator; an insulator assembled to the stator core; and a coil formed by winding the coils through the insulator at the plurality of protrusions respectively, wherein the circuit board is disposed at a position inward of the outer axial end of the housing and disposed between the stator and the end cap, the rotary motor further comprising: a first insulating sheet disposed between the stator and the circuit board to insulate the circuit board from the coil; and a second insulating sheet disposed between the circuit board and the end cap to insulate the circuit board from the end cap.

[0016] (2) In the rotary motor described in (1) above, the LOI value of the first insulating sheet and the second insulating sheet at 220°C is higher than 20.8%.

[0017] (3) In the rotary motor described in (1) or (2) above, the gaps between the housing and the insulator, and between each of the plurality of protrusions in the stator core, may be filled with resin, and the housing and the stator may be integrated.

[0018] (4) In any of the rotating motors described in (1) to (3) above, the insulator may have an abutting portion that abuts against the stator side surface of the first insulating sheet.

[0019] (5) In any of the rotary motors described in (1) to (4) above, the second insulating sheet may be sandwiched between an opening on one side of the housing and the front end of the cylindrical portion of the end cap.

[0020] (6) In any of the rotary motors described in (1) to (5) above, the first insulating sheet and the second insulating sheet may be formed of aramid fibers and have a thickness of 0.25 mm or more.

[0021] (7) In any of the rotary motors described in (1) to (6) above, the circuit board may also include a magnetic sensor disposed on the stator side of the circuit board.

[0022] Invention Effects

[0023] According to the present invention, a circuit board can be internally formed and a rotary motor can be miniaturized in the axial direction at the same time. Attached Figure Description

[0024] Figure 1 This is a cross-sectional view of the rotary electric machine according to the first embodiment, including the axis.

[0025] Figure 2 yes Figure 1 Enlarged view of the enclosed part II.

[0026] Figure 3 This is a diagram showing the rotary motor of the first embodiment viewed from one side along the axial direction.

[0027] Figure 4 This is a diagram showing the rotary motor of the first embodiment viewed from the radial outside.

[0028] Figure 5 This is a perspective view of the rotary motor of the first embodiment as seen from the circuit board side.

[0029] Figure 6 This is a perspective view of the rotary electric motor of the first embodiment as viewed from the side of the first insulator.

[0030] Figure 7A This is a top view of the circuit board of the first embodiment viewed from one axial side.

[0031] Figure 7B This is a top view of the circuit board of the first embodiment viewed from the other side of the axial direction. Figure 7A (Top view of the opposite side).

[0032] Figure 8 This is an explanatory diagram of the arrangement of resistors, etc., according to the first embodiment.

[0033] Figure 9 This is a diagram of the stator core of the first embodiment viewed from the axial direction.

[0034] Figure 10 This is an explanatory diagram of the resin filling structure inside the housing according to the first embodiment.

[0035] Figure 11 This represents the cross-section of the rotary electric motor according to the second embodiment, equivalent to... Figure 1 The image.

[0036] Figure 12 yes Figure 11 Enlarged view of the XII enclosure.

[0037] Figure 13 This refers to the configuration of the resistors, etc., in the first modified example. Figure 8 The image.

[0038] Figure 14 This refers to the configuration of the resistors, etc., in the second variation, equivalent to Figure 8 The image.

[0039] Figure 15 This refers to the configuration of the resistors, etc., in the third variation, equivalent to Figure 8 The image. Detailed Implementation

[0040] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the following description, an internal rotor type brushless DC motor will be used as an example of a rotary motor.

[0041] [First Implementation Method]

[0042] Rotary Electric Machine

[0043] like Figure 1 As shown, the rotary motor 1 includes a stator 2, a rotor 3, a housing 4, an end cover 5, and a temperature sensor 6 (see reference). Figure 3 The components include a circuit board 7, a first insulating sheet 8, a second insulating sheet 9, and a resin sheet 10. In this embodiment, a stator unit is configured by providing the stator 2 in the housing 4. Furthermore, a stator unit assembly is configured by providing the temperature sensor 6 and the circuit board 7 in the stator unit.

[0044] exist Figure 1 In the diagram, symbol 12 indicates a bearing that supports shaft 11 for rotation. Bearings 12 are respectively provided in housing 4 and end cover 5. The shaft 11 of the rotary motor 1 is rotatably supported in housing 4 and end cover 5 via bearings 12. Hereinafter, the direction along the axis CL of shaft 11 will be referred to as "axial direction", the direction orthogonal to axis CL will be referred to as "radial direction", and the direction about axis CL will be referred to as "circumferential direction".

[0045] <Stator>

[0046] The stator 2 is cylindrical. The stator 2 includes a stator core 20, insulators 21 and 22, and coils 23.

[0047] For example, the stator core 20 is formed by stacking multiple thin iron sheets (electromagnetic steel sheets) axially. The stator core 20 has an annular shape coaxial with the axis CL. The stator core 20 is fixed to the inner circumferential surface of the housing 4.

[0048] like Figure 9 As shown, the stator core 20 has an annular core body 20a and a plurality of protrusions 20b extending from the inner circumferential surface of the core body 20a toward the radial center (the center of the stator 2) with a predetermined length and forming along the inner circumferential surface of the core body 20a in the axial direction with a predetermined length (e.g., nine in this embodiment).

[0049] The protrusion 20b includes a protruding flange 20d that extends circumferentially from the protruding end 20c, which is a radially inner end. In this embodiment, the protruding flange 20d extends to both sides of the protruding end 20c with approximately the same length in the circumferential direction. The nine protrusions 20b are arranged at approximately equal intervals in the circumferential direction. In this embodiment, the nine protrusions 20b are arranged at approximately 40-degree (central angle) intervals in the circumferential direction.

[0050] The protruding flanges 20d provided on each protrusion 20b are arranged at intervals along the circumference. The stator core 20 has a space 91 surrounded by the protruding ends 20c of each protrusion 20b.

[0051] <Insulator>

[0052] like Figure 1 As shown, insulators 21 and 22 are assembled into the stator core 20. Insulators 21 and 22 can be divided along the axial direction (see reference). Figure 5 Insulators 21 and 22 are assembled into the core body 20a (refer to...). Figure 9 The inner circumference of the stator core 20. Insulators 21 and 22 are mounted on both sides of the stator core 20 along the axial direction. Insulators 21 and 22 are composed of a first insulator 21 mounted on one side of the stator core 20 along the axial direction and a second insulator 22 mounted on the other side of the stator core 20 along the axial direction. In this embodiment, insulators 21 and 22 are formed by combining the first insulator 21 and the second insulator 22.

[0053] Coil 23 passes through multiple protrusions 20b (see reference) Figure 9 They are formed by winding 24 through insulators 21 and 22 respectively. For example... Figure 3 As shown, coils 23 group together multiple coils 23U, 23V, and 23W of different phases (e.g., U phase, V phase, W phase), forming three groups. The U-phase, V-phase, and W-phase coils 23U, 23V, and 23W are arranged in this order along the circumference of the stator core 20. Adjacent coils 23 are spaced apart from each other along the circumference. In this embodiment, the nine coils 23 are arranged at approximately 40-degree (central angle) intervals along the circumference. That is, the three groups of coils 23U, 23V, and 23W are arranged at approximately 120-degree (central angle) intervals along the circumference. Figure 4 As shown, coil 23 has bent portions 24a at both ends of the axial direction, where the windings 24 are bent. The bent portions 24a are respectively provided on both sides of the axial direction of the windings 24 of the coils 23 adjacent in the circumferential direction. The bent portions 24a are respectively provided on both sides of the axial direction of the windings 24 of the U-phase, V-phase, and W-phase coils 23U, 23V, and 23W.

[0054] <rotor>

[0055] like Figure 1As shown, rotor 3 is disposed in space 91 (internal space) of stator 2. Rotor 3 is spaced apart from stator 2 and disposed radially inside stator 2. Rotor 3 is fixed to shaft 11. Rotor 3 is capable of rotating integrally with shaft 11 around axis CL. Rotor 3 has a yoke 30 and a magnet 31.

