brushless motor

Abstract

The brushless motor (1) includes a rotor that rotates integrally with the shaft (4), a stator (3) that is radially opposed to the rotor and has an iron core with a winding (31) wound on it, a base plate (10) that is axially separated from one end face of the shaft (4) and extends in a direction intersecting the axial direction, a retainer (6) that is fixed relative to the stator (3) and holds the base plate (10), and a connection unit (9) that is electrically connected to the winding (31).

Description

Technical Field

[0001] This item relates to a brushless motor with a substrate. Background Technology

[0002] A brushless motor has a substrate (also called an electronic substrate or control substrate) on which electronic components such as sensors and electronic circuits are installed. The substrate is positioned close to the axial end face of the stator or rotor with a gap between it and the substrate. For example, Patent Document 1 discloses a motor having a motor substrate, which is positioned opposite a resin block provided on the stator with a gap between it and the substrate. In this motor, the axial positioning of the stator is achieved by pressing a stepped pin provided on the motor substrate into a hole provided on the stator.

[0003] Prior technology literature

[0004] [Patent Documents]

[0005] Patent Document 1: Japanese Patent No. 5937554 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] However, in the motor of Patent Document 1 mentioned above, the motor substrate has holes through which the bearing cage passes. Therefore, reducing the substrate area and the number of holes limits the number of electronic components that can be mounted on the substrate. In addition, to ensure the number of electronic components, the substrate needs to be enlarged, which may lead to the motor becoming larger.

[0008] The brushless motor of this invention was developed in response to this problem, one of its objectives being to avoid increasing the size of the motor and the inclusion of more electronic components. It should be noted that, besides this objective, other objectives of this invention include achieving the effects derived from the structures shown in the detailed embodiments described later, and effects that cannot be obtained through conventional techniques.

[0009] Solution for solving the problem

[0010] The disclosed brushless motor can be implemented as the following disclosed solutions (applicable examples), solving at least a portion of the aforementioned problems. Solutions 2 and later are additionally selectable solutions and can be omitted. Solutions 2 and later are not disclosed solutions or structural solutions that are necessary and indispensable for this document.

[0011] Option 1. The disclosed brushless motor comprises: a rotor that rotates integrally with a shaft; a stator that is radially opposed to the rotor and has an iron core with windings wound around it; a base plate that is axially separated from one end face of the shaft and extends in a direction intersecting the axial direction; a retainer that is fixed relative to the stator and retains the base plate; and a connecting unit that electrically connects the windings to the base plate.

[0012] Option 2. Based on Option 1 above, preferably, the connecting unit is electrically connected to the substrate at the outer periphery of the substrate.

[0013] Option 3. Based on Option 1 or 2 above, preferably, the connecting unit is a pin fixed to the retaining member, and at least a portion of the pin does not overlap with the iron core when viewed from the axial direction.

[0014] Option 4. Based on any of Options 1 to 3 above, preferably, the brushless motor includes a Hall effect sensor for detecting the rotational position of the rotor. In this case, preferably, the retainer has a mounting hole for mounting the Hall effect sensor.

[0015] Option 5. Based on Option 4 above, preferably, the mounting hole has a through hole through which the retainer passes along the axial direction, and has a stepped shape in which the opening on the rotor side is larger than the opening on the substrate side.

[0016] Option 6. Based on any of the options 1 to 5 above, it is preferred that the brushless motor includes a cover, which is mounted on the retainer with the substrate disposed between the cover and the retainer.

[0017] Option 7. Based on any of Options 1 to 6 above, preferably, the brushless motor includes a plate-shaped small housing plate fixed relative to the stator and disposed in a direction separated from the core by the substrate relative to one end face, i.e., a directional side. In this case, preferably, the retaining member has: a fixing portion fixed in the small housing plate at a position on the core side; and a protrusion extending from the fixing portion toward the directional side beyond the small housing plate, the substrate extending in a direction orthogonal to the axial direction and riveted to the protrusion.

