Electric motor and its manufacturing method

Abstract

This invention provides an electric motor and its manufacturing method, which improves assemblability by preventing short circuits or broken wires in the conductive wires. The bottom of the cut is arranged circumferentially with the terminal housing, and the winding direction of the pair of coil ends inside the terminal housing is oriented in a direction intersecting the insertion direction of the flat male terminal. Therefore, when inserting the flat male terminal into the terminal housing, excessive force can be suppressed on the pair of coil ends, thereby preventing broken wires and other defects. Furthermore, the pair of coil ends can be neatly wound onto the insulator via the bottom of the cut, thus preventing short circuits with other phase coils.

Description

TECHNICAL FIELD

[0001] The present application relates to an electric motor including a stator in which a plurality of electrically conductive wires are wound, a rotor that rotates relative to the stator, and a holding member that holds the stator, and a manufacturing method thereof. BACKGROUND

[0002] In Patent Literature 1, there is described an electric motor (brushless motor) in which end portions of a plurality of coils (electrically conductive wires) wound on a stator core (stator) are respectively electrically connected to a plurality of terminals (connection terminals) by welding. Further, the terminals to which the coils are electrically connected are respectively electrically connected to a control substrate by welding.

[0003] In addition, in Patent Literature 2, there is described a terminal member for wire connection in which, by pressing a terminal member (connection terminal) having a slit against a housing in which an end portion of a winding (electrically conductive wire) is disposed, the end portion of the winding is caused to enter the slit, whereby the winding and the terminal member can be electrically connected. If the terminal member for wire connection described in Patent Literature 2 is used, an electrical connection work based on welding is not required.

[0004] [Patent Literature]

[0005] [Patent Literature]

[0006] [Patent Literature 1] Japanese Patent Application Laid-Open No. 2017-073860

[0007] [Patent Literature 2] Japanese Patent Application Laid-Open No. 2000-266083 SUMMARY

[0008] [Problems to be Solved by the Invention]

[0009] In order to improve the assembly of the brushless motor, it is desirable to concentrate the three connection terminals that supply driving currents to the electrically conductive wires of the U phase, the V phase, and the W phase, respectively, on one side in the radial direction of the housing that forms the brushless motor. In addition, it is desirable to electrically connect the connection terminals and the electrically conductive wires without using welding. In order to meet such a requirement, it is necessary to arrange the electrically conductive wires drawn out from the stator along the circumferential direction of the housing at a prescribed portion (a portion where the connection terminals are concentrated), and to press the connection terminals at the portion to electrically connect the connection terminals and the electrically conductive wires corresponding thereto.

[0010] However, if the electrically conductive wires drawn out from the stator are arranged by being drawn only at the prescribed portion, and the connection terminals are pressed at the portion to electrically connect the connection terminals and the electrically conductive wires corresponding thereto, there can occur, for example, an undesirable situation in which the electrically conductive wire of the V phase and the connection terminal corresponding to the U phase are short-circuited, or an excessive force is applied to the electrically conductive wire when the connection terminal is pressed, and the electrically conductive wire is broken.

[0011] The object of the present application is to provide an electric motor and a manufacturing method thereof, which can improve assembly without causing a short circuit or a disconnection of the electrically conductive wire, and the like.

[0012] [Technical means for solving the problem]

[0013] In the electric motor of the present application, including a stator in which a plurality of electrically conductive wires are wound, a rotor that rotates with respect to the stator, and a holding member that holds the stator, the electric motor is characterized by having a terminal housing box provided at a radially outer side of the holding member, through which the electrically conductive wires are inserted, a connection terminal that is inserted into the terminal housing box from a direction crossing the electrically conductive wires to electrically connect the plurality of electrically conductive wires to each other, and a first electrically conductive wire restriction portion that is arranged in the circumferential direction of the holding member with the terminal housing box, and that causes the lead direction of the electrically conductive wire inside the terminal housing box to be directed in a direction crossing the insertion direction of the connection terminal.

[0014] In the manufacturing method of the electric motor of the present application, the electric motor including a stator in which a plurality of electrically conductive wires are wound, a rotor that rotates with respect to the stator, and a holding member that holds the stator, the manufacturing method of the electric motor is characterized by having a first step of leading the electrically conductive wires in the circumferential direction of the holding member on one axial side of the holding member, a second step of leading the electrically conductive wires to the other axial side of the holding member and hooking the electrically conductive wires on a first electrically conductive wire restriction portion arranged on the other axial side of the holding member, a third step of inserting the electrically conductive wires hooked on the first electrically conductive wire restriction portion into a terminal housing box arranged in the circumferential direction of the holding member with the first electrically conductive wire restriction portion, and causing the lead direction of the electrically conductive wire inside the terminal housing box to be directed in a direction crossing the insertion direction of a connection terminal inserted into the terminal housing box, and a fourth step of inserting the connection terminal into the terminal housing box from a direction crossing the electrically conductive wires to electrically connect the plurality of electrically conductive wires to each other.

[0015] [Effects of the invention]

[0016] According to the present application, the first electrically conductive wire restriction portion is arranged in the circumferential direction of the holding member with the terminal housing box, and causes the lead direction of the electrically conductive wire inside the terminal housing box to be directed in a direction crossing the insertion direction of the connection terminal. Thereby, when the connection terminal is inserted into the terminal housing box, an excessive force applied to the electrically conductive wire can be suppressed, and further, the occurrence of a disconnection of the electrically conductive wire, and the like can be prevented. In addition, the electrically conductive wires can be led on the holding member in order via the first electrically conductive wire restriction portion, and further, a short circuit with the electrically conductive wires of the other phase, and the like can be prevented. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1is a perspective view showing the output rotating body side of the electric motor.

[0018] Figure 2 is a plan view showing the output rotating body side of the electric motor.

[0019] Figure 3 is a sectional view along Figure 2 the A-A line of

[0020] Figure 4 is an exploded perspective view showing the cover side of the electric motor.

[0021] Figure 5 is an exploded perspective view showing the structure inside the cover.

[0022] Figure 6 is a perspective view showing the stator core from the flat male terminal side.

[0023] Figure 7 is a sectional view along the extending direction of the coil end of the terminal housing box.

[0024] Figure 8 (a) of is a sectional view along Figure 7 the B-B line of Figure 8 (b) of is a sectional view along Figure 7 the C-C line of

[0025] Figure 9 (a) of and (b) of are perspective views showing the detailed structure of the flat male terminal. Figure 9

[0026] is a perspective view showing the detailed structure of the terminal housing box. Figure 10

[0027] is an enlarged perspective view of a part of the terminal housing box for the W phase and the U phase. Figure 11

[0028] is an enlarged perspective view of a part of the terminal housing box for the V phase. Figure 12

[0029] is an explanatory view showing the first step and the early stage of the second step (with the fifth step) of the terminal housing box for the U phase. Figure 13

[0030] is an explanatory view showing the late stage of the second step of the terminal housing box for the U phase. Figure 14

[0031] is an explanatory view showing the third step and the fourth step of the terminal housing box for the U phase. Figure 15

[0032] Figure 16 ​is an explanatory view of a first step and a second step of a terminal housing case for the V-phase.

[0033] Figure 17 is an explanatory view of a latter stage of the second step of the terminal housing case for the V-phase.

[0034] Figure 18 is an explanatory view of a third step and a fourth step of the terminal housing case for the V-phase.

[0035] [Explanation of symbols]

[0036] 10: motor

[0037] 20: housing

[0038] 21: large-diameter cylindrical portion

[0039] 22: small-diameter cylindrical portion

[0040] 23: partition wall

[0041] 23a: through hole

[0042] 30: cover

[0043] 31: bottom wall portion

[0044] 32: side wall portion

[0045] 33: grommet

[0046] 34: fixing plate

[0047] 35a to 35c: terminal holder

[0048] 36a, 36b: engagement protrusions

[0049] 40: flat motor

[0050] 41: stator core (stator)

[0051] 42: rotor

[0052] 42a: main body portion

[0053] 42b: permanent magnet

[0054] 43: insulator (holding member)

[0055] 44: coil (electrically conductive wire)

[0056] 44a: coil end (front end side portion)

[0057] 44b: coil base (base end side portion)

[0058] 45: rotor shaft

[0059] 45a: shaft body

[0060] 45b: first shaft portion

[0061] 45c: second shaft portion

[0062] 45d: small diameter portion

[0063] 50: sensor substrate

[0064] 60: internal cycloid reducer

[0065] 61: external gear

[0066] 61a: tooth portion

[0067] 62: internal gear

[0068] 62a: first tooth portion

[0069] 62b: second tooth portion

[0070] 63: output rotary body

[0071] 63a: tooth portion

[0072] 64: cover member

[0073] 70u: U-phase power supply line

[0074] 70v: V-phase power supply line

[0075] 70w: W-phase power supply line

[0076] 80: sensor cable

[0077] 90: anti-drop plate

[0078] 93: rectangular-shaped cutout portion

[0079] 96: threaded hole

[0080] 97: support protrusion

[0081] 100: terminal housing box

[0082] 100a to 100c: terminal housing box (W-phase to V-phase)