[0056] For example, the magnetic yoke 30 is formed of a metallic material such as aluminum. The magnetic yoke 30 has a ring shape coaxial with the axis CL. For example, the inner circumferential surface of the magnetic yoke 30 is fixed to the outer circumferential surface of the shaft 11 by an adhesive.

[0057] For example, magnet 31 is a permanent magnet. Magnet 31 has a ring shape coaxial with the axis CL. Magnet 31 is fixed to yoke 30 by inserting yoke 30 into insertion hole provided in magnet 31. Thus, magnet 31 can rotate integrally with yoke 30 and shaft 11. It should be noted that magnet 31 has multiple magnetic poles, N and N poles, in the portion facing the inner circumference of stator 2. The multiple magnetic poles, N and N poles, are arranged alternately in the circumferential direction.

[0058] <Shell>

[0059] The housing 4 has a bottomed cylindrical shape (bottomed cylindrical shape) for housing the stator 2. The housing 4 (bottomed cylindrical housing) has an open end 41 on one side of the housing 4 in the axial direction. The housing 4 has a bottom 42 on the other side of the housing 4 in the axial direction. For example, the housing 4 is made of a metal such as aluminum.

[0060] The housing 4 includes: a cylindrical portion 40 extending axially (hereinafter also referred to as "housing cylindrical portion 40"); and a bottom 42 connected to the other side of the housing cylindrical portion 40 along its axial direction. The housing cylindrical portion 40 and the bottom 42 are integrally formed by the same member. For example, the bottom 42 of the housing 4 is mounted on a mounting member 101 formed of a sheet metal such as aluminum (see reference 101). Figure 1 The other side of the housing 4 becomes the mounting surface for mounting the mounting member 101.

[0061] The bottom 42 of the housing 4 has a communicating hole in its central portion, which communicates with one side and the other side. The bottom 42 of the housing 4 has a bearing assembly for mounting a bearing 12. The hole of the bearing 12 mounted in the bearing assembly communicates with the communicating hole.

[0062] like Figure 2 As shown, the housing 4 has a stepped portion 43 on one side of the housing cylindrical portion 40 in the axial direction. The stepped portion 43 has: an annular surface 43a that is circular when viewed from the axial direction (hereinafter also referred to as "housing-side annular surface 43a"); and a circumferential surface 43b extending from the outer periphery of the housing-side annular surface 43a to one side in the axial direction (hereinafter also referred to as "housing-side circumferential surface 43b").

[0063] The axial length of the shell side circumferential surface 43b is greater than the radial length of the shell side annular surface 43a.

[0064] <End Cap>

[0065] like Figure 1 As shown, the end cap 5 is mounted on the open end 41 on one axial side of the housing 4. For example, the end cap 5 is made of a metal such as aluminum. The end cap 5 has a cylindrical portion 50 (hereinafter also referred to as "cap portion 50") extending axially and a cover portion 51 connected to one axial side of the cap portion 50. The axial length of the cap portion 50 is smaller than the axial length of the housing cylindrical portion 40. The cap portion 50 and the cover portion 51 are integrally formed by the same component. The cover portion 51 of the end cap 5 has a bearing mounting portion for mounting the bearing 12 at the center of the housing 4 side.

[0066] like Figure 2 As shown, the end cap 5 has a protrusion 52 that rises from one side of the cap cylinder portion 50 in the axial direction to the other side. The protrusion 52 has an annular surface 52a (hereinafter also referred to as "cap-side annular surface 52a") that is circular when viewed from the axial direction, and a peripheral surface 52b (hereinafter also referred to as "cap-side peripheral surface 52b") that extends from the outer periphery of the cap-side annular surface 52a in the axial direction.

[0067] The radial length of the cover-side annular surface 52a is greater than the radial length of the shell-side annular surface 43a.

[0068] The axial length of the cover side circumferential surface 52b is smaller than the axial length of the shell side circumferential surface 43b.

[0069] The axial length of the cover side circumferential surface 52b is greater than the radial length of the cover side annular surface 52a.

[0070] The end cap 5 is fitted onto the open end 41 on one side of the housing 4 by engaging the protrusion 52 of the cap cylinder portion 50 with the stepped portion 43 of the housing cylinder portion 40. The cap side circumferential surface 52b abuts against the housing side circumferential surface 43b. The cap side annular surface 52a is axially separated from the housing side annular surface 43a.

[0071] <Temperature Sensor>

[0072] For example, temperature sensor 6 is a PTC (Positive Temperature Coefficient) thermistor. Temperature sensor 6 is located on the end cover 5 side of stator 2.

[0073] Temperature sensor 6 has the function of rapidly increasing resistance when the temperature exceeds a certain level. Temperature sensor 6 is electrically connected to a power supply for motor drive (not shown) and circuit board 7, respectively. For example, when the temperature near temperature sensor 6 exceeds a predetermined value, the resistance of temperature sensor 6 increases, thereby stopping the power supply to circuit board 7.

[0074] like Figure 4 As shown, the temperature sensor 6 is disposed between the bends 24a of the windings 24 in adjacent coils 23. The temperature sensor 6 abuts against the bends 24a of the windings 24. The temperature sensor 6 abuts against the bends 24a of the windings 24 of each of the two circumferentially adjacent coils 23 (in this embodiment, adjacent coils 23V and 23W). In this embodiment, only one temperature sensor 6 is provided. In this embodiment, the temperature sensor 6 is disposed between the bends 24a of the windings 24 in the circumferentially adjacent V-phase coil 23V and W-phase coil 23W.

[0075] For example, the temperature sensor 6 is brought into contact with the bend 24a of the adjacent winding 24 using a tool not shown. In this state, resin is filled around the contact area between the bend 24a of the winding 24 and the temperature sensor 6 using a filling device not shown. This maintains the contact between the temperature sensor 6 and the bend 24a of the winding 24.

[0076] <Circuit substrate>

[0077] The circuit board 7 controls the drive of the rotary motor 1. For example... Figure 1 As shown, the circuit board 7 is disposed inside the housing 4, which is located inside the housing 4 at an axially inner end. The circuit board 7 is supported by an abutment portion 82 (described later) that protrudes upward from the upper surface of the first insulator 21. The circuit board 7 is disposed at a predetermined interval from the upper surface of the first insulator 21, supported by the abutment portion 82. The circuit board 7 is disposed between the stator 2 and the end cover 5. The circuit board 7 is disposed at a position axially inner from the opening end 41 on one side of the housing 4. The circuit board 7 is disposed at a position slightly axially inner from the annular surface 43a on the housing side (see reference). Figure 2 The circuit board 7 is fixed to the inner circumferential surface of the housing 4.

[0078] like Figure 7A As shown, the circuit board 7 includes: a board body 70 that is circular in shape when viewed from above; and a detection coil 23 (see reference 23). Figure 1 Resistor 75 supplying current; Field Effect Transistors 76A-76C (FET) serving as switching elements; for sensing axis 11 (see reference). Figure 1 The encoder 78 measures the rotation angle; various electronic components 79; and IC 102 is used for motor controller.

[0079] The motor controller uses IC102 to selectively turn on / off each of the FETs 76A to 76C in a predetermined sequence, thereby generating current in each phase of the coils 23U, 23V, and 23W of the U-phase, V-phase, and W-phase.

[0080] Figure 7B Viewed from above in circuit board 7 Figure 7A A diagram of the opposite side (back side).

[0081] like Figure 7B As shown, the circuit board 7 is equipped with magnetic sensors 77A to 77C for detecting the state of the magnetic force (magnetic field magnitude and direction) of the magnet 31.

[0082] The substrate body 70 has: a shaft hole 71 coaxial with the axis CL; engaging portions 72A to 72C (substrate-side engaging portions) that engage with the first insulator 21; and a cable 100 (see reference) for mounting the cable 100. Figure 1 The connection hole 73 for electrical connection; and the leads 25A to 25C of the coil 23 (see reference) Figure 3 The incisions 74A to 74C were made through this point.