[0018] Option 8. Based on any of the options 1 to 7 above, preferably, the brushless motor is an outer rotor type in which the stator is arranged radially inside the rotor.

[0019] Invention Effects

[0020] According to the publicly available brushless motor, there is no need to provide holes in the substrate for the shaft to pass through, thus allowing for the placement of more electronic components without increasing the substrate size. Therefore, it is possible to accommodate more electronic components without making the motor too large. Attached Figure Description

[0021] Figure 1 This is an axial sectional view of the brushless motor involved in the implementation method. Figure 2 (BB-directed sectional view).

[0022] Figure 2 yes Figure 1 AA-direction sectional view.

[0023] Figure 3 From Figure 1 The 3D view obtained by omitting the cover in the brushless motor.

[0024] Figure 4 It means Figure 1 A 3D view of the retainer of a brushless motor.

[0025] Figure 5 Is to make Figure 4 The three-dimensional image is obtained by flipping the retainer up and down.

[0026] Figure 6 yes Figure 5 Enlarged view of part D. Detailed Implementation

[0027] The brushless motor as an embodiment is described with reference to the accompanying drawings. The embodiments shown below are merely illustrative and are not intended to exclude the application of various modifications and techniques not explicitly shown in these embodiments. The structures of this embodiment can be implemented in various modifications without departing from its spirit. Furthermore, selections can be made as necessary, or appropriate combinations can be made.

[0028] [1. Structure]

[0029] [1-1. Overall Structure]

[0030] Figure 1 and Figure 2 This is a cross-sectional view along the axial direction of the brushless motor 1 (hereinafter referred to as "motor 1") according to this embodiment. Figure 1 yes Figure 2 BB-direction sectional view, Figure 2 yes Figure 1 A sectional view from direction AA. Additionally... Figure 3 This is a perspective view of motor 1 obtained by omitting the cover 7 described later from one end of the motor 1 along the axial direction.

[0031] like Figures 1-3As shown, the motor 1 includes a rotor 2 that rotates integrally with the shaft 4, a stator 3 that is radially opposed to the rotor 2, a base plate 10 that extends in a direction intersecting the axial direction, a retaining member 6 that holds the base plate 10, and a connecting unit 9 that electrically connects the winding 31 (described later) to the base plate 10. The motor 1 of this embodiment is an external rotor type brushless DC motor in which the stator 3 is arranged radially inside the rotor 2.

[0032] In this embodiment, the direction (axial, circumferential, radial) of motor 1 is determined with shaft 4 as a reference. Axial direction is the direction along the centerline C of shaft 4 (the length direction of shaft 4). Figure 1 The upper side (substrate 10 side) is designated as "one end side", and its opposite side is designated as "the other end side". The circumferential direction is the direction around the center line C of axis 4 (circumferential direction), and the radial direction is the direction orthogonal to both the axial and circumferential directions.

[0033] like Figure 1 and Figure 2 As shown, rotor 2 has a bottomed cylindrical rotor yoke 20 and a magnet 21 fixed to the inner circumferential surface of rotor yoke 20. The bottom of rotor yoke 20 is located at the other end of the axial direction, and rotor yoke 20 has an open shape at one end of the axial direction. A through hole is provided at the center of the bottom of rotor yoke 20 to fix the shaft 4 when it passes through. Thus, shaft 4 and rotor yoke 20 (rotor 2) rotate together. Magnet 21 is fixed to the inner circumferential surface of rotor yoke 20 at a position separate from the bottom part, and rotates together with rotor yoke 20.

[0034] The stator 3 is located radially outside the shaft 4 and radially inside the rotor 2, and has a stator core 30 (core) with windings 31 wound around it. Hereinafter, the component formed by windings 31 will be called a coil, and the portion connecting the multiple coils in the windings 31 will be called a connection wire. Furthermore, the stator 3 of this embodiment has an insulating layer (insulating coating) on ​​the surface of the stator core 30. That is, in the motor 1 of this embodiment, an insulating coating is provided instead of an insulating component.