[0083] 101: housing chamber

[0084] 102: housing box end face

[0085] 103: housing chamber bottom face

[0086] 104: housing chamber side wall

[0087] 105: insertion restriction recess

[0088] 106: first inclined wall portion

[0089] 107: support protrusion

[0090] 108: positioning groove

[0091] 108a: groove bottom (mounting portion)

[0092] 109: facing wall portion

[0093] 110: second inclined wall portion

[0094] 150a to 150c: first column portion (for W-phase to V-phase)

[0095] 151a to 151c: cutout portion (for W-phase to V-phase)

[0096] 152a to 152c: cutout bottom (first wire restricting portion, for W-phase to V-phase)

[0097] 153a to 153c: second column portion (for W-phase to V-phase)

[0098] 154a to 154c: protrusion (second wire restricting portion, for W-phase to V-phase)

[0099] 200: flat male terminal (connection terminal)

[0100] 201: terminal connecting portion

[0101] 202: terminal main body portion

[0102] 202a: terminal front end portion

[0103] 202b: terminal base end portion

[0104] 203: wide portion

[0105] 204: slit

[0106] 204a: coil inlet portion

[0107] 204b: slit bottom

[0108] 205: guide opening portion

[0109] 206: anti-disengagement protrusion

[0110] B1: first ball bearing

[0111] B2: second ball bearing

[0112] B3: third ball bearing

[0113] B4: fourth ball bearing

[0114] C1: First Cover Section

[0115] C2: Second Cover

[0116] CN1: First connector connecting part

[0117] CN2: Second connector connection part

[0118] G1: First retaining groove

[0119] G2: Second retaining groove

[0120] HS: Hall sensor

[0121] M1~M3: Flat female terminals (for W phase to V phase)

[0122] MS: Motor Containment Chamber

[0123] RS: Gearbox housing

[0124] S1: End face

[0125] SP: Containment Space

[0126] T1~T3: Flat male terminals (connecting terminals, for W phase to V phase)

[0127] TH: teeth Detailed Implementation

[0128] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0129] Figure 1 It is a three-dimensional view showing the output rotating body side of the electric motor; Figure 2 It is a plan view showing the output rotating body side of the electric motor; Figure 3 It is along Figure 2 A cross-sectional view of line AA; Figure 4 This is an exploded perspective view showing the casing of the electric motor; Figure 5 It is an exploded 3D diagram illustrating the structure inside the enclosure; Figure 6 This is a three-dimensional view of the stator core as seen from the side of the flat male terminal; Figure 7 It is a cross-sectional view along the extension direction of the coil end of the terminal housing; Figure 8 (a) is along Figure 7 A cross-sectional view of the BB line. Figure 8 (b) is along Figure 7 A cross-sectional view of the CC line; Figure 9 of (a), Figure 9 (b) is a perspective view illustrating the detailed structure of the flat male terminal; Figure 10 This is a perspective view illustrating the detailed structure of the terminal housing box; Figure 11is a perspective view of a portion of the terminal housing case for the W phase enlarged; Figure 12 is a perspective view of a portion of the terminal housing case for the V phase enlarged.

[0130] Further, Figure 13 is an explanatory view of the first step and the early stage of the second step (with the fifth step) of the terminal housing case for the U phase; Figure 14 is an explanatory view of the late stage of the second step of the terminal housing case for the U phase; Figure 15 is an explanatory view of the third step and the fourth step of the terminal housing case for the U phase; Figure 16 is an explanatory view of the first step and the early stage of the second step (without the fifth step) of the terminal housing case for the V phase; Figure 17 is an explanatory view of the late stage of the second step of the terminal housing case for the V phase; Figure 18 is an explanatory view of the third step and the fourth step of the terminal housing case for the V phase.

[0131] Figure 1 The motor 10 illustrated in the drawing drives wheels (not illustrated) of an electrically driven vehicle that carries harvested crops and the like, and is a motor device with a relatively high output. The motor 10 is rotated in a forward direction or a reverse direction at a predetermined rotational speed by supplying a driving current from a battery or the like in accordance with an operation of an operation switch or the like (not illustrated).

[0132] As illustrated in the drawing, Figures 1 to 3 the motor 10 is formed in a substantially disc-like flat shape, and thus can be made small and light. The motor 10 includes a housing 20 and a cover 30 that form the outer shape thereof, and the housing 20 and the cover 30 are fixed by five total fixing screws SC1 in a state of being butted against each other.

[0133] As illustrated in the drawing, Figure 3 a motor housing chamber MS is formed inside the housing 20 and the cover 30, and a flat motor 40 as a brushless motor is housed inside the motor housing chamber MS. Further, a sensor substrate 50 that is provided with three Hall sensors (magnetic sensors) HS that detect the rotational state of the flat motor 40 (rotor 42) is housed inside the motor housing chamber MS (refer to Figure 5 ).

[0134] As illustrated in the drawing, Figure 3 the housing 20 is formed in a substantially bowl shape with steps by casting from an aluminum material or the like, and includes a large-diameter cylindrical portion 21 and a small-diameter cylindrical portion 22. The large-diameter cylindrical portion 21 is disposed on the cover 30 side (lower side in the drawing) in the axial direction of the housing 20, and the small-diameter cylindrical portion 22 is disposed on the side opposite to the cover 30 side (upper side in the drawing) in the axial direction of the housing 20.

[0135] A partition wall 23 formed in a substantially disc shape is integrally provided between the large-diameter cylindrical portion 21 and the small-diameter cylindrical portion 22 in the axial direction of the housing 20. The partition wall 23 forms the motor housing chamber MS together with the large-diameter cylindrical portion 21. In addition, the partition wall 23 forms the speed reducer housing chamber RS together with the small-diameter cylindrical portion 22. That is, the partition wall 23 separates the motor housing chamber MS from the speed reducer housing chamber RS.

[0136] A through-hole 23a through which the rotor shaft 45 penetrates is provided in a central portion of the partition wall 23. In addition, a first ball bearing Bl rotatably supporting a shaft body 45a of the rotor shaft 45 is installed on the radially inner side of the through-hole 23a.

[0137] A flat motor 40 housed inside the motor housing chamber MS has a thickness dimension smaller than a diameter dimension, thereby having a flat shape. The flat motor 40 is a brushless motor of an inner rotor type, including: a ring-shaped stator core (stator) 41 formed by laminating a plurality of steel sheets; and a rotor 42 rotatably provided on the radially inner side of the stator core 41 with a prescribed air gap therebetween. The stator core 41 is fixed to the partition wall 23 by three fixing screws SC2 (refer to FIG. 2) in total, whereby the rotor 42 rotates with respect to the stator core 41. Figure 4 ) The rotor shaft 45 is rotatably supported by the first ball bearing Bl and the second ball bearing B2.

[0138] An insulator 43 including an insulating material such as plastic is installed on the stator core 41. The insulator 43 corresponds to the holding member in the present application, and holds the stator core 41. The insulator 43 is formed in a substantially ring shape in accordance with the shape of the stator core 41, and covers substantially the entire stator core 41 including a plurality of teeth TH (refer to FIG. 2). Moreover, a plurality of coils (electrically conductive wires) 44 are respectively wound in a concentrated manner in portions of the insulator 43 corresponding to the teeth TH. That is, the coils 44 are wound on the respective teeth TH of the stator core 41 with the insulator 43 interposed therebetween. Figure 6

[0139] The rotor 42 includes a main body portion 42a formed in a substantially bowl shape by press processing or the like of a steel sheet. A permanent magnet 42b formed in a cylindrical shape is fixed to the radially outer side of the main body portion 42a. The permanent magnet 42b is magnetized such that N poles and S poles appear alternately in the circumferential direction of the rotor 42. In addition, a shaft body 45a of a rotor shaft 45 is fixed to the radially inner side of the rotation center of the main body portion 42a, and the rotor shaft 45 rotates in conjunction with the rotation of the rotor 42.

[0140] ​The rotor shaft 45 includes a shaft body 45a, a first shaft portion 45b, a second shaft portion 45c, and a small-diameter portion 45d. The shaft center of the first shaft portion 45b is disposed at a position that is offset (eccentric) from the shaft center of the shaft body 45a by a prescribed amount. In contrast, the shaft centers of the second shaft portion 45c and the small-diameter portion 45d coincide with the shaft center of the shaft body 45a. The shaft body 45 is rotatably supported to the housing 20 via a first ball bearing B1, and the rotor 42 is rotatably supported to the housing 20 via the rotor shaft 45.

[0141] An internal cycloid reduction mechanism 60 as a reduction mechanism is housed inside the reduction mechanism housing chamber RS. The internal cycloid reduction mechanism 60 reduces the rotation of the flat motor 40 (rotor shaft 45) and outputs to the outside, and has an external gear 61 and an internal gear 62.