[0083] Viewed from above, the shaft hole 71 has a circular shape. The diameter of the shaft hole 71 is larger than the outer diameter of the shaft 11. The circuit board 7 is arranged radially outward from the shaft 11 at a distance (see reference). Figure 1 ).

[0084] Viewed from above, the engaging portions 72A to 72C have an elongated hole shape extending circumferentially. Multiple engaging portions 72A to 72C are provided at circumferential intervals (for example, three in this embodiment). The three engaging portions 72A to 72C (first engaging portion 72A, second engaging portion 72B, and third engaging portion 72C) are arranged at approximately the same circumferential intervals.

[0085] Viewed from above, the connecting holes 73 have a circular shape. Multiple connecting holes 73 are provided at circumferential intervals (e.g., eight in this embodiment). The eight connecting holes 73 are circumferentially arranged between the first engaging portion 72A and the third engaging portion 72C.

[0086] Viewed from above, the cuts 74A to 74C have concave shapes that open radially outward toward the circuit board 7. Multiple cuts 74A to 74C are provided at circumferential intervals (for example, three in this embodiment). The three cuts 74A to 74C (first cut 74A, second cut 74B, and third cut 74C) are arranged circumferentially between the second engaging portion 72B and the third engaging portion 72C.

[0087] For example, resistor 75 is a shunt resistor. In this embodiment, only one resistor 75 is provided. Resistor 75 is provided on the side of end cap 5 of substrate body 70 (circuit board 7). That is, resistor 75 is provided on the side of substrate body 70 opposite to the side of stator 2.

[0088] Multiple FETs 76A to 76C are provided circumferentially spaced apart (for example, three in this embodiment). FETs 76A to 76C are disposed on the surface of the substrate body 70 on the side of the end cap 5. That is, FETs 76A to 76C are disposed on the substrate body 70 on the same side as the resistor 75.

[0089] Three FETs 76A-76C (first FET 76A, second FET 76B, and third FET 76C) are respectively arranged near three notches 74A-74C (first notch 74A, second notch 74B, and third notch 74C). Leads 25A-25C for coil 23 are respectively provided between the three FETs 76A-76C and the three notches 74A-74C (see reference). Figure 3 The areas to be soldered are 26A to 26C.

[0090] Regions 26A to 26C are positioned near the leads 25A to 25C of coil 23. This helps to suppress the excessive length of the leads 25A to 25C of coil 23, thereby reducing noise generation.

[0091] FETs 76A to 76C are electrically connected to leads 25A to 25C of coil 23. For example, after leads 25A to 25C of coil 23 are soldered in regions 26A to 26C, they are electrically connected to FETs 76A to 76C via wiring formed on the circuit board 7. By placing FETs 76A to 76C near regions 26A to 26C, the wiring on the circuit board 7 can be shortened and simplified.

[0092] For example, magnetic sensors 77A to 77C are Hall elements. Multiple magnetic sensors 77A to 77C are provided at circumferential intervals (for example, three in this embodiment). Magnetic sensors 77A to 77C are disposed on the surface of the substrate body 70 on the stator 2 side. Figure 7B face).

[0093] exist Figure 7B From a top-down view, the three magnetic sensors 77A to 77C (first magnetic sensor 77A, second magnetic sensor 77B, and third magnetic sensor 77C) detect the change in magnetic flux caused by the rotation of the magnet 31 by magnetic sensors placed at specific positions on the substrate body 70 on the stationary side.

[0094] For example, the magnetic sensor can be positioned directly above the magnet 31 when viewed from above, and close to the magnet 31 in the axial direction. This improves the sensitivity of the rotation detection of the magnet 31.

[0095] For example, encoder 78 is an optical encoder that uses an infrared light-emitting diode (IR LED) as its light-emitting element. For example, encoder 78 detects the rotation of a circular plate (not shown) for detecting a sensor mounted on shaft 11, generating an on / off signal for light. In this embodiment, only one encoder 78 is provided. Encoder 78 has the largest mounting area among the electronic components provided on the circuit board 7. Encoder 78 is provided on the end cap 5 side of the board body 70.

[0096] like Figure 8 As shown, in a top view, the encoder 78 is positioned between the leftmost first FET 76A and resistor 75 among the three FETs 76A to 76C. That is, the encoder 78 is circumferentially positioned between the first FET 76A and resistor 75. In this embodiment, in a top view, the resistor 75 is positioned across the shaft hole 71 on the side opposite to the second FET 76B. It should be noted that... Figure 8 The illustrations of holes, cuts, etc., other than the shaft hole 71 of the substrate body 70 are omitted.

[0097] <First Insulating Sheet>

[0098] like Figure 1 As shown, a first insulating sheet 8 is disposed between the stator 2 and rotor 3 and the circuit board 7. The first insulating sheet 8 insulates at least the circuit board 7 from the coil 23. The first insulating sheet 8 has an annular shape when viewed axially. The first insulating sheet 8 has an inner peripheral portion with a through hole formed in the center for the shaft 11 to pass through. The inner peripheral portion of the first insulating sheet 8 is disposed radially outward from the shaft 11 at a distance. Thus, the first insulating sheet 8 allows the shaft 11 to rotate. The first insulating sheet 8 is supported by a first insulator 21. Specifically, the first insulating sheet 8 is supported by a plurality of abutment portions 81, described later, provided on the first insulator 21.

[0099] <Second Insulating Sheet>

[0100] The second insulating sheet 9 is disposed between the circuit board 7 and the end cap 5. The second insulating sheet 9 is positioned adjacent to the circuit board 7. The second insulating sheet 9 at least insulates the circuit board 7 from the end cap 5. The second insulating sheet 9, when viewed axially, has an annular shape larger than the first insulating sheet 8. The second insulating sheet 9 has an inner peripheral edge portion with a through hole formed in its central portion for the shaft 11 to pass through. The inner peripheral edge portion of the second insulating sheet 9 is disposed radially outward of the shaft 11, spaced apart from the shaft 11. Thus, the second insulating sheet 9 allows rotation of the shaft 11.

[0101] like Figure 2As shown, the second insulating sheet 9 extends radially from the inner periphery toward the outer periphery. The outer periphery of the second insulating sheet 9 is disposed near the side peripheral surface 43b of the housing. The outer periphery of the second insulating sheet 9 is held between an opening on one side of the housing 4 and the front end of the cylindrical portion 50 of the end cap 5. The second insulating sheet 9 is held by being held between the stepped portion 43 of the housing cylindrical portion 40 and the protrusion 52 of the cap cylindrical portion 50. The second insulating sheet 9 abuts against the housing-side annular surface 43a and the cap-side annular surface 52a. The second insulating sheet 9 is slightly separated from the housing-side peripheral surface 43b. The second insulating sheet 9 is slightly separated axially from the end cap 5 side surface of the circuit board 7. By providing a gap between the end cap 5 side surface of the circuit board 7 and the second insulating sheet 9, further insulation between the circuit board 7 and the end cap 5 is ensured.

[0102] Characteristics of the first and second insulating sheets

[0103] The first insulating sheet 8 and the second insulating sheet 9 are both insulating and flame-retardant sheets. The first insulating sheet 8 and the second insulating sheet 9 are both formed of aramid fibers. For example, the first insulating sheet 8 and the second insulating sheet 9 are insulating papers. The first insulating sheet 8 and the second insulating sheet 9 each have a thickness of 0.25 mm or more. For example, the first insulating sheet 8 and the second insulating sheet 9 each have a thickness of 0.25 mm or more and 0.35 mm or less.

[0104] For example, the thermal conductivity of the first insulating sheet 8 and the second insulating sheet 9 at a test temperature of 150°C, in accordance with the test method of ASTM E1530, is greater than 0.12 W / m·K and less than 0.14 W / m·K.