[0035] The stator core 30 is a stacked core consisting of multiple steel plates of the same shape. The shaft 4 passes through the center of the stator core 30 with its axial direction aligned with the stacking direction of the steel plates. The stator core 30 includes a cylindrical portion through which the shaft 4 passes, multiple teeth protruding radially outward from the cylindrical portion, and blade portions extending circumferentially from the outer ends of each tooth portion. In this embodiment, the stator 3 has six teeth (blades) arranged at equal intervals circumferentially.

[0036] The inner diameter of the cylindrical portion of the stator core 30 is set to be larger than the outer diameter of the shaft 4 to prevent interference between the shaft 4 and the stator 3. The tooth portion is the part where the winding 31 is wound. The aforementioned insulating layer is provided on the surface of the tooth portion. The blade portion is the face facing the magnet 21 of the rotor 2, and is arc-shaped when viewed from the axial direction. The radially outward facing surface of the blade portion is called the outer peripheral surface 30a of the stator core 30 (hereinafter referred to as "core outer peripheral surface 30a"). The mounting structure of the stator 3 is described later.

[0037] Shaft 4 is the rotating shaft that supports rotor 2, and also functions as an output shaft that extracts the output (mechanical energy) of motor 1 to the outside. In this embodiment, one end of shaft 4 is supported by bearing 33 for free rotation, and the portion of shaft 4 on the other end side of rotor yoke 20 is supported by bearing 34 for free rotation. One bearing 33 is fixed to the metal retainer 32 described later, and the other bearing 34 is fixed to housing 5. It should be noted that housing 5 is a bottomed cylindrical component that covers rotor 2 radially outward and is installed with a gap between it and the outer peripheral surface of rotor 2.

[0038] The substrate 10 is a plate-shaped component axially separated from one end face 4a of the shaft 4, also known as an electronic substrate or control substrate. It should be noted that the direction in which the substrate 10 is separated from one end face 4a of the shaft 4 is a directional side (e.g., Figure 1 The upper side (in this embodiment) is the "one end side". Electronic components (not shown) are mounted on the substrate 10. The substrate 10 is separated from one end face 4a of the shaft 4, therefore... Figure 3 As shown, no hole is provided for the shaft 4 to pass through. Therefore, the area (substrate area) on which electronic components can be arranged increases by the amount of the absence of a hole. In this embodiment, the substrate 10 is arranged to extend in a direction orthogonal to the axial direction. As a result, the motor 1 can be made into a compact structure. The mounting structure of the substrate 10 will be described later.

[0039] like Figures 1-3 As shown, the retainer 6 is a component fixed relative to the stator 3, and is made of resin, for example. The retainer 6 has a fixing portion 60 that overlaps with the rotor 2 and the stator 3 when viewed axially, and a connector portion 61 on which the terminal block 12 is provided. The shape of the connector portion 61 varies depending on the type of motor 1. On the other hand, the shape of the fixing portion 60 is preferably common regardless of the type of motor 1. The detailed structure of the retainer 6 and the connecting unit 9 will be described later.

[0040] In addition to the structure described above, the motor 1 of this embodiment also includes a Hall effect sensor 11 for detecting the rotational position of the rotor 2, a metal retainer 32 connecting the stator 3 and the retainer 6, a bushing 35 for guiding the contact wire, a small housing plate 8 fixed relative to the stator 3, and a cover 7 mounted on the retainer 6. It should be noted that these components are not essential and can be omitted where possible, or replaced by other components.