[0142] The external gear 61 is formed in a ring shape, and is disposed at a position close to the flat motor 40 in the axial direction of the small-diameter cylinder portion 22. Also, the radially outer side of the external gear 61 is fixed to the radially inner side of the small-diameter cylinder portion 22, and a tooth portion 61a including a spur gear is formed on the radially inner side of the external gear 61.

[0143] The internal gear 62 is disposed on the radially inner side of the external gear 61, and has an outer diameter dimension that is smaller than the inner diameter dimension of the external gear 61. A first tooth portion 62a including a spur gear is formed on the radially outer side of the internal gear 62, and the first tooth portion 62a of the internal gear 62 engages with the tooth portion 61a of the external gear 61. That is, the internal gear 62 rolls without slipping on the inner side of the external gear 61.

[0144] The rotational center of the internal gear 62 is rotatably supported to the first shaft portion 45b of the rotor shaft 45 via a pair of second ball bearings B2. Thus, when the first shaft portion 45b rotates on the radially inner side of the external gear 61, the internal gear 62 rotatably supported to the pair of second ball bearings B2 rotates at a lower speed than the rotor shaft 45 on the radially inner side of the external gear 61.

[0145] In addition, a second tooth portion 62b including a flat gear is formed on the radially inner side of the first tooth portion 62a of the internal gear 62. Also, the second tooth portion 62b engages with a tooth portion 63a including a spur gear of an output rotating body 63. Specifically, the tooth portion 63a of the output rotating body 63 is disposed on the radially inner side of the second tooth portion 62b of the internal gear 62, and has an outer diameter dimension that is smaller than the inner diameter dimension of the second tooth portion 62b of the internal gear 62. Thus, the output rotating body 63 rolls without slipping on the radially inner side of the second tooth portion 62b of the internal gear 62, and rotates at a lower speed than the internal gear 62.

[0146] Here, the radially inner side of the output rotating body 63 is rotatably supported on a third ball bearing B3 provided on the second shaft portion 45c, and the radially outer side is rotatably supported on a fourth ball bearing B4 provided on the cover member 64. This allows the output rotating body 63, subjected to particularly large loads, to rotate smoothly over a long period. Furthermore, the wheels of the electric transport vehicle (not shown) are fixed to the output rotating body 63. Therefore, the rotation of the flat motor 40, which is reduced in speed by the cycloidal reducer 60, is transmitted to the wheels of the electric transport vehicle under high torque conditions.

[0147] In addition, the cover member 64 encloses the gearbox housing RS of the housing 20, such as Figure 1 and Figure 2 As shown, the small-diameter cylindrical portion 22 of the housing 20 is fixed by a total of four fixing screws SC3.

[0148] In addition, such as Figure 3 As shown, the cycloidal reducer 60 has a flat shape and can achieve a relatively large reduction ratio (1 / 90). Therefore, by employing it in a flat-shaped motor 10, further flattening (thinning) of the motor 10 can be easily achieved. The "reduction ratio (1 / 90)" mentioned here means that when the rotor shaft 45 rotates 90 times at high speed, the output rotating body 63 rotates 1 revolution in a gradually increasing torque state.

[0149] like Figures 3 to 5 As shown, the cover 30 is formed into a generally bowl-shaped form by injection molding of a resin material such as plastic. The cover 30 includes a bottom wall portion 31 formed in a disc shape and a cylindrical side wall portion 32 integrally formed on the outer periphery of the bottom wall portion 31. Furthermore, on the side wall portion 32, a grommet 33 (see reference 33) functions as a sealing member. Figure 3 The cable is connected to three power supply wires (70u, 70v, 70w) and one sensor cable (80). Figure 5 This prevents rainwater or dust from entering the interior of the cover 30.

[0150] Additionally, a fixing plate 34 is provided on the outer side of the side wall portion 32 and at the portion containing the cable ring 33 to prevent the cable ring 33 from falling off (see reference). Figure 1 and Figure 3 The fixing plate 34 is fixed to the side wall portion 32 by a pair of fixing screws SC4.

[0151] Here, as Figure 5 As shown, the line segment connecting the central portion of the cover 30 and the central portion of the circumferentially oriented loop 33 of the sidewall portion 32 in the radial direction is designated as CT. Furthermore, using line segment CT as a boundary, the radial side of the cover 30 ( Figure 5 The upper side) is set as the first cover C1, and the other radial side of the cover 30 (Figure 5 The second cover portion C2 is provided on the lower side of the first cover portion C1.

[0152] As shown in Figure 5 , three terminal holders 35a, 35b, 35c are provided on the inner side of the side wall portion 32 on the first cover portion C1 side. These terminal holders 35a, 35b, 35c are each formed in a hollow box shape, and a flat male terminal Ml riveted to the base end portion of the W-phase power supply wire 70w, a flat male terminal M2 riveted to the base end portion of the U-phase power supply wire 70u, and a flat male terminal M3 riveted to the base end portion of the V-phase power supply wire 70v are respectively installed in the inner sides thereof.

[0153] Further, on the inner side of the side wall portion 32 on the first cover portion C1 side and the second cover portion C2 side, engagement protrusions 36a, 36b each formed in a rod shape are provided. These engagement protrusions 36a, 36b protrude beyond the height dimension of the side wall portion 32 of the cover 30, and have a function of guiding the installation of the cover 30 to the housing 20 (see Figure 4 ). Specifically, when the cover 30 is installed on the housing 20, these engagement protrusions 36a, 36b are first inserted into engagement recesses (not shown) of the housing 20.

[0154] Thus, the cover 30 can be positioned with good precision with respect to the housing 20, and can be installed with good certainty. Further, by merely installing the cover 30 on the housing 20, the flat male terminals Tl, T2, T3 (see Figure 4 and Figure 6 ) on the housing 20 side can be electrically connected with good precision to each of the flat female terminals Ml, M2, M3.

[0155] Here, the flat male terminal Tl connected to the flat female terminal Ml (W-phase) is electrically connected to the coil 44 corresponding to the W-phase, the flat male terminal T2 connected to the flat female terminal M2 (U-phase) is electrically connected to the coil 44 corresponding to the U-phase, and the flat male terminal T3 connected to the flat female terminal M3 (V-phase) is electrically connected to the coil 44 corresponding to the V-phase.

[0156] Thus, by supplying drive current to each of the power supply wires 70u, 70v, 70w at a prescribed timing, the coils 44 (see Figure 4 and Figure 6 ) corresponding to the U-phase, V-phase, and W-phase are respectively supplied with power, and electromagnetic force is generated in the stator core 41 (see Figure 4 and Figure 6 ). Therefore, the rotor 42 (see Figure 3 and Figure 4 ) is rotationally driven in a prescribed rotational direction at a prescribed rotational speed.

[0157] Further, as shown inFigure 5 As shown, the sensor substrate 50 and the anti-falling plate 90 are housed inside the cover. The anti-falling plate 90 prevents each of the power supply wires 70u, 70v, 70w and the sensor cable 80 installed on the inner side of the cover 30 from falling off the cover.

[0158] Three first holding grooves G1 that individually hold each of the power supply wires 70u, 70v, 70w are provided on the first cover portion Cl side of the bottom wall portion 31 of the cover 30. Thus, each of the power supply wires 70u, 70v, 70w can be easily arranged on the inner side of the cover 30 without interfering or crossing each other.

[0159] In addition, a single second holding groove G2 that holds the sensor cable 80 is provided on the second cover portion C2 side of the bottom wall portion 31 of the cover 30. Here, the sensor cable 80 is thicker than each of the power supply wires 70u, 70v, 70w. Therefore, the width dimension of the second holding groove G2 is larger than the width dimension of the first holding groove G1.

[0160] Further, a relatively large housing space SP that houses the sensor cable 80 is provided on the second cover portion C2 side of the cover 30 and in the vicinity of the second holding groove G2. Thus, the sensor cable 80 can be substantially bent with slack on the inner side of the cover 30. Therefore, the sensor cable 80 can be arranged without being forcibly bent between the sensor substrate 50 and the second holding groove G2.

[0161] Thus, the U-phase power supply wire 70u, the V-phase power supply wire 70v, and the W-phase power supply wire 70w are arranged on the first cover portion Cl on the one radial side of the line segment CT that divides the cover 30, and the sensor cable 80 is arranged on the second cover portion C2 on the other radial side. Thus, on the inner side of the cover 30, each of the power supply wires 70u, 70v, 70w and the sensor cable 80 do not contact or cross each other.

[0162] Therefore, the reliability of the motor 10 can be improved by practically suppressing short-circuiting or the like of each of the power supply wires 70u, 70v, 70w and the sensor cable 80. Further, each of the power supply wires 70u, 70v, 70w and the sensor cable 80 can be easily arranged in the cover 30, and further, the improvement of the assembly workability of the motor 10 can be achieved.