[0105] The LOI (Limiting Oxygen Index) values ​​of the first insulating sheet 8 and the second insulating sheet 9 at 220°C are both higher than 20.8%. Here, the LOI value is a numerical value used as a measure of inferring flame retardancy and is specified by the "JIS K7201 Limiting Oxygen Index". For example, when the thickness of the first insulating sheet 8 and the second insulating sheet 9 is 0.25 mm, the LOI value at 220°C is 22% or higher and 25% or lower.

[0106] <Resin Sheet>

[0107] like Figure 1 As shown, the resin sheet 10 is disposed between the bottom 42 of the housing 4 and the stator 2. The resin sheet 10 is also disposed between the bottom 42 of the housing 4 and the second insulator 22. The resin sheet 10 has an annular shape when viewed axially. The resin sheet 10 has an inner peripheral edge portion with a through hole formed in its central portion for the shaft 11 to pass through. The inner peripheral edge portion of the resin sheet 10 is disposed radially outward from the shaft 11 at a distance. Thus, the resin sheet 10 allows rotation of the shaft 11.

[0108] In this embodiment, to suppress misalignment of the resin sheet 10, an annular protrusion 44 is provided at the bottom 42 of the housing 4, abutting against the inner periphery of the insertion hole of the resin sheet 10. The axial height of the annular protrusion 44 is slightly larger than the thickness of the resin sheet 10. For example, the inner diameter of the insertion hole of the resin sheet 10 is designed to match the outer diameter of the annular protrusion 44.

[0109] It should be noted that the structure used to suppress misalignment of the resin sheet 10 is not limited to the case where the annular protrusion 44 is provided. For example, the outer diameter of the resin sheet 10 can be made to match the inner diameter of the housing 4 instead of providing the annular protrusion 44.

[0110] In this embodiment, the second insulator 22 determines its axial position by abutting against the annular protrusion 44. Thus, the resin sheet 10 separates from the second insulator 22 axially. However, this is not a limitation; the resin sheet 10 may also abut against the second insulator 22.

[0111] The resin sheet 10 is formed of silicone. The resin sheet 10 has a thickness of 0.2 mm or more. For example, the resin sheet 10 has a thickness of 0.2 mm or more and 0.3 mm or less.

[0112] For example, the thermal conductivity of resin sheet 10 under a load of 20 psi, as determined by the method of ASTM D5470, is greater than 1.0 W / m·K and less than 1.4 W / m·K.

[0113] Resin sheet 10 has a V-0 rating under the UL94 standard, which indicates the degree of flame retardancy of a material.

[0114] <First Insulator>

[0115] like Figure 1 As shown, the first insulator 21 includes: an annular portion 80 coaxial with the stator core 20; a contact portion 81 (hereinafter also referred to as "sheet-side contact portion 81") that abuts against the stator 2 side surface of the first insulating sheet 8; a contact portion 82 (hereinafter also referred to as "substrate-side contact portion 82") that abuts against the stator 2 side surface of the circuit board 7; and a plurality of extension portions 83 extending toward the stator 2 side surface of the circuit board 7 (see reference 80). Figure 6 ); and engagement portions 84A to 84C that engage with the circuit board 7 via multiple engagement portions 72A to 72C (see reference 7) Figure 5 ).

[0116] The sheet-side abutment portion 81 extends from the inner circumferential side of the annular portion 80 toward the axial side. The front end of the sheet-side abutment portion 81 abuts against the stator 2 side surface of the first insulating sheet 8. Multiple sheet-side abutment portions 81 are provided at circumferential intervals (for example, nine in this embodiment) (see reference). Figure 6The nine side contact portions 81 are arranged at approximately equal intervals along the circumference (see reference). Figure 6 ).

[0117] The substrate-side abutment portion 82 extends axially from the outer periphery of the annular portion 80. The front end of the substrate-side abutment portion 82 abuts against the stator 2 side surface of the circuit board 7. The substrate-side abutment portion 82 extends axially longer than both the sheet-side abutment portion 81 and the extension portion 83 (see reference). Figure 6 The substrate-side contact portion 82 is provided in a plurality of spaced intervals along the circumference (for example, 11 in this embodiment) (see reference). Figure 6 ).

[0118] like Figure 6 As shown, the extension 83 extends from the outer periphery of the annular portion 80 toward one side in the axial direction. Multiple extensions 83 are provided at circumferential intervals (for example, four in this embodiment). The front end of the extension 83 separates from the stator 2 side surface of the circuit board 7. That is, the extension 83 does not abut against the circuit board 7. A gap is formed between the front end of the extension 83 and the stator 2 side surface of the circuit board 7. The gap between the front end of the extension 83 and the circuit board 7 is at the wiring portion 1001 of the cable 100 (see reference). Figure 2 The gap is a space used to accommodate the wiring portion 1001 when electrically connected to the circuit board 7. This gap functions as a recess for the protruding wiring portion 1001 as described below. Specifically, with the wiring portion 1001 passing through the connection hole 73, it is soldered to the circuit board 7. Thus, the wiring portion 1001 and the solder protrude from the stator 2 side of the circuit board 7 towards the stator 2 side. The gap serves as a recess for this protruding wiring portion 1001.

[0119] like Figure 6 As shown, the engaging portions 84A to 84C (insulator-side engaging portions) extend axially from the outer periphery of the annular portion 80. The engaging portions 84A to 84C extend axially longer than the substrate-side abutment portion 82. The engaging portions 84A to 84C have a hook shape capable of engaging with the circuit board 7 (see reference). Figure 5 The engaging portions 84A to 84C extend axially from the annular portion 80 and then bend radially outward. Thus, the engaging portions 84A to 84C can maintain an engaged state with the circuit board 7.

[0120] Multiple engaging portions 84A to 84C are provided at circumferential intervals (for example, three in this embodiment). The three engaging portions 84A to 84C (first engaging portion 84A, second engaging portion 84B, and third engaging portion 84C) are arranged at approximately the same circumferential intervals. The three engaging portions 84A to 84C (first engaging portion 84A, second engaging portion 84B, and third engaging portion 84C) engage with the circuit board 7 via three engaging portions 72A to 72C (first engaging portion 72A, second engaging portion 72B, and third engaging portion 72C) respectively (see reference). Figure 5 ).

[0121] The 11 substrate-side abutment portions 82 are: 5 substrate-side abutment portions 82 disposed circumferentially between the first engaging portion 84A and the second engaging portion 84B; 5 substrate-side abutment portions 82 disposed circumferentially between the second engaging portion 84B and the third engaging portion 84C; and 1 substrate-side abutment portion 82 disposed circumferentially between the first engaging portion 84A and the third engaging portion 84C.

[0122] Four extensions 83 are arranged circumferentially between the first engaging portion 84A and the third engaging portion 84C.

[0123] <Resin filling structure inside the shell>

[0124] like Figure 10 As shown, the gap between the housing 4 and the insulators 21 and 22 (first insulator 21 and second insulator 22) is filled with resin 90. Thus, the gap between the housing 4 and the insulators 21 and 22 is filled with resin 90. Multiple protrusions 20b in the stator core 20 (see reference) Figure 9 The gaps between each of the protrusions 20b in the stator core 20 are filled with resin 90. Thus, the gaps between each of the multiple protrusions 20b in the stator core 20 are filled with resin 90. (See housing 4, stator 2, and temperature sensor 6 for reference.) Figure 4 It is integrated through resin 90.

[0125] For example, the filling process of filling resin 90 into housing 4 is carried out according to the following steps.

[0126] For example, using a tool not shown, the temperature sensor 6 is brought into contact with the bend 24a of the coil 23, and the lead 60 of the temperature sensor 6 is led outward. Then, in this state, resin 90 is filled into the housing 4 (see reference). Figure 4 Thus, the housing 4, stator 2, and temperature sensor 6 are integrated using resin 90. Then, the lead wire 60 is soldered to the circuit board 7 through a slit (not shown) in the circuit board 7. This completes the wiring process of connecting the lead wire 60 to the circuit board 7.

[0127] Resin 90 has a central space 91 for inserting the shaft 11 and rotor 3, and fills the gaps within the housing 4 except for this space. For example, resin 90 is a thermosetting resin such as epoxy resin. Resin 90 fills the housing 4 axially up to the coil 23 (see reference). Figure 1 (The area that is not exposed.)