[0041] like Figure 2 As shown, the Hall effect sensor 11 has a detection section 11a that detects a signal corresponding to the rotational position of the rotor 2, and three terminals 11b extending linearly from the detection section 11a. The detection section 11a of the Hall effect sensor 11 faces one end of the rotor 2, and the Hall effect sensor 11 is mounted in the mounting hole 62 of the retaining member 6 (described later) with each terminal 11b penetrating the substrate 10. It should be noted that each terminal 11b is mounted relative to the substrate 10, for example, by soldering, but... Figures 1-3 The middle figure shows the state where the substrate 10 is penetrated.

[0042] The metal retainer 32 is a component that retains the bearing 33 and is fixed from one end to the middle of the inner circumferential surface of the stator core 30. The metal retainer 32 is, for example, made of resin and is a cylindrical strip that is elongated in the axial direction, with the shaft 4 passing through a central through hole. The centerline of the metal retainer 32 coincides with the centerline C of the shaft 4, and a gap is formed between the inner circumferential surface of the metal retainer 32 and the outer circumferential surface of the shaft 4.

[0043] An enlarged step is provided on the inner circumferential surface of one end of the metal retainer 32. A bearing 33 is fixed to one end of this step. Additionally, two steps are provided on the outer circumferential surface of the metal retainer 32. The first step is located radially outward at the enlarged portion of the inner circumferential surface of the metal retainer 32. That is, both the inner and outer circumferential surfaces of the metal retainer 32 are enlarged at the portion where the bearing 33 is fixed, thereby ensuring the plate thickness. The second step is located at the portion that abuts against one end face of the stator core 30. The portion further to the other end than this second step is the smallest outer diameter portion of the metal retainer 32 and is embedded within the cylindrical portion of the stator core 30.

[0044] The bushing 35 is a component that guides the contact line to prevent interference with the shaft 4, and is fixed to the other end portion of the inner circumferential surface of the stator core 30. The bushing 35 is, for example, made of resin, and is a cylindrical shape with a shorter axial dimension compared to the metal retainer 32, with the shaft 4 passing through a central through-hole. The centerline of the bushing 35 coincides with the centerline C of the shaft 4, forming a gap between the inner circumferential surface of the bushing 35 and the outer circumferential surface of the shaft 4. Additionally, a gap is formed between the other end face of the metal retainer 32 and one end face of the bushing 35.

[0045] The inner diameter of the bushing 35 is constant in the axial direction. On the other hand, a stepped portion is provided on the outer circumferential surface of the bushing 35. This stepped portion is located at the part that abuts against the other end face of the stator core 30. Regarding the bushing 35, the outer diameter of one end is smaller than the outer diameter of the other end compared to this stepped portion, and it is fitted into the cylindrical portion of the stator core 30. It should be noted that the end face (stepped surface) of the stepped portion of the bushing 35 abuts against the other end face of the stator core 30, thus providing insulation even if no insulating layer is provided on the other end face of the stator core 30.

[0046] like Figures 1-3 As shown, the small housing plate 8 is a plate-shaped component, positioned at one end closer to the stator core 30 with its thickness direction aligned with the axial direction. The small housing plate 8 is, for example, shaped like a disk with an outer diameter approximately equal to the outer diameter of the rotor 2, with its periphery partially removed. A circular through-hole is provided in the center of the small housing plate 8, and a cylindrical portion is erected around the through-hole. One end of the metal retainer 32 is pressed and fixed into the through-hole and the cylindrical portion of the small housing plate 8. Thus, the metal retainer 32 is integrated with the small housing plate 8.

[0047] like Figure 1 and Figure 2 As shown, the cover 7 is mounted from one end of the retainer 6 to cover the substrate 10 held in the retainer 6. That is, the cover 7 is mounted to the retainer 6 with the substrate 10 disposed between it and the retainer 6. The cover 7 is formed of resin, for example. In the motor 1 of this embodiment, one end face 4a of the shaft 4 does not penetrate the substrate 10, so there is naturally no through hole in the cover 7 for the shaft 4 to pass through.