[0163] Here, the sensor substrate 50 is fixed on the inner side of the cover 30 in a manner that spans the line segment CT. Specifically, the sensor substrate 50 is fixed on the inner side of the cover 30 by a pair of fixing screws SC5 (see FIG. 6) that are screwed into the cover 30. Figure 5 In addition, the sensor substrate 50 is welded with a plurality of electronic parts including three Hall sensors, and becomes a printed circuit board (PCB) that functions as an electronic circuit.

[0164] The three Hall sensors HS provided on the sensor substrate 50 are arranged at regular intervals in the length direction of the sensor substrate 50. These Hall sensors HS detect the rotational state (rotational speed, etc.) of the rotor 42, and face the permanent magnet 42b in the axial direction of the rotor 42 (refer to Figure 3 and Figure 4 ). Thus, the three Hall sensors HS perform switching operation by the switching of the N-pole and S-pole of the permanent magnet 42b accompanying the rotation of the rotor 42, and output rectangular wave signals at regular timings, respectively.

[0165] Further, the sensor cable 80 is electrically connected to the sensor substrate 50, and the rectangular wave signals from the three Hall sensors HS flow through the sensor cable 80. Here, the connected portion of the sensor cable 80 to the sensor substrate 50 is a portion fixed by soldering, and the rigidity becomes relatively low. Thus, if a relatively large tensile force is applied to the sensor cable 80, a solder crack (conduction failure) can occur. Therefore, in the present embodiment, in order to suppress the occurrence of a solder crack, as shown in Figure 5 , the sensor cable 80 is largely bent with slack in the accommodation space SP.

[0166] Further, as shown in Figure 1 , Figure 2 , Figure 4 , Figure 5 , at the portion of each of the power supply lines 70u, 70v, 70w drawn to the outside of the cover 30, a first connector connecting portion CN1 for connecting an external connector (not shown) for power supply is provided. Further, at the portion of the sensor cable 80 drawn to the outside of the cover 30, a second connector connecting portion CN2 for connecting an external connector (not shown) for control is provided.

[0167] Thus, by separating the cable (power supply lines 70u, 70v, 70w) of the power supply system and the cable (sensor cable 80) of the control system, the adverse effects, etc. of the electric noise, etc. diffused from the cable of the power supply system on the cable of the control system are suppressed.

[0168] As shown in Figure 5 , the fall-off preventing plate 90 is formed in a substantially disc shape by a resin material such as plastic. A rectangular shape cutout portion 93 cut in a substantially rectangular shape is provided on the fall-off preventing plate 90, and the sensor substrate 50 is disposed at the portion of the rectangular shape cutout portion 93. Thus, the fall-off preventing plate 90 and the sensor substrate 50 are not overlapped in the axial direction of the cover 30, and further, the increase in the thickness dimension of the motor 10 is suppressed.

[0169] Further, at a portion of the anti-falling plate 90 on a radially outer side thereof, five screw holes 96 are provided in a manner of being arranged in a circumferential direction thereof. In these screw holes 96, respectively, a fixing screw SC6 (total of five) is inserted, whereby the anti-falling plate 90 is fixed to the inside of the cover 30 without being shaken.

[0170] In addition, at a portion of the anti-falling plate 90 on a radially outer side thereof, three support protrusions 97 are integrally provided in a manner of being arranged in a circumferential direction thereof. These support protrusions 97 are portions which, in a radial direction of the cover 30, respectively face the terminal holders 35a, 35b, 35c, and support side surfaces (not shown in detail) of the flat female terminals Ml, M2, M3.

[0171] Thus, when the flat male terminals Tl, T2, T3 (refer to Figure 4 and Figure 6 ) on the housing 20 side are connected to the flat female terminals Ml, M2, M3, inclination of the flat female terminals Ml, M2, M3 is prevented. Therefore, the flat male terminals Tl, T2, T3 can be surely electrically connected to the flat female terminals Ml, M2, M3.

[0172] As shown in Figure 6 , on a radially outer side of the insulator 43 which holds the stator core 41, three terminal housing boxes 100a, 100b, 100c are integrally provided. That is, these terminal housing boxes 100a, 100b, 100c are also formed of an insulating material such as plastic. Further, in a state where the motor 10 is assembled, these terminal housing boxes 100a, 100b, 100c face the respective terminal holders 35a, 35b, 35c (refer to Figure 5 ) provided on the cover 30 in an axial direction of the motor 10.

[0173] The three terminal housing boxes 100a, 100b, 100c become W-phase, U-phase, and V-phase in this order, respectively, and are formed in substantially the same shape as each other. Therefore, hereinafter, the terminal housing box 100a for the W-phase will be taken as a representative, and a detailed structure thereof will be described. However, for the sake of convenience in description, in (a) of Figure 7 , Figure 8 , (b) of Figure 8 , and (c) of Figure 10 , the symbol of the terminal housing box is simply written as "100".

[0174] In addition, in each of the terminal housing boxes 100a, 100b, 100c, a flat male terminal Tl for the W phase, a flat male terminal T2 for the U phase, and a flat male terminal T3 for the V phase are respectively inserted. These flat male terminals Tl, T2, T3 are also formed in substantially the same shape. Therefore, hereinafter, the flat male terminal Tl for the W phase will be taken as a representative example, and its detailed structure will be described. However, in order to facilitate the description, in Figures 7 to 9 (b), the symbol of the flat male terminal is simply written as "200".

[0175] As shown in Figure 7 and Figure 8 (a), Figure 8 (b), a pair of coil ends 44a (here, a pair of coil ends for the W phase) of the coil 44 wound around the tooth TH (see Figure 6 ) are electrically connected to each other via the flat male terminal 200 at a portion of the terminal housing box 100. Specifically, by housing (inserting) the flat male terminal 200 in the housing chamber 101 of the terminal housing box 100, the flat male terminal 200 scrapes off the enamel paint (not shown) applied to the surface of each of the coil ends 44a. Thus, the pair of coil ends 44a are electrically connected to each other via the flat male terminal 200.

[0176] First, the structure of the flat male terminal 200 will be described in detail using the drawings. The flat male terminal 200 corresponds to the connection terminal in the present application. The flat male terminal 200 is formed in a three-dimensional shape as shown in Figures 7 to 9 (b) by press working and bending working a brass plate or the like having excellent electrical conductivity. Specifically, the flat male terminal 200 includes a flat plate-shaped terminal connection portion 201 inserted into the flat female terminal Ml (see Figure 5 ), and a terminal body portion 202 inserted into the housing chamber 101 of the terminal housing box 100.

[0177] The terminal connection portion 201 stands toward the axial cover 30 side of the motor 10 in a state where the flat male terminal 200 is fixed to the housing chamber 101 of the terminal housing box 100. Thus, at the time of assembly of the motor 10, the terminal connection portion 201 is inserted into the flat female terminal Ml, and the both are electrically connected to each other.

[0178] As shown in Figure 9 (a), Figure 9 (b), the terminal body portion 202 is formed in a hollow substantially box shape, and is inserted into the housing chamber 101 of the terminal housing box 100.

[0179] Further, a terminal tip portion 202a facing the housing bottom surface 103 of the housing chamber 101 is provided on the front end side of the insertion direction of the terminal main body portion 202 with respect to the housing chamber 101. Further, a terminal base portion 202b facing the axial cover 30 side of the motor 10 is provided on the base end side of the insertion direction of the terminal main body portion 202 with respect to the housing chamber 101.

[0180] Further, a wide portion 203 having a width wider than the terminal connecting portion 201 is integrally provided between the terminal connecting portion 201 and the terminal main body portion 202 of the flat male terminal 200.

[0181] A single slit 204 is provided on the terminal main body portion 202. As shown in Figure 7 and Figure 8 (a) of Figure 8 (b), a pair of coil ends 44a are inserted into the slit 204. That is, the slit 204 arranges and holds the pair of coil ends 44a (the coil 44) in a manner of overlapping in the insertion direction of the terminal main body portion 202 with respect to the housing chamber 101.

[0182] The slit 204 is cut in a prescribed depth dimension toward the terminal base portion 202b from the terminal tip portion 202a side, and is opened on the terminal tip portion 202a side. Further, a coil inlet portion 204a is provided on the opening side (the lower side of (b) of Figures 7 to 9 ) of the slit 204, and a slit bottom portion 204b having a substantially circular arc shape is provided on the side opposite to the opening side (the upper side of (b) of Figures 7 to 9 ) of the slit 204.

[0183] Further, the pair of coil ends 44a are arranged between the coil inlet portion 204a and the slit bottom portion 204b in the length direction of the slit 204. In addition, the opening width between the coil inlet portion 204a and the slit bottom portion 204b in the length direction of the slit 204 is smaller than the diameter of the coil end 44a. Thus, the enamel paint applied on the surface of the coil end 44a is surely scraped off, and further the pair of coil ends 44a are surely electrically connected to each other via the flat male terminal 200.

[0184] However, the opening width of the slit 204 is desirably substantially half (about 1 / 2) of the diameter of the coil end 44a. Thus, the enamel paint can be surely scraped off, and the pull-out strength of the pair of coil ends 44a with respect to the flat male terminal 200 can be sufficiently ensured. Further, the pair of coil ends 44a can be surely prevented from being broken by the slit 204.