[0128] For example, Resin 90 has a thermal conductivity of ≥0.1 W / m·K and ≤0.9 W / m·K under a load of 20 psi, as determined by ASTM D5470. Resin 90 has a V-0 rating under UL 94, a standard indicating the degree of flame retardancy of materials. Resin 90 has a volume resistivity of 1 × 10⁻⁶ at 25°C, as determined by ASTM D257. 15 Ω·cm, the volume resistivity at 100℃ is 1×10 15 Ω·cm, the volume resistivity at 150℃ is 3×10 Ω·cm 13 Ω·cm.

[0129] For example, the manufacturing method of a stator unit by providing a stator 2 in a housing 4 and filling the housing 4 with resin 90 is carried out according to the following steps (processes).

[0130] First, resin sheets 10 are placed inside the housing 4 (sheet preparation process).

[0131] Next, the stator 2 is placed into the housing 4 (stator configuration process).

[0132] Next, a cylindrical profile of approximately the same size as the rotor 3 is placed into the housing 4 (first filling preparation step). For example, the profile is cylindrical in size, having multiple protruding ends 20c forming the space 91 and abutting against the outer peripheral surface of the rotor 3. The profile is, for example, a sheet of polytetrafluoroethylene (PTFE).

[0133] Next, using a tool not shown, the temperature sensor 6 is positioned between the bends 24a of the adjacent coil 23 in a state of contact with the bends 24a of the adjacent coil 23 (second filling preparation step).

[0134] Next, resin 90 is filled between the inner circumferential surface of the housing 4 and the outer circumferential surface of the profile using a filling device (not shown) (resin filling process).

[0135] Next, after placing the shell filled with resin 90 into the 4-way vacuum tank, vacuum suction and degassing are performed to remove air bubbles contained in the filled resin 90 (degassing) (filling finishing process).

[0136] Next, the profile is removed (filling completion process). As a result, a space 91 for the rotor 3 to enter is formed inside the housing 4 filled with resin 90.

[0137] <Effects>

[0138] As described above, the rotary motor 1 of the above embodiment includes: a cylindrical stator 2; a rotor 3 disposed within the internal space of the stator 2; a bottomed cylindrical housing 4 housing the stator 2; an end cap 5 with an open end 41 mounted on one side of the housing 4; and a circuit board 7 for controlling the drive of the rotary motor 1. The stator 2 includes: a stator core 20 having a plurality of protrusions 20b protruding toward the center of the stator 2; insulators 21 and 22 assembled to the stator core 20; and a coil 23 formed by winding a winding 24 through the plurality of protrusions 20b via the insulators 21 and 22 respectively. The circuit board 7 is disposed at a position closer to the axial outer end of the housing 4 and is disposed between the stator 2 and the end cap 5. The rotary motor 1 also includes a first insulating sheet 8 disposed between the circuit board 7 and the stator 2 to insulate the circuit board 7 from the coil 23, and a second insulating sheet 9 disposed between the circuit board 7 and the end cap 5 to insulate the circuit board 7 from the end cap 5.

[0139] According to this structure, the assembly of the circuit board 7 is easier compared to the case where the circuit board 7 is disposed outside the housing 4 (inside the end cover 5). Therefore, the assembly of the rotary motor 1 can be performed efficiently. Furthermore, by insulating and isolating the circuit board 7 from the coil 23 with the first insulating sheet 8, and by insulating the circuit board 7 from the end cover 5 with the second insulating sheet 9, insulation can be ensured even when the circuit board 7 is disposed close to the coil 23 and the end cover 5, thus improving safety. Moreover, by using the first insulating sheet 8 and the second insulating sheet 9 for axial insulation respectively, the axial thickness can be reduced compared to the case where sealing resin (molding resin) is used as the insulating material, thus enabling miniaturization of the rotary motor 1 in the axial direction. Therefore, the circuit board 7 can be internally constructed while simultaneously miniaturizing the rotary motor in the axial direction.

[0140] Furthermore, resin 90 is filled in the gap between the housing 4 and the stator 2 disposed within the housing 4, and the coil 23 of the stator 2 is covered by resin 90, thereby ensuring insulation. Further insulation is ensured by the first insulating sheet 8. Additionally, the circuit board 7 is insulated from the end cover 5 by the second insulating sheet 9, thereby allowing the use of a metal end cover 5, achieving electromagnetic compatibility (EMC), and improving heat dissipation.

[0141] In the above embodiment, the LOI values ​​of the first insulating sheet 8 and the second insulating sheet 9 at 220°C are higher than 20.8%, thereby achieving the following effect.

[0142] Materials with an LOI value higher than 20.8% at 220°C exhibit heat resistance and flame retardancy. For example, even if the ambient temperature of coil 23 rises to 200°C, it has almost no impact on electrical and mechanical properties. Therefore, even under high-temperature use, the insulation between circuit board 7 and coil 23, as well as between circuit board 7 and end cap 5, can be ensured, further improving safety.

[0143] In the above embodiment, the gaps between the housing 4 and the insulators 21 and 22 of the stator 2 disposed in the housing 4, as well as between each of the plurality of protrusions 20b in the stator core 20, are filled with resin 90, and the housing 4 and the stator 2 are integrated, thereby achieving the following effect.

[0144] The resin 90 filling the gaps within the housing 4 increases the thermal conductivity of the heat emitted from the coil 23 of the stator 2, allowing the emitted heat to dissipate from the housing 4 as a whole, thereby suppressing the temperature rise of the rotary motor 1 (the temperature rise of the coil 23). Therefore, it is possible to more effectively suppress adverse conditions caused by the overheating of the rotary motor 1 (coil 23).

[0145] In the above embodiment, the first insulator 21 has a sheet-side contact portion 81 that abuts against the stator 2 side surface of the first insulating sheet 8, thereby achieving the following effect.

[0146] The first insulating sheet 8 can be supported axially by the side contact portion 81.

[0147] In the above embodiment, the second insulating sheet 9 is sandwiched between the opening on one side of the housing 4 and the front end of the cylindrical portion 50 of the end cap 5, thereby achieving the following effect.

[0148] The second insulating sheet 9 is held in place by the opening on one side of the housing 4 and the front end of the cylindrical portion 50 of the end cap 5, which allows the second insulating sheet 9 to be positioned in a predetermined position in the axial direction.

[0149] In the above embodiments, the first insulating sheet 8 and the second insulating sheet 9 are respectively formed of aramid fibers and have a thickness of 0.25 mm or more, thereby achieving the following effects.

[0150] Excellent voltage withstand characteristics (e.g., 5000V under UL standard) can be obtained in the first insulating sheet 8 and the second insulating sheet 9 respectively.

[0151] In the above embodiment, the circuit board 7 includes magnetic sensors 77A to 77C, which are disposed on the surface of the circuit board 7 on the stator 2 side, thereby achieving the following effect.

[0152] Compared to the case where magnetic sensors 77A to 77C are disposed on the end cap 5 side of the circuit board 7, the magnetic sensors 77A to 77C can be brought closer to the rotor 3, thus improving the detection accuracy of the magnetic sensors 77A to 77C. Furthermore, when a first insulating sheet 8 is provided between the circuit board 7 and the stator 2, insulation between the coil 23 and the magnetic sensors 77A to 77C can be achieved through the first insulating sheet 8.

[0153] In the above embodiment, the temperature sensor 6 is located on the end cover 5 side of the stator 2, between the bends 24a of the windings 24 in the adjacent coils 23.

[0154] According to this structure, the temperature sensor 6 is disposed on the end cover 5 side of the stator 2 between the bends 24a of the windings 24 in adjacent coils 23, thereby enabling the detection of the temperature of the bends 24a, which are most prone to overheating in the rotary motor 1. For example, based on the detection result of the temperature sensor 6 (the temperature of the bends 24a of the windings 24 in the coils 23 of the rotary motor 1), the drive of the rotary motor 1 can be made to operate most appropriately. Therefore, by using the temperature sensor 6, adverse conditions caused by overheating of the rotary motor 1 can be suppressed.