[0048] [1-2. Main structural components]

[0049] Next, the main structure of the motor 1, including the detailed structure of the retainer 6 and the connecting unit 9, the mounting structure of the base plate 10, and the mounting structure of the stator 3, will be described.

[0050] Figure 4 This is a perspective view of retainer 6 taken from one end. Figure 5 This is obtained by observing the retainer 6 from the other end (making) Figure 4 (The three-dimensional view is obtained by flipping the retainer 6 up and down.) Additionally, Figure 6 It is Figure 5 The three-dimensional view shown in magnification of part D.

[0051] like Figure 4 and Figure 5 As shown, in addition to the aforementioned fixing part 60 and connector part 61, the retainer 6 also has a mounting hole part 62, a first protrusion part 63, a second protrusion part 64 (protrusion), a base part 65, and a guide part 66.

[0052] The fixing part 60 is the part that fixes the retaining member 6 to the small housing plate 8. The surface 60a of the fixing part 60 facing one end (hereinafter referred to as "upper surface 60a") is fixed to the surface of the small housing plate 8 facing the other end (the surface facing the stator core 30). When viewed from the axial direction, the fixing part 60 is a disc-shaped part with a circular hole in the center, and has a peripheral wall part 60c that is erected axially from the outer peripheral edge of the surface 60b facing the other end (hereinafter referred to as "lower surface 60b").

[0053] The connector portion 61 is continuously disposed on a portion of the radially outer side of the fixing portion 60. In the motor 1 of this embodiment, a bottomed, cylindrical (rectangular cylindrical) connector portion 61 is exemplified. Figure 1 and Figure 3 As shown, in this embodiment, the connector portion 61 is arranged adjacent to the housing 5 with a gap between them and opens towards the other end (i.e., axially). That is, the bottom of the connector portion 61 is located at one end. Cutouts, slits, protrusions, etc., are formed at the bottom of the connector portion 61. Two terminals 12 are mounted inside the connector portion 61 with their axial length penetrating the bottom. It should be noted that one end 12a of each terminal 12 is mounted relative to the substrate 10, for example, by soldering, but... Figure 1 and Figure 3 The middle figure shows the state where the substrate 10 is penetrated.

[0054] Mounting hole 62 is the part for mounting Hall effect sensors 11, and is disposed on the outer periphery of fixing part 60. In the motor 1 of this embodiment, three Hall effect sensors 11 are provided, so the three mounting holes 62 are arranged at intervals in the circumferential direction. The three mounting holes 62 are also configured to have through holes 62a that pass through the retaining member 6 in the axial direction. Hall effect sensors 11 are mounted in the through holes 62a.

[0055] In this embodiment, the mounting hole 62 is a cylindrical (rectangular) shape that protrudes from the upper surface 60a of the fixing part 60 to one end and from the lower surface 60b to the other end. The size (opening area) of the through hole 62a of the mounting hole 62 is not the same in the axial direction; the opening area on the other end (rotor 2 side) is larger than the opening area on the one end (substrate 10 side). Therefore, as... Figure 6 As shown, a stepped portion 62b is formed inside the mounting hole portion 62. That is, the interior of the mounting hole portion 62 is stepped.

[0056] like Figure 2As shown, the detection section 11a of the Hall sensor 11 is positioned on the other side of the stepped portion 62b, and the terminal 11b of the Hall sensor 11 passes through the position on one side of the stepped portion 62b. The detection section 11a protrudes slightly from the other end of the mounting hole 62 of the retainer 6. It should be noted that, as Figure 6 As shown, rib 62c protrudes from the inner surface of the opening on the other end side of the mounting hole 62. Rib 62c is in close contact with the detection part 11a of the Hall sensor 11 to prevent the detection part 11a from shifting position.