[0185] In addition, since only one slit 204 extending in the insertion direction of the pair of coil ends 44a is provided on the terminal main body portion 202, as shown in Figure 8 (a) of Figure 8(b) shown, the increase in the width direction (left-right direction in the drawing) dimension of the terminal body portion 202 can be suppressed. As observed from the front Figure 6 It is also ascertained that this means that the increase in the dimension of the insulator 43 holding the stator core 41 to the radially outer side can be suppressed, and further, the increase in the dimension of the motor 10 to the radially outer side can be suppressed.

[0186] Further, since the increase in the width direction dimension of the terminal body portion 202 can be suppressed, as observed from the front Figure 8 (a) of FIG. 1, Figure 8 (b) shown, the flat male terminal 200 can be formed in a longitudinal shape that is long in the longitudinal direction. By this, the flat male terminal 200 can be easily inserted straight into the terminal housing box 100. Therefore, the damage to the terminal housing box 100 can be suppressed, and further, the generation of defective products can be suppressed.

[0187] As observed from the front Figure 8 (a) of FIG. 1, Figure 8 (b) of FIG. 1, and Figure 9 (a) of FIG. 1, Figure 9 (b) shown, a guide opening portion 205 is provided on the terminal body portion 202 on the side closer to the terminal front end portion 202a than the coil inlet portion 204a of the slit 204, and the opening width of the guide opening portion 205 gradually increases toward the terminal front end portion 202a (lower side in the drawing). The guide opening portion 205 has a function of guiding (inducing) the pair of coil ends 44a toward the slit 204. Specifically, the opening width of the guide opening portion 205 closest to the terminal front end portion 202a is larger than the diameter of the coil end 44a. By this, the pair of coil ends 44a, which are disposed inside the housing chamber 101 and cannot be observed from the outside of the terminal housing box 100, can be easily and surely inserted into the slit 204, respectively.

[0188] In addition, a plurality of drop prevention protrusions 206 for preventing the terminal body portion 202 housed in the housing chamber 101 from falling off are provided on the terminal body portion 202. Specifically, as shown in Figure 8 (a) of FIG. 1, Figure 8 (b) shown, the drop prevention protrusions 206 are arranged on both sides (left and right sides in the drawing) of the terminal body portion 202, and the cross-sectional shape thereof is formed in a substantially triangular shape. Moreover, the corner portion on the front end side of these drop prevention protrusions 206 protrudes toward the housing chamber side wall 104 that forms the housing chamber 101, and is caught and hooked in the housing chamber side wall 104.

[0189] Next, the structure of the terminal housing box 100 is described in detail using the drawings. As observed from the front Figure 7 (a) of FIG. 1, Figure 8 (b) of FIG. 1, Figure 8 (b) of FIG. 1, Figure 10As shown, the terminal housing 100 is generally rectangular in shape. Inside the terminal housing 100 is a terminal body 202 that houses the flat male terminal 200 (see reference). Figure 9 of (a), Figure 9 (b)) containment room 101.

[0190] Additionally, the terminal housing 100 includes: a housing end face 102, disposed on the opening side of the housing chamber 101 ( Figure 10 (near the front side); and the bottom surface 103 of the containment chamber, located on the side of the containment chamber 101 opposite to the opening side ( Figure 10 (The inside of the storage chamber). Furthermore, a storage chamber side wall 104 is erected from the bottom surface 103 of the storage chamber toward the opening side of the terminal storage box 100. That is, the storage chamber 101 is surrounded by the bottom surface 103 of the storage chamber and the storage chamber side wall 104.

[0191] Furthermore, inside the terminal housing 100, a wide portion 203 for the flat male terminal 200 is provided (see reference). Figure 9 of (a), Figure 9 (b) A pair of insertion limiting recesses 105 are inserted. These insertion limiting recesses 105 form part of the receiving chamber 101 and are shallower than the receiving chamber 101 at a depth from the receiving chamber end face 102. Specifically, the depth dimension of the insertion limiting recesses 105 is approximately 1 / 4 of the depth dimension of the receiving chamber 101 (see reference). Figure 8 (b)

[0192] Furthermore, a first inclined wall portion 106 is provided on the opening side of the receiving chamber 101 and the insertion limiting recess 105, and the first inclined wall portion 106 guides the insertion of the terminal body portion 202 and the width portion 203 of the flat male terminal 200. Specifically, the first inclined wall portion 106 is provided all around the opening side of the receiving chamber 101 and the insertion limiting recess 105. As a result, the flat male terminal 200 can be easily inserted into the interior of the terminal receiving box 100.

[0193] Additionally, a support for a pair of coil ends 44a is provided approximately in the center of the bottom surface 103 of the terminal housing 100 (see reference). Figure 7 and Figure 8 The support protrusion 107 (a) is a support protrusion. Specifically, the support protrusion 107 protrudes from the bottom surface 103 of the receiving chamber toward the opening side of the receiving chamber 101, supporting a pair of coil ends 44a in an overlapping state in the protruding direction of the support protrusion 107. Moreover, the height of the support protrusion 107 protruding from the bottom surface 103 of the receiving chamber is approximately 1 / 3 of the depth dimension of the receiving chamber 101 (see reference). Figure 8 (a)

[0194] Here, the support protrusion 107 enters the interior of the terminal body 202 while the terminal body 202 is inserted into the receiving chamber 101. As a result, as the flat male terminal 200 is inserted into the terminal receiving box 100, the pair of coil ends 44a supported by the support protrusion 107 are positioned at a predetermined position (crimping effective range) in the slit 204.

[0195] Furthermore, such as Figure 7 and Figure 10 As shown, a pair of positioning grooves 108 are provided in the terminal housing 100. These positioning grooves 108 are respectively provided on opposing wall portions 109 facing each other in the extending direction of a pair of coil ends 44a, and are recessed from the end face 102 of the housing towards the bottom surface 103 of the housing chamber. That is, the pair of positioning grooves 108 are along the insulator 43 (refer to...) Figure 6 The axial extension of the locating recess 108. Specifically, the depth dimension of each locating recess 108 is approximately 2 / 3 of the depth dimension of the receiving chamber 101 (see reference). Figure 8 (b)). In other words, the depth dimension of the positioning groove 108 is the depth dimension reaching the front end portion of the support protrusion 107.

[0196] Furthermore, the opening width of the pair of positioning grooves 108 is slightly larger than the diameter of the pair of coil ends 44a. Therefore, the pair of coil ends 44a entering the positioning grooves 108 overlap in the insertion direction of the flat male terminal 200 relative to the terminal housing 100.

[0197] Additionally, groove bottoms 108a are provided on the side of each pair of positioning grooves 108 opposite to the opening side. A pair of coil ends 44a, which enter the positioning grooves 108, are placed on these groove bottoms 108a. The pair of groove bottoms 108a are positioned on the insertion-direction inlet side of the coil ends 44a in the terminal housing 100. Figure 7 (right side) and the outlet side of the insertion direction ( Figure 7 (on the left side), which corresponds to the mounting portion in this invention.

[0198] Thus, on the insertion direction inlet side and insertion direction outlet side of the coil end 44a of the terminal housing 100, a pair of coil ends 44a are respectively placed on a pair of slot bottoms 108a, thereby the pair of coil ends 44a are wound inside the terminal housing 100 in a direction orthogonal (crossing) to the insertion direction of the flat male terminal 200 toward the terminal housing 100.

[0199] Therefore, when the flat male terminal 200 is inserted into the terminal housing 100, the pair of coil ends 44a, which are placed on the front end portion of the support protrusion 107 and overlap in the protruding direction of the support protrusion 107, can face the slit 204 of the flat male terminal 200 from their front side. Therefore, excessive tensile force applied to the pair of coil ends 44a can be suppressed, thereby preventing wire breakage of the coil ends 44a (coils 44).

[0200] Furthermore, a second inclined wall portion 110 is provided on the opening side of the pair of positioning grooves 108 to guide the insertion of the pair of coil ends 44a into the pair of positioning grooves 108. As a result, the pair of coil ends 44a can be easily inserted (arranged) into their respective positioning grooves 108.

[0201] like Figure 6 , Figure 11 , Figure 12 As shown, near the terminal housing 100a for the W phase, the terminal housing 100b for the U phase, and the terminal housing 100c for the V phase, first pillar portions 150a, 150b, and 150c are respectively provided extending axially along the insulator 43. These first pillar portions 150a, 150b, and 150c are integrally formed on the insulator 43, and are also formed of insulating materials such as plastic. Furthermore, the three first pillar portions 150a, 150b, and 150c are designated as W-phase, U-phase, and V-phase respectively, in the aforementioned order.