[0155] In the above embodiment, the temperature sensor 6 abuts against the bend 24a of the winding 24, thereby enabling direct detection of the temperature of the bend 24a of the winding 24. Therefore, the temperature of the bend 24a, which is most prone to overheating in the rotary motor 1, can be detected with higher accuracy.

[0156] In the above embodiment, the first insulator 21 has a substrate-side contact portion 82 that abuts against the stator 2 side surface of the circuit board 7, thereby achieving the following effect.

[0157] The circuit board 7 can be separated from the coil 23 and supported at a predetermined position in the axial direction by means of the substrate-side abutment portion 82. Specifically, by separating the circuit board 7 from the coil 23 by means of the substrate-side abutment portion 82, the circuit board 7 can be separated from the coil 23, which is a heat source, at predetermined intervals. In addition, the magnet 31 of the rotor 3 can be set at a position that is most suitable for detection by the three magnetic sensors 77A to 77C.

[0158] In the above embodiment, the circuit board 7 has a plurality of engaging portions 72A to 72C arranged at predetermined intervals along the circumference. The first insulator 21 has engaging portions 84A to 84C corresponding to the plurality of engaging portions 72A to 72C respectively. When the engaging portions 84A to 84C of the first insulator 21 pass through the plurality of engaging portions 72A to 72C of the circuit board 7, the circuit board 7 is engaged with the first insulator 21, thereby achieving the following effect.

[0159] The multiple engaging parts 84A to 84C can define the circumferential and radial positions of the circuit board 7 while simultaneously holding the circuit board 7 in place.

[0160] In the above embodiment, the gaps between the housing 4 and the insulators 21 and 22 of the stator 2 disposed in the housing 4, as well as between each of the plurality of protrusions 20b in the stator core 20, are filled with resin 90, and the housing 4, the stator 2 and the temperature sensor 6 are integrated, thereby achieving the following effect.

[0161] The resin 90 filling the gaps within the housing 4 improves the thermal conductivity of heat emitted from the coil 23 of the stator 2, allowing the emitted heat to dissipate entirely from the housing 4, thereby suppressing the temperature rise of the rotary motor 1 (coil 23). Furthermore, the contact state of the temperature sensor 6 with the coil 23 of the stator 2 is maintained effectively, improving temperature detection accuracy. Therefore, by using the temperature sensor 6, adverse conditions caused by overheating of the rotary motor 1 (coil 23) can be more effectively suppressed.

[0162] In the above embodiment, the housing 4 is a bottomed cylindrical housing with a bottom 42 on the other side, and also includes a resin sheet 10 disposed between the bottom 42 and the stator 2, thereby achieving the following effects.

[0163] By placing a resin sheet 10 with a higher thermal conductivity than the resin between the bottom 42 of the housing 4 and the stator 2, heat conduction (heat dissipation) from the coil 23 to the mounting member 101 is promoted when the bottom 42 of the housing 4 is mounted on the mounting member 101, thus suppressing the temperature rise of the rotary motor 1 (coil 23). Furthermore, the resin sheet 10 ensures insulation between the bottom 42 of the housing 4 and the stator 2 disposed within the housing 4.

[0164] In the above embodiment, the circuit board 7 has a resistor 75 for detecting the current supplied to the coil 23. The resistor 75 is disposed on the side of the end cap 5 of the circuit board 7, thereby achieving the following effect.

[0165] The circuit board 7 is positioned between the coil 23, which serves as a heat source, and the resistor 75, thereby separating the resistor 75 from the coil 23 and suppressing the influence of heat on the resistor 75. Therefore, it is possible to suppress the decrease in the detection accuracy of the current supplied to the coil 23.

[0166] In the above embodiment, the circuit board 7 also has an encoder 78 and a plurality of FETs 76A to 76C. When viewed from above, the encoder 78 is disposed between the leftmost first FET 76A and the resistor 75 among the plurality of FETs 76A to 76C, thereby achieving the following effect.

[0167] Multiple electronic components are mounted on the side of the end cap 5 of the circuit board 7. Therefore, the space for each electronic component is limited. However, the resistor 75, the encoder 78 and multiple FETs 76A to 76C can be appropriately arranged in the limited space of the circuit board 7.

[0168] [Second Implementation]

[0169] In the first embodiment described above, the example of a bottomed cylindrical shell with a bottom 42 on the other side of the housing 4 was given, but it is not limited to this. For example, it may also be as follows: Figure 11 As shown, the shell 204 is a cylindrical shell. Figure 11 In this document, structures identical to those in the first embodiment described above are marked with the same symbols, and their detailed descriptions are omitted.

[0170] like Figure 11 As shown, the rotary motor 201 includes a cylindrical housing 204, a front cover 215 mounted on the open end 245 on the other side of the cylindrical housing 204, and a resin sheet 10 disposed between the front cover 215 and the stator 2.

[0171] The axial length of the cylindrical shell 204 is greater than that of the bottomed cylindrical shell 4 in the first embodiment described above (see reference). Figure 1 The axial length of () is large. For example, Figure 12 As shown, the cylindrical shell 204 has a second stepped portion 246 on the opposite side of the axial direction. The second stepped portion 246 has: an annular surface 246a that is circular when viewed from the axial direction (hereinafter also referred to as "second shell side annular surface 246a"); and a circumferential surface 246b (hereinafter also referred to as "second shell side circumferential surface 246b") extending from the outer periphery of the second shell side annular surface 246a to the opposite side of the axial direction. The axial length of the second shell side circumferential surface 246b is greater than the radial length of the second shell side annular surface 246a.

[0172] For example, a portion of the other side of the front cover 215 is mounted to a mounting member 101 made of a sheet metal such as aluminum. The other side of the front cover 215 becomes a mounting surface for mounting to the mounting member 101.

[0173] The front cover 215 is mounted on the open end 245 on the opposite side of the cylindrical housing 204 in the axial direction. For example, the front cover 215 is made of a metal such as aluminum. The portion of the front cover 215 on one side in the axial direction has: an annular surface 215a that is circular when viewed from the axial direction (hereinafter also referred to as "front cover side annular surface 215a"); and a circumferential surface 215b extending from the outer periphery of the front cover side annular surface 215a to the opposite side in the axial direction (hereinafter also referred to as "front cover side circumferential surface 215b").

[0174] The radial length of the annular surface 215a on the front cover side is greater than the radial length of the annular surface 246a on the second housing side.

[0175] The axial length of the front cover side circumferential surface 215b is smaller than the axial length of the second housing side circumferential surface 246b.

[0176] The axial length of the front cover side circumferential surface 215b is smaller than the radial length of the front cover side annular surface 215a.

[0177] The front cover 215 is fitted onto the opening end 245 of the cylindrical housing 204 on the other side by engaging with the second stepped portion 246 of the cylindrical housing 204 on one axial side of its outer peripheral portion. The front cover side peripheral surface 215b abuts against the second housing side peripheral surface 246b. The front cover side annular surface 215a is axially separated from the second housing side annular surface 246a.

[0178] The resin sheet 10 is disposed between the front cover 215 and the stator 2. The resin sheet 10 is also disposed between the front cover 215 and the second insulator 22. In the second embodiment, to suppress misalignment of the resin sheet 10, an annular protrusion 217 is provided at the bottom 216 of the front cover 215, abutting against the inner periphery of the insertion hole of the resin sheet 10. The axial height of the annular protrusion 217 is slightly larger than the thickness of the resin sheet 10. For example, the inner diameter of the insertion hole of the resin sheet 10 is designed to match the outer diameter of the annular protrusion 217.

[0179] It should be noted that the structure used to suppress the misalignment of the resin sheet 10 is not limited to the case where the annular protrusion 217 is provided. For example, the outer diameter of the resin sheet 10 can be made to match the inner diameter of the cylindrical shell 204 instead of providing the annular protrusion 217.