[0057] like Figure 1 , Figure 2 and Figure 4 As shown, the first protrusion 63 is a portion that protrudes from the fixing portion 60 of the retainer 6 towards one end, is inserted into and riveted to the hole through which the small housing plate 8 passes, thereby fixing the retainer 6 to the small housing plate 8. In this embodiment, the first protrusion 63 is a cylindrical shape that protrudes from the upper surface 60a of the fixing portion 60 of the retainer 6, and has a protruding length capable of allowing the small housing plate 8 to pass through. It should be noted that in Figure 1 and Figure 2 The diagram shows the first protrusion 63 penetrating the small housing plate 8 (in its unriveted state). Figure 4 As shown, in this embodiment, the three first protrusions 63 are equally spaced around the hole in the center of the fixing part 60, and are well fixed in a balanced manner relative to the small housing plate 8. It should be noted that the number and arrangement of the first protrusions 63 are not limited thereto.

[0058] like Figures 1-4 As shown, the second protrusion 64 is a portion that protrudes from the fixing portion 60 of the retainer 6 towards one end of the housing plate 8, and is inserted into and riveted to the hole through which the substrate 10 passes, thereby fixing the retainer 6 to the substrate 10. In this embodiment, the second protrusion 64 is a cylindrical shape protruding from the upper surface 60a of the fixing portion 60 of the retainer 6, and has a protruding length capable of penetrating the substrate 10. That is, the second protrusion 64 has a longer protruding length than the first protrusion 63. It should be noted that in this embodiment, the same second protrusion 64 is also provided on the surface of one end of the connector portion 61. Figures 1-3 The figure shows the state in which the second protrusion 64 penetrates the substrate 10 (in the unriveted state).

[0059] like Figure 3 and Figure 4As shown, in this embodiment, a second protrusion 64 is disposed at the position furthest from the connector portion 61 in the fixing portion 60, and two second protrusions 64 are disposed at intervals from each other at the positions furthest from the fixing portion 60 in the connector portion 61. That is, the three second protrusions 64 are arranged in a triangular configuration when viewed from one end, and are fixed in a good balance relative to the substrate 10. It should be noted that the number and arrangement of the second protrusions 64 are not limited to this.

[0060] like Figure 2 and Figure 4 As shown, the pedestal portion 65 is a pedestal-shaped part that is fixed as a pin for connecting unit 9. The number, arrangement, and shape of the pedestal portions 65 are set according to the connecting unit 9.

[0061] Here, the connection unit 9 will be described. In the motor 1 of this embodiment, the substrate 10 is disposed separately from one end face 4a of the shaft 4, so the distance between the coil and the substrate 10 is longer compared to the conventional structure where the shaft passes through the substrate. Therefore, by providing a unit that electrically connects the starting wire (winding 31) of the coil to the substrate 10, their connection can be easily and reliably achieved.

[0062] The connecting unit 9 is electrically connected to the substrate 10 at its outer periphery. Furthermore, in this embodiment, the connecting unit 9 is a rod-shaped (pin-shaped) pin made of a conductive material, such as... Figure 2 and Figure 3 As shown, it is electrically connected to the winding 31. In this way, the winding 31 and the substrate 10 are electrically connected to each other via the pin 9. Hereinafter, the connecting unit 9 will also be referred to as "pin 9". In the motor 1 of this embodiment, the pin 9 is set as a "binding pin" for binding the winding 31. In the case of the binding pin, the pin 9 and the winding 31 are electrically connected to the substrate 10, for example, by brazing.

[0063] In the motor 1 of this embodiment, when viewed axially, each pin 9 is configured such that at least a portion of each pin 9 does not overlap with the stator core 30. In other words, each pin 9 is configured in either a radially outer position relative to the outer peripheral surface 30a of the stator core 30, or a position that partially overlaps with the stator core 30 when viewed axially. This arrangement, where the pin 9 is not entirely radially inner to the outer peripheral surface 30a, ensures that the pin 9 is reliably positioned on the outer periphery of the substrate 10, preventing a reduction in the substrate area due to the pin 9.