[0202] like Figure 11 As shown, the first post portion 150a for the W phase and the first post portion 150b for the U phase are respectively disposed on the base end side of the winding direction of the coil 44 relative to the terminal housing box 100a for the W phase and the terminal housing box 100b for the U phase. Figure 11 (Right side). Specifically, the first post portion 150a for the W phase and the first post portion 150b for the U phase are configured with a spacing distance P1 between them and the terminal housing 100a for the W phase and the terminal housing 100b for the U phase. The spacing distance P1 is adjacent to the tooth TH in the circumferential direction of the stator core 41 (refer to...). Figure 6 The distances between them are approximately equal.

[0203] Cutouts 151a and 151b are provided on the first column portion 150a and 150b, respectively. These cutouts 151a and 151b are cut to a predetermined depth from one axial side to the other axial side of the insulator 43. Furthermore, a pair of coil ends 44a are hooked onto the cutout bottoms 152a and 152b of the cutouts 151a and 151b. Additionally, the opening width of the cutouts 151a and 151b is equal to the width of a pair of positioning grooves 108 (see reference). Figure 10The opening widths are approximately the same. Thus, a pair of coil ends 44a, which enter the cutout portions 151a and 151b and are hooked onto the bottom of the cutouts 152a and 152b, are axially aligned with the insulator 43. Figure 8 of (a), Figure 8 As shown in (b), the flat male terminal 200 overlaps with the terminal housing 100 in the insertion direction.

[0204] like Figure 13 As shown, the depth dimension D of the cut portion 151a and the cut portion 151b is ideally set as the width dimension W (diameter of coil end 44a × 2 (number of coils)) obtained by overlapping a pair of coil ends 44a and the slack SC when the pair of coil ends 44a are hooked onto the bottom of the cut portion 152a and the bottom of the cut portion 152b (refer to...). Figure 14 The condition is "and" or higher. Specifically, ideally, "D≧W+SC" should be satisfied. By satisfying this condition, when arranging a pair of coil ends 44a relative to the insulator 43, it is possible to prevent the pair of coil ends 44a from falling off from the cutouts 151a and 151b. In other words, the condition specified by "D≧W+SC" is a condition used to facilitate the arrangement of the pair of coil ends 44a relative to the cutouts 151a and 151b.

[0205] Here, as Figure 13 As shown, the opening directions of the cutouts 151a and 151b are opposite to the opening directions of the terminal housings 100a and 100b in the axial direction of the insulator 43. Specifically, the opening directions of the terminal housings 100a and 100b are on one side of the axial direction of the insulator 43. Figure 13 The opening directions of the cut portions 151a and 151b are on the other side of the axial direction of the insulator 43 (on the upper side). Figure 13 (the lower side).

[0206] Furthermore, the bottom 152a and bottom 152b of the cuts at the hooked coil ends 44a respectively correspond to the first conductive wire limiting portion in this invention. Moreover, as... Figure 11 As shown, the bottom cut 152a, the bottom cut 152b, and the terminal housing 100a and the terminal housing 100b are disposed on the other side of the insulator 43 along the axial direction.

[0207] In addition, such as Figure 6 , Figure 11 , Figure 12As shown, the portion of the coil 44 on the side of the stator core 41 in the winding direction and disposed on the one axial side of the insulator 43 becomes a coil base (proximal end side portion) 44b, and the portion of the coil 44 on the side opposite the coil base 44b in the winding direction and disposed on the other axial side of the insulator 43 becomes a coil end (distal end side portion) 44a.

[0208] Thus, the cutout bottoms 152a, 152b are arranged on the circumference of the insulator 43 with the terminal housing boxes 100a, 100b. Also, the cutout bottoms 152a, 152b have the function of causing the pair of coil ends 44a wound from the one axial side of the insulator 43 to the other axial side to respectively face in a direction (winding) intersecting the insertion direction of the flat male terminal T1, T2 into the terminal housing box 100a, 100b from the flat male terminal T1, T2 into the terminal housing box 100a, 100b.

[0209] In addition, as shown in Figure 13 , the height dimension H1 from the end surface S1 on the other axial side of the insulator 43 to the cutout bottoms 152a, 152b is larger (H1 > H2) than the height dimension H2 from the end surface S1 to the groove bottoms 108a (see Figure 10 and Figure 13 ) of the terminal housing boxes 100a, 100b. Also, the difference H3 (H3 = H1 - H2) between the height dimension H1 and the height dimension H2 is desirably set to be equal to or less than the sum of the width dimension W of the pair of coil ends 44a overlapping each other and the slack amount SC (see Figure 14 ) that occurs when the pair of coil ends 44a are hooked onto the cutout bottoms 152a, 152b. Specifically, it is desirable to satisfy "H3 ≦ W + SC". By satisfying the condition, the pair of coil ends 44a hooked onto the cutout bottoms 152a, 152b can be respectively stably placed on the pair of groove bottoms 108a (see Figure 7 ) provided on the terminal housing boxes 100. In other words, the condition prescribed by "H3 ≦ W + SC" is a condition for preventing the pair of coil ends 44a from being broken or the like by not applying excessive tension to the pair of coil ends 44a.

[0210] Further, as shown in Figure 6 , Figure 11 , Figure 12As shown, on the side opposite to the terminal housing case 100a, 100b, 100c side of the first pillar portion 150a, 150b, 150c, on the circumferential direction of the insulator 43, a second pillar portion 153a, 153b, 153c is provided so as to extend in the axial direction of the insulator 43. These second pillar portions 153a, 153b, 153c are also provided integrally with the insulator 43, and are formed of an insulating material such as plastic. Further, the three second pillar portions 153a, 153b, 153c in total become W-phase, U-phase, and V-phase in the order described.

[0211] As shown, Figure 11 the second pillar portion 153a for W-phase and the second pillar portion 153b for U-phase are disposed on the stator core 41 side (right side of the stator core 41) in the direction of the winding of the coil 44, with respect to the first pillar portion 150a for W-phase and the first pillar portion 150b for U-phase, respectively. Specifically, the second pillar portion 153a for W-phase and the second pillar portion 153b for U-phase are disposed apart from the first pillar portion 150a for W-phase and the first pillar portion 150b for U-phase by a separation distance P2. The separation distance P2 is substantially the same distance as the separation distance PI (P2≒PI). Figure 11

[0212] The second pillar portion 153a and the second pillar portion 153b are provided with a protrusion 154a, 154b, respectively. These protrusions 154a, 154b protrude at a prescribed height on the side in the axial direction of the insulator 43, and the portion of the coil base portion 44b disposed on the side in the axial direction of the insulator 43, which is close to the coil end 44a, is hooked on the protrusion 154a, 154b. Further, the protrusion height of the protrusion 154a, 154b is substantially the same size as the width dimension W (refer to FIG. 6) of the pair of coil ends 44a overlapped. Thereby, the pair of coil base portions 44b hooked on the protrusion 154a, 154b can be prevented from falling off from these protrusions 154a, 154b. Figure 13

[0213] Here, the pair of protrusions 154a, 154b are provided on the side in the axial direction of the insulator 43, and correspond to the second electrically conductive wire restricting portion in the present application. Further, as shown in the portion of the protrusion 154b, for example, by hooking the portion of the pair of coil base portions 44b close to the coil end 44a on the protrusion 154b, the portion of the coil 44 in the direction of the winding of the coil 44, which is closer to the stator core 41 than the hooked portion of the coil base portion 44b with respect to the protrusion 154b, can be caused to follow the circumferential direction of the insulator 43. Figure 11

[0214] ​​​Therefore, it is possible to effectively prevent short circuits in the coil base 44b, which is located on the axial side of the insulator 43 and extends toward the protrusion 154b, relative to the flat male terminal T1 (for the W phase) disposed between the protrusion 154b (for the U phase) and the first post portion 150a (for the W phase). Thus, both the protrusion 154a and the protrusion 154b have the function of causing the coil base 44b to move along the circumference of the insulator 43 on the axial side of the insulator 43.

[0215] Here, as Figure 12 As shown, the circumferential arrangement of the insulator 43 is reversed relative to that of the terminal housing 100c for the V phase, the first post portion 150c for the V phase, and the second post portion 153c for the V phase, compared to the terminal housing 100a for the W phase, the terminal housing 100b for the U phase, the first post portion 150a for the W phase, the first post portion 150b for the U phase, the second post portion 153a for the W phase, and the second post portion 153b for the U phase.

[0216] Specifically, the first column portion 150c for the V phase is positioned on the side opposite to the stator core 41 side in the winding direction of the coil 44, relative to the terminal housing 100c for the V phase. Figure 12 (Left side). Additionally, the second post 153c for the V phase is disposed on the side of the first post 150c for the V phase opposite to the side of the terminal housing 100c for the V phase in the circumferential direction of the insulator 43. Figure 12 (Left side).

[0217] However, the circumferential spacing of the terminal housing 100c for the V-phase, the first post portion 150c for the V-phase, and the second post portion 153c for the V-phase in the insulator 43, or the structure or function of the cutout portion 151c or cutout bottom 152c (first conductive wire limiting portion) of the first post portion 150c for the V-phase, and the structure or function of the protrusion 154c (second conductive wire limiting portion) of the second post portion 153c for the V-phase, are the same as those described above for the W-phase and U-phase. Therefore, detailed descriptions of the terminal housing 100c for the V-phase, the first post portion 150c for the V-phase, and the second post portion 153c for the V-phase, which are repeated above, are omitted.