[0180] In the second embodiment, the second insulator 22 determines its axial position by abutting against the annular protrusion 217. Thus, the resin sheet 10 separates from the second insulator 22 axially. However, this is not a limitation; the resin sheet 10 may also abut against the second insulator 22.

[0181] In the second embodiment, the housing 204 is a cylindrical housing, and has a front cover 215 installed at the open end 245 on the other side of the cylindrical housing 204 and a resin sheet 10 disposed between the front cover 215 and the stator 2, thereby achieving the following effects.

[0182] By placing a resin sheet 10 with a higher thermal conductivity than the resin between the front cover 215 and the stator 2, heat conduction (heat dissipation) from the coil 23 to the mounting member 101 can be promoted when the front cover 215 is mounted on the mounting member 101, thus suppressing the temperature rise of the rotary motor 201 (coil 23). In addition, the resin sheet 10 ensures the insulation between the front cover 215 and the stator 2 disposed in the housing 204.

[0183] <Variation Example>

[0184] It should be noted that the technical scope of the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the spirit of the present invention.

[0185] For example, in the first embodiment described above, an example was given in which the encoder 78 is arranged between the leftmost first FET 76A and the resistor 75 among the plurality of FETs 76A to 76C when viewed from above, but it is not limited to this.

[0186] For example, it can also be like Figure 13 As shown, in a top view of the circuit board 7A, resistor 75 is disposed between the leftmost first FET 76A and encoder 78 among the plurality of FETs 76A to 76C. That is, resistor 75 is disposed circumferentially between the first FET 76A and encoder 78. In this modified example, in a top view, resistor 75 is disposed on the side opposite to the third FET 76C, separated by shaft hole 71. In this modified example, in a top view, encoder 78 is disposed on the side opposite to the second FET 76B, separated by shaft hole 71.

[0187] In this modified example, when viewed from above, resistor 75 is positioned between the leftmost first FET 76A and encoder 78 among the plurality of FETs 76A to 76C, thereby achieving the following effect.

[0188] Multiple electronic components are mounted on the side of the end cap 5 of the circuit board 7A. Therefore, the space for each electronic component is limited. However, the resistor 75, the encoder 78 and multiple FETs 76A to 76C can be appropriately arranged in the limited space of the circuit board 7A.

[0189] In the first embodiment described above, an example was given in which the resistor 75 was disposed on the side opposite to the second FET 76B through the shaft hole 71 when viewed from above, but it is not limited to this.

[0190] For example, it can also be like Figure 14 As shown, in a top view of the circuit board 7B, the resistor 75 is disposed on the side opposite to the first FET 76A, separated by the shaft hole 71. In this modified example, in a top view, the encoder 78 is disposed on the side opposite to the second FET 76B, separated by the shaft hole 71.

[0191] exist Figure 13 The example given is one in which, when viewed from above, the resistor 75 is positioned on the opposite side of the third FET 76C via the axial hole 71, but this is not the only example.

[0192] For example, it can also be like Figure 15 As shown, in a top view of the circuit board 7C, the resistor 75 is disposed on the side opposite to the second FET 76B, separated by the axial hole 71. In this modified example, in a top view, the encoder 78 is disposed near the third FET 76C.

[0193] In the above embodiment, an example of the temperature sensor 6 abutting against the bend 24a of the winding 24 has been given, but the embodiment is not limited to this. For example, the temperature sensor 6 may also be separated from the bend 24a of the winding 24. For example, the temperature sensor 6 may be disposed near the bend 24a of the winding 24 via resin 90. Thus, the temperature of the bend 24a of the winding 24 can be detected via resin 90.

[0194] In the above embodiment, an example was described where a circuit board 7 for controlling the drive of the rotary motor 1 (201) was provided. The circuit board 7 was positioned inside the outer axial end of the housing 4 (204) and between the stator 2 and the end cover 5. However, this is not a limitation. For example, the circuit board 7 may also be positioned outside the outer axial end of the housing 4 (204).

[0195] In the above embodiment, an example was described where the first insulator 21 has a substrate-side abutment portion 82 that abuts against the stator 2 side of the circuit board 7, but the embodiment is not limited to this. For example, the first insulator 21 may not have a substrate-side abutment portion 82. For example, the circuit board 7 may be supported by a support portion different from the substrate-side abutment portion 82.

[0196] In the above embodiment, an example was given where the circuit board 7 has a plurality of engaging portions 72A to 72C arranged circumferentially spaced apart, and the first insulator 21 has engaging portions 84A to 84C that engage with the circuit board 7 via the plurality of engaging portions 72A to 72C. However, this is not a limitation. For example, the first insulator 21 may not have engaging portions 84A to 84C. For example, the circuit board 7 may engage with engaging portions different from those of engaging portions 84A to 84C.

[0197] In the above embodiment, an example has been described where the gaps between the housing 4 (204) and the insulators 21, 22, and between each of the plurality of protrusions 20b in the stator core 20, are filled with resin 90, and the housing 4 (204), stator 2, and temperature sensor 6 are integrated; however, this is not a limitation. For example, the gaps between the housing 4 and the insulators 21, 22, and between each of the plurality of protrusions 20b in the stator core 20 may not be filled with resin 90. For example, the housing 4 (204), stator 2, and temperature sensor 6 may be integrated using a bonding member different from resin 90.

[0198] In the above embodiment, an example of providing a resin sheet 10 on the other side of the axial direction of the stator 2 has been given, but it is not limited to this. For example, the resin sheet 10 may not be provided on the other side of the axial direction of the stator 2. For example, an insulating sheet such as insulating paper may be provided instead of the resin sheet 10. For example, the structure for insulating the coil 23 can be changed according to the required specifications.

[0199] In the above embodiment, an example has been described where the circuit board 7 has a resistor 75 for detecting the current supplied to the coil 23, and the resistor 75 is disposed on the side of the end cap 5 of the circuit board 7, but this is not a limitation. For example, the resistor 75 may also be disposed on the side of the stator 2 of the circuit board 7. For example, a substrate different from the circuit board 7 (e.g., a heat insulation plate) may be placed between the coil 23, which serves as a heat source, and the resistor 75.

[0200] In the above embodiments, an example has been described where the rotary motor 1 (201) includes a first insulating sheet 8 disposed between the circuit board 7 and the stator 2 to insulate the circuit board 7 and the coil 23, and a second insulating sheet 9 disposed between the circuit board 7 and the end cap 5 to insulate the circuit board 7 and the end cap 5. However, this is not a limitation. For example, the rotary motor 1 (201) can have a structure that achieves the same effect by replacing the first insulating sheet 8 and the second insulating sheet 9. For example, the rotary motor 1 (201) can have a resin sheet by replacing the first insulating sheet 8 and the second insulating sheet 9, respectively. For example, the structure for insulating the circuit board 7 and the coil 23, and the structure for insulating the circuit board 7 and the end cap 5, can be changed according to required specifications.

[0201] In the above embodiments, examples were given where the LOI values ​​of the first insulating sheet 8 and the second insulating sheet 9 at 220°C were higher than 20.8%, but this is not a limitation. For example, the LOI values ​​of the first insulating sheet 8 and the second insulating sheet 9 at 220°C could also be less than 20.8%.

[0202] In the above embodiment, an example was described where the first insulator 21 has a sheet-side abutment portion 81 that abuts against the stator 2 side surface of the first insulating sheet 8, but the embodiment is not limited to this. For example, the first insulator 21 may not have a sheet-side abutment portion 81. For example, the first insulating sheet 8 may be supported by a support portion different from the sheet-side abutment portion 81.

[0203] In the above embodiment, an example was given in which the second insulating sheet 9 is sandwiched between an opening on one side of the housing 4 (204) and the front end of the cylindrical portion 50 of the end cap 5, but it is not limited to this. For example, the second insulating sheet 9 may be supported by a support portion that is different from the opening on one side of the housing 4 (204) and the front end of the cylindrical portion 50 of the end cap 5.