[0218] Furthermore, regarding the first column 150c used in the V phase, it is ideal to satisfy the aspects of "D≧W+SC" and "H3≦W+SC", which are the same as those used in the W phase and U phase (see reference). Figure 16 Furthermore, in the terminal housing 100c for the V phase, the first post 150c for the V phase, and the second post 153c for the V phase, their arrangement positions and the winding direction of the coil 44 are opposite to those for the W phase and U phase as described above. Therefore, the second post 153c (protrusion 154c) is not used during the arrangement of the coil 44 (coil base 44b and coil end 44a) (see reference).Figure 12 ).

[0219] Next, the manufacturing method of the motor 10 formed in the above manner, particularly, the electrical connection method of the pair of coil ends 44a based on the flat male terminal T1, the flat male terminal T2, the flat male terminal T3 in the terminal housing case 100a, the terminal housing case 100b, the terminal housing case 100c will be described in detail using the drawings. Further, the parts of the terminal housing case 100a, the terminal housing case 100b are substantially the same, respectively, and therefore, the parts of the terminal housing case 100b and the flat male terminal T2 for the U phase will be described only. Figure 13 、 Figure 14 、 Figure 15 .

[0220] [First arrangement step (for U phase)

[0221] First, as shown by an arrow (1) in FIG. 10, the portion of the coil 44 (coil base portion 44b) drawn out from the stator core 41 is stretched with a prescribed tension while being made to follow the circumferential direction of the insulator 43 on the axial one side (upper side in the drawing) of the insulator 43. At this time, it is made to follow the inside of the second column portion 153a, the protrusions 154a, 154b of the second column portion 153b (the radially inner side of the insulator 43). Thus, the first arrangement step ends. Further, the first arrangement step corresponds to the first step in the present application. Figure 13 [First hooking step (for U phase)

[0222] Next, as shown by an arrow (2) in FIG. 11, the portion of the coil base portion 44b disposed on the axial one side of the insulator 43, which is close to the coil end 44a, is drawn toward the axial other side (lower side in the drawing) of the insulator 43. At this time, it is hooked on the protrusion 154b for the U phase. Thus, the first hooking step ends. Further, the first hooking step corresponds to the hooking step in the present application.

[0223] Figure 13 [Second hooking step (for U phase)

[0224] Thereafter, as shown by an arrow (3) in FIG. 12, the portion of the coil base portion 44b disposed on the axial other side of the insulator 43, which is close to the coil end 44a, is drawn toward the axial one side (upper side in the drawing) of the insulator 43. At this time, it is hooked on the protrusion 154a for the U phase. Thus, the second hooking step ends. Further, the second hooking step corresponds to the hooking step in the present application.

[0225] [Second arrangement step (for U phase) Figure 14 ​As indicated by arrow (3), the pair of coil ends 44a, which are wound to the other axial side (lower side in the figure) of the insulator 43, are folded back 180 degrees toward the axial side (upper side in the figure) of the insulator 43 and hooked onto the bottom 152b of the cut of the cut portion 151b of the first post portion 150b. At this time, it is ideal to stretch with a relatively large tension in the direction of arrow (4). This reduces the slack SC and effectively prevents the pair of coil ends 44a from falling off the cut portion 151b. However, in order to prevent damage to the coil 44 or breakage, the condition of the coil base 44b side is observed while stretching with a moderate tension. Thus, the second hooking process is completed. Furthermore, the second hooking process corresponds to the second process in this invention.

[0226] [Second arrangement process (U phase)]

[0227] Next, as Figure 15 As indicated by arrow (5), a pair of coil ends 44a hooked on the bottom 152b of the cut of the first post 150b are inserted into the terminal housing 100b arranged circumferentially along the insulator 43. At this time, a prescribed tension is applied to the pair of coil ends 44a, while they are inserted from the opening side of the terminal housing 100b into a pair of positioning grooves 108 (see reference). Figure 10 This eliminates excess slack in the pair of coil ends 44a, and the winding direction of the pair of coil ends 44a inside the terminal housing 100b is perpendicular to the circumference of the insulator 43. That is, the winding direction of the pair of coil ends 44a is oriented in a direction that intersects with the insertion direction of the flat male terminal T2 inserted into the terminal housing 100b. Therefore, the pair of coil ends 44a are respectively placed on the bottom 108a of the slots of the pair of positioning grooves 108 (see reference). Figure 7 Thus, the second arrangement step is completed. Furthermore, the second arrangement step corresponds to the third step in this invention.

[0228] Terminal connection process (for U-phase)

[0229] Then, as Figure 15 As indicated by arrow (6), the pair of coil ends 44a are stretched with a predetermined tension while placed on the bottom 108a of the positioning groove 108, and simultaneously, as indicated by arrow (7), the flat male terminal T2 is inserted into the terminal housing 100b. At this time, the flat male terminal T2 is moved vertically relative to the terminal housing 100b from the axial side of the insulator 43, that is, from the direction intersecting with the pair of coil ends 44a. Then, the flat male terminal T2 is pressed relative to the terminal housing 100b with a predetermined pressure. As a result, the supported protrusion 107 (see reference) Figure 7 A pair of coil ends 44a supported by the slit 204 are arranged in the slit (refer to) Figure 7) and are electrically connected to each other. At this time, since the pair of coil ends 44a are placed on the groove bottoms 108a (see FIG. 8) of the pair of positioning grooves 108, respectively, excessive tensile force acting on the pair of coil ends 44a can be suppressed when the flat male terminal T2 is pressed against the terminal housing box 100b. Therefore, breakage of the coil ends 44a (the coil 44) can be prevented. Thus, the terminal connecting process ends. Further, the terminal connecting process corresponds to the fourth process in the present application. Figure 7

[0230] Further, as shown in FIG. 10, the arrangement work and the electrical connection work of the pair of coil ends 44a are performed on the portion of the terminal housing box 100c for the V-phase and the flat male terminal T3. Figure 16 Figure 17 Figure 18

[0231] [First arrangement step (for the V-phase)]

[0232] First, as shown by an arrow (8) in FIG. 9, the portion (coil base 44b) of the coil 44 drawn out from the stator core 41 is stretched with a prescribed tension while being made to follow the circumferential direction of the insulator 43 on the axial one side (upper side in the drawing) of the insulator 43. At this time, it is made to follow the inside of the first column portion 150c (the radially inner side of the insulator 43). Thus, the first arrangement process (first process) ends. Figure 16 [Hooking process (for the V-phase)]

[0233] Next, as shown by an arrow (9) in FIG. 10, the portion of the coil base 44b close to the coil end 44a, which is disposed on the axial one side of the insulator 43, is drawn toward the axial other side (lower side in the drawing) of the insulator 43. At this time, it is drawn on the circumferential direction of the insulator 43 from the side of the first column portion 150c opposite to the terminal housing box 100c side toward the axial other side (lower side in the drawing) of the insulator 43. Thereafter, as shown by an arrow (10) in FIG. 11, the pair of coil ends 44a drawn to the axial other side (lower side in the drawing) of the insulator 43 are folded back by 180 degrees toward the axial one side (upper side in the drawing) of the insulator 43 while being hooked on the notch bottom 152c of the notch portion 151c of the first column portion 150c. At this time, it is desirable to stretch with a relatively large tension in the direction of the arrow (11). Thus, as similarly described above, the amount of slack with respect to the notch bottom 152c can be reduced, and the pair of coil ends 44a can be prevented from falling off from the notch portion 151c. However, in order to prevent damage or breakage of the coil 44, etc., the state of the coil base 44b side is observed while stretching with a moderate tension. Thus, the hooking process (second process) ends.

[0234] Figure 16 Figure 17 ​​​​​​​

[0235] [Second arrangement process (for V phase)]

[0236] Next, as Figure 18 As indicated by arrow (12), a pair of coil ends 44a hooked on the bottom 152c of the cut of the first post 150c are inserted into the terminal housing 100c arranged circumferentially in the insulator 43. At this time, a prescribed tension is applied to the pair of coil ends 44a, while they are inserted from the opening side of the terminal housing 100c into a pair of positioning grooves 108 (see reference). Figure 10 This eliminates excess slack in the pair of coil ends 44a, and the winding direction of the pair of coil ends 44a inside the terminal housing 100b is perpendicular to the circumference of the insulator 43. That is, the winding direction of the pair of coil ends 44a is oriented in a direction that intersects with the insertion direction of the flat male terminal T3 inserted into the terminal housing 100c. Therefore, the pair of coil ends 44a are respectively placed on the bottom 108a of the slots of the pair of positioning grooves 108 (see reference). Figure 7 Thus, the second arrangement process (the third process) is completed.

[0237] Terminal connection process (for V phase)

[0238] Then, as Figure 18 As indicated by arrow (13), the pair of coil ends 44a are stretched with a predetermined tension while placed on the bottom 108a of the positioning groove 108, and simultaneously, as indicated by arrow (14), the flat male terminal T3 is inserted into the terminal housing 100b. At this time, the flat male terminal T3 is moved vertically relative to the terminal housing 100c from the axial side of the insulator 43, that is, from the direction intersecting with the pair of coil ends 44a. Then, the flat male terminal T3 is pressed relative to the terminal housing 100c with a predetermined pressure. As a result, the supported protrusion 107 (see reference) Figure 7 A pair of coil ends 44a supported by the slit 204 are arranged in the slit (refer to) Figure 7 The coil ends 44a are respectively placed at the specified positions (within the effective crimping range) and electrically connected to each other. At this time, since a pair of coil ends 44a are respectively placed at the bottom 108a of a pair of positioning grooves 108 (refer to...) Figure 7 Therefore, when the flat male terminal T2 is pressed against the terminal housing 100c, excessive tensile force on the pair of coil terminals 44a can be suppressed. Thus, wire breakage at the coil terminals 44a can be effectively prevented. The terminal connection process (fourth process) is thus completed.

[0239] Therefore, the "first hooking process" performed on the U-phase portion is unnecessary in the terminal housing 100c and flat male terminal T3 portions used for the V-phase. That is, as... Figure 16 , Figure 17 , Figure 18As shown, the second column portion 153c (the protrusion 154c) is not used in the direction of the winding of the coil 44 in the present embodiment. However, in the case where the direction of the winding of the coil 44 is opposite to the present embodiment, the second column portion 153c (the protrusion 154c) is used in the portion of the terminal housing case 100c and the flat male terminal T3.

[0240] As described in detail above, according to the present embodiment, the cutout bottom portion 152a, the cutout bottom portion 152b, and the cutout bottom portion 152c are arranged in the circumferential direction of the insulator 43 with the terminal housing case 100a, the terminal housing case 100b, and the terminal housing case 100c, and the direction of the winding of the pair of coil ends 44a inside the terminal housing case 100a, the terminal housing case 100b, and the terminal housing case 100c is made to be in the direction intersecting the insertion direction of the flat male terminal T1, the flat male terminal T2, and the flat male terminal T3. Thereby, when the flat male terminal T1, the flat male terminal T2, and the flat male terminal T3 are inserted into the terminal housing case 100a, the terminal housing case 100b, and the terminal housing case 100c, the application of excessive force to the pair of coil ends 44a can be suppressed, and further, the occurrence of defects such as disconnection of the pair of coil ends 44a can be prevented. In addition, the pair of coil ends 44a can be neatly wound on the insulator 43 via the cutout bottom portion 152a, the cutout bottom portion 152b, and the cutout bottom portion 152c, and further, short circuiting with the coil 44 of the other phase and the like can be prevented.

[0241] In addition, according to the present embodiment, the coil base portion 44b of the coil 44 is disposed on one side in the axial direction of the insulator 43, and the coil end 44a of the coil 44, the terminal housing case 100a, the terminal housing case 100b, the terminal housing case 100c, the cutout bottom portion 152a, the cutout bottom portion 152b, and the cutout bottom portion 152c are disposed on the other side in the axial direction of the insulator 43. Thereby, the increase in the axial dimension of the stator core 41 (the insulator 43) can be suppressed, and further, the motor 10 can be further flattened (thinned).

[0242] Further, according to the present embodiment, the protrusion 154a, the protrusion 154b, and the protrusion 154c are provided on the side opposite to the terminal housing case 100a, the terminal housing case 100b, and the terminal housing case 100c of the cutout bottom portion 152a, the cutout bottom portion 152b, and the cutout bottom portion 152c arranged in the circumferential direction of the insulator 43 on one side in the axial direction of the insulator 43, and the portion of the coil base portion 44b close to the coil end 44a is made to follow the circumferential direction of the insulator 43. Thereby, the short circuiting and the like of the coil 44 of one phase with the coil 44 of the other phase disposed in the vicinity can be reliably prevented.

[0243] In addition, according to the present embodiment, a pair of groove bottoms 108a (see FIG. 6) for placing the pair of coil terminals 44a are provided on the terminal housing case 100a, the terminal housing case 100b, and the terminal housing case 100c, respectively, on the insertion direction entrance side and the insertion direction exit side of the pair of coil terminals 44a. The pair of coil terminals 44a hooked to the cutout bottoms 152a, 152b, 152c are placed on the pair of groove bottoms 108a, respectively. Thus, the pair of coil terminals 44a can face the slits 204 (see FIG. 6) of the flat male terminal 200 from the front side thereof. Therefore, the pair of coil terminals 44a can be inhibited from being excessively stretched, and thus, breakage of the coil terminals 44a (the coil 44) can be reliably prevented. Figure 10 Figure 7

[0244] Further, according to the present embodiment, the soldering work can be removed to improve the assembly workability of the motor 10, and thus, the occurrence of a short circuit of the coil 44 between the phases, breakage of the coil 44, or the like can be inhibited. Thus, the life cycle of the product can be extended, and at the same time, the manufacturing of energy can be labor-saving. Therefore, in the sustainable development goals (SDGs) led by the United Nations, contribution to Goal 7 (ensuring access to affordable, reliable, sustainable, and modern energy) and Goal 13 (taking urgent action to combat climate change and its impacts) can be made, in particular.

[0245] The present application is not limited to the described embodiments, and various modifications can of course be made within the scope of the present application. In the described embodiments, the case where the motor 10 is applied to an electrically powered vehicle for carrying harvested crops or the like is shown, but the present application is not limited thereto, and can be applied to a driving source of a welfare device such as a wheelchair device, or the like.

[0246] In addition, the material, shape, size, number, arrangement position, and the like of each of the constituent elements in the described embodiments are arbitrary as long as the present application can be achieved, and are not limited to the described embodiments.​​

Claims

1. An electric motor comprising: a stator wound with a plurality of electrically conductive wires; a rotor rotating relative to the stator; and a holding member holding the stator, the electric motor characterized by having: a terminal housing provided on a radially outer side of the holding member for the electrically conductive wires to pass through; a connection terminal inserted into the terminal housing from a direction crossing the electrically conductive wires to electrically connect the plurality of electrically conductive wires to each other; and a column portion provided on a radially outer side of the holding member and having a cutout bottom as a first electrically conductive wire restriction portion, the column portion being arranged at a distance apart from the terminal housing in a circumferential direction of the holding member so that a direction of winding of the electrically conductive wires inside the terminal housing is directed toward a direction crossing an insertion direction of the connection terminal.

2. The electric motor according to claim 1, wherein a base end side portion of the electrically conductive wires is disposed on one axial side of the holding member, a front end side portion of the electrically conductive wires, the terminal housing, and the first electrically conductive wire restriction portion are disposed on the other axial side of the holding member.

3. The electric motor according to claim 2, wherein a second electrically conductive wire restriction portion is provided on the one axial side of the holding member on a side opposite the terminal housing side of the first electrically conductive wire restriction portion in the circumferential direction of the holding member and causes the electrically conductive wires to follow the circumferential direction of the holding member.

4. The electric motor according to any one of claims 1 to 3, wherein a placement portion for placing the electrically conductive wires is provided on the terminal housing on each of an insertion direction entrance side and an insertion direction exit side of the electrically conductive wires, the electrically conductive wires hooked on the first electrically conductive wire restriction portion are placed on the respective placement portions.

5. A manufacturing method of an electric motor comprising: a stator wound with a plurality of electrically conductive wires; a rotor rotating relative to the stator; and a holding member holding the stator, the manufacturing method of the electric motor characterized by having: a first step of causing the electrically conductive wires to follow a circumferential direction of the holding member on one axial side of the holding member; a second step of winding the electrically conductive wires to the other axial side of the holding member and hooking the electrically conductive wires on a cutout bottom as a first electrically conductive wire restriction portion of a column portion disposed on the other axial side of the holding member; a third step of passing the electrically conductive wires hooked on the first electrically conductive wire restriction portion into a terminal housing arranged at a distance apart from the first electrically conductive wire restriction portion in the circumferential direction of the holding member so that a direction of winding of the electrically conductive wires inside the terminal housing is directed toward a direction crossing an insertion direction of a connection terminal inserted into the terminal housing; and a fourth step of inserting the connection terminal into the terminal housing from a direction crossing the electrically conductive wires to electrically connect the plurality of electrically conductive wires to each other, the column portion being provided on a radially outer side of the holding member and being arranged at a distance apart from the terminal housing in the circumferential direction of the holding member. ​ ​ 6. The method of manufacturing an electric motor according to claim 5, wherein on the side of the holding member opposite the terminal housing case side, a second electrically conductive wire restriction portion that restricts the electrically conductive wire in the circumferential direction of the holding member is provided, between the first process and the second process, a hooking process of hooking the electrically conductive wire to the second electrically conductive wire restriction portion is provided.

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