[0204] In the above embodiments, examples were given where the first insulating sheet 8 and the second insulating sheet 9 are each formed of aramid fiber and have a thickness of 0.25 mm or more, but the embodiments are not limited thereto. For example, the raw materials and thicknesses of the first insulating sheet 8 and the second insulating sheet 9 can be changed according to required specifications.

[0205] In the above embodiment, an example of having only one temperature sensor 6 was given, but it is not limited to this. For example, multiple temperature sensors 6 can be provided. For example, the number of temperature sensors 6 can be changed according to required specifications.

[0206] In the above embodiment, an example was described where the circuit board 7 includes one resistor 75, three FETs 76A to 76C, and three magnetic sensors 77A to 77C, but the embodiment is not limited to this. For example, multiple resistors 75 may be provided. For example, the number of FETs 76A to 76C may be more than three. For example, the number of magnetic sensors 77A to 77C may be more than three. For example, the number of resistors 75, FETs 76A to 76C, magnetic sensors 77A to 77C, and encoders 78 may be changed according to required specifications.

[0207] Furthermore, without departing from the spirit of the invention, the constituent elements in the above embodiments can be replaced with well-known constituent elements. Additionally, the various modifications described above can be combined.

[0208] Symbol explanation:

[0209] 1 Rotary electric motor

[0210] 2. Stator

[0211] 3 rotors

[0212] 4. Bottomed cylindrical shell (shell)

[0213] 5. End caps

[0214] 7, 7A, 7B, 7C circuit boards

[0215] 8 First insulating sheet

[0216] 9 Second insulating sheet

[0217] 20 stator core

[0218] 20b Protrusion

[0219] 21 First Insulator (Insulator)

[0220] 23 coils

[0221] 24 windings

[0222] 77A First Magnetic Sensor (Magnetic Sensor)

[0223] 77B Second Magnetic Sensor (Magnetic Sensor)

[0224] 77C Third Magnetic Sensor (Magnetic Sensor)

[0225] 81 side contact parts (contact parts)

[0226] 90 resin

[0227] 91 Space (internal space of the stator)

[0228] 201 Rotary Electric Machine

[0229] 204 Cylindrical shell (shell)

Claims

1. A rotary electric motor, characterized in that, The rotary motor includes: cylindrical stator; The rotor is disposed within the internal space of the stator; A cylindrical or bottomed cylindrical shell that houses the stator; An end cap, which is mounted on an open end on one side of the housing; and The circuit board controls the drive of the rotating motor. The stator comprises: The stator core has a plurality of protrusions projecting toward the center of the stator; An insulator, which is assembled into the stator core; as well as A coil, which is formed by winding a portion of the protrusions through the insulator. The end cap has an axially extending cylindrical portion and a cap portion connected to the front end of the cylindrical portion on one side of the axial direction. The circuit board is positioned inside the axial outer end of the housing, and is located between the front end of the stator and the cylindrical portion of the end cover on the other side. The insulator has: Annular portion; An engaging portion extending axially from the outer periphery of the annular portion; and The substrate-side abutment portion abuts against the stator-side surface of the circuit substrate. The circuit board abuts against and engages with the insulator via the board-side abutment portion and the engaging portion. The rotary motor also includes a second insulating sheet disposed between the front end of the circuit board and the cylindrical portion of the end cap on the other side, to insulate the circuit board from the end cap.

2. The rotary motor according to claim 1, characterized in that, The rotary motor also includes a first insulating sheet disposed between the stator and the circuit board to insulate the circuit board from the coil.

3. The rotary motor according to claim 2, characterized in that, The LOI values ​​of the first insulating sheet and the second insulating sheet are higher than 20.8% at 220°C.

4. The rotary electric motor according to any one of claims 1 to 3, characterized in that, The gaps between the housing and the insulator, and between the plurality of protrusions in the stator core, are filled with resin, and the housing and the stator are integrated.

5. The rotary motor according to claim 2, characterized in that, The insulator has a sheet-side contact portion that abuts against the stator-side surface of the first insulating sheet.

6. The rotary electric motor according to claim 1, characterized in that, The second insulating sheet is held between an opening on one side of the housing and the front end of the cylindrical portion of the end cap on the other side.

7. The rotary motor according to claim 2, characterized in that, The first insulating sheet and the second insulating sheet are respectively formed of aramid fibers and have a thickness of 0.25 mm or more.

8. The rotary electric motor according to any one of claims 1 to 3, characterized in that, The circuit board is equipped with a magnetic sensor. The magnetic sensor is disposed on the stator side of the circuit board.

9. The rotary motor according to claim 1, characterized in that, The housing has a stepped portion on one side of the housing cylinder in the axial direction. The stepped portion has a shell-side annular surface that is circular when viewed from the axial direction and a shell-side peripheral surface that extends from the outer periphery of the shell-side annular surface in the axial direction. The circuit board is positioned axially inward from the annular surface of the housing and is located between the front end of the stator and the cylindrical portion of the end cap on the other side.

10. The rotary electric motor according to any one of claims 1 to 3, characterized in that, The opening on one side of the housing has a stepped portion on one side of the housing cylinder in the axial direction. The stepped portion has a shell-side annular surface that is circular when viewed from the axial direction. The circuit board is positioned axially inward from the annular surface of the housing. The second insulating sheet is sandwiched between the annular surface of the housing side and the front end of the cylindrical portion of the end cap on the other side.

11. A rotary electric motor, characterized in that, The rotary motor includes: cylindrical stator; The rotor is disposed within the internal space of the stator; A cylindrical or bottomed cylindrical shell that houses the stator; An end cap, which is mounted on an open end on one side of the housing; and The circuit board controls the drive of the rotating motor. The stator comprises: The stator core has a plurality of protrusions projecting toward the center of the stator; An insulator, which is assembled into the stator core; as well as A coil, which is formed by winding a portion of the protrusions through the insulator. The end cap has an axially extending cylindrical portion and a cap portion connected to the front end of the cylindrical portion on one side of the axial direction. The housing has a stepped portion on one side of the housing cylinder in the axial direction. The stepped portion has a shell-side annular surface that is circular when viewed from the axial direction and a shell-side peripheral surface that extends from the outer periphery of the shell-side annular surface in the axial direction. The circuit board is positioned axially inward from the annular surface of the housing, and is located between the front end portion of the stator and the cylindrical portion of the end cap on the other side. The rotary motor also includes a second insulating sheet disposed between the front end of the circuit board and the cylindrical portion of the end cap on the other side, to insulate the circuit board from the end cap.

12. The rotary electric motor according to claim 11, characterized in that, The end cap has a protrusion that rises from one side of the cylindrical portion along the axial direction to the other side. The protrusion has a cover-side annular surface that is circular when viewed from the axial direction and a cover-side peripheral surface that extends from the outer periphery of the cover-side annular surface toward one side in the axial direction.

13. A rotary electric motor, characterized in that, The rotary motor includes: cylindrical stator; The rotor is disposed within the internal space of the stator; A cylindrical or bottomed cylindrical shell that houses the stator; An end cap, which is mounted on an open end on one side of the housing; and The circuit board controls the drive of the rotating motor. The stator comprises: The stator core has a plurality of protrusions projecting toward the center of the stator; An insulator, which is assembled into the stator core; as well as A coil, which is formed by winding a portion of the protrusions through the insulator. The end cap has an axially extending cylindrical portion and a cap portion connected to the front end of the cylindrical portion on one side of the axial direction. The circuit board is positioned inside the axial outer end of the housing, and is located between the front end of the stator and the cylindrical portion of the end cover on the other side. The insulator has: Annular portion; An engaging portion extending axially from the outer periphery of the annular portion; and The substrate-side abutment portion abuts against the stator-side surface of the circuit substrate. The engaging portion extends axially from the annular portion and then bends radially outward. The rotary motor also includes a second insulating sheet disposed between the front end of the circuit board and the cylindrical portion of the end cap on the other side, to insulate the circuit board from the end cap.

14. The rotary electric motor according to claim 13, characterized in that, The circuit board has a board-side engaging portion that engages with the engaging portion.

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