[0064] The aforementioned pedestal portion 65 is disposed on the outer periphery of the fixing portion 60. In the motor 1 of this embodiment, three pins 9 are provided, so the three pedestal portions 65 are arranged at intervals in the circumferential direction. The three pedestal portions 65 are similarly constructed, each having a pin hole 65a extending axially from one end of the retaining member 6. It should be noted that the pin hole 65a is not a through hole. The pin 9 is fixed to the pin hole 65a.

[0065] It should be noted that in the retaining member 6 of this embodiment, the three mounting holes 62 and the three bases 65 (i.e., six parts) are arranged approximately equally in the circumferential direction at the outer periphery of the fixing part 60. However, the three mounting holes 62 are arranged within a 180-degree range at the outer periphery of the fixing part 60, and the three bases 65 are arranged within the remaining 180-degree range. In this way, the part that mounts the Hall sensor 11 and the part that mounts the mounting pin 9 are different but are arranged in a good balance.

[0066] like Figure 2 and Figure 5 As shown, the guide portion 66 is the portion that guides the winding 31 toward the substrate 10 via the pin 9, and is disposed on the outer periphery of the fixing portion 60. In the motor 1 of this embodiment, three pins 9 are provided, so the three guide portions 66 are arranged at intervals in the circumferential direction. The three guide portions 66 are similarly constructed, each having a slit 66a that passes through the retaining member 6 in the axial direction. The winding 31 passes through the slit 66a.

[0067] In this embodiment, the guide portion 66 protrudes from the lower surface 60b of the fixing portion 60 to the other end, forming a U-shape that opens radially outward when viewed from the axial direction. That is, at the location of the guide portion 66, the peripheral wall portion 60c is also cut away axially, forming a slit 66a. It should be noted that the slit 66a can also be... Figure 5 It is positioned on the pedestal section 65 as shown. Figure 2 As shown, the starting wires of the U-phase, V-phase, and W-phase of the winding 31 wound around the teeth pass through the slit 66a of the guide portion 66 and are guided toward the pin 9, and are electrically connected to the substrate 10 together with the pin 9 while being bound to the pin 9.

[0068] Finally, the mounting structure of the substrate 10, the mounting structure of the stator 3, and the assembly process of the motor 1 will be explained.

[0069] The substrate 10 is riveted and fixed to the second protrusion 64 of the retainer 6 as described above.

[0070] Regarding the stator 3, firstly, one end of the metal retainer 32 is pressed and fixed to the small housing plate 8, and the fixing part 60 of the retainer 6 is riveted and fixed to the small housing plate 8. It should be noted that either the fixing of the metal retainer 32 to the small housing plate 8 or the fixing of the metal retainer 32 to the retainer 6 can be performed first. In addition, a pin 9 is pre-fixed to the base part 65 of the retainer 6.

[0071] Next, the bearing 33 and the stator core 30, which has been coated with insulation, are fixed to the metal retainer 32, and the bushing 35 is fixed to the stator core 30. Furthermore, the winding 31 is wound onto the stator core 30, and the starting wires of the coils forming the U-phase, V-phase, and W-phase are guided to the pins 9 via the guide portion 66 and secured to the pins 9. Thus, in this embodiment, the retainer 6 is fixed to the stator 3 via the small housing plate 8 and the metal retainer 32. At this stage, the stator 3 is completed; therefore, the above process is also referred to as the "stator process."

[0072] Regarding rotor 2, magnet 21 is fixed to rotor yoke 20, shaft 4 is further fixed, and housing 5, to which bearing 34 is fixed, is installed. At this stage, base plate 10 is not installed, but a dummy base plate is installed instead of base plate 10, thereby enabling tests to be performed to determine whether the motor is functioning properly.

[0073] Next, the substrate 10 is placed on the retainer 6. At this time, the pin 9, the terminal 11b of the Hall sensor 11, one end 12a of the terminal 12, and the second protrusion 64 pass through one end of the substrate 10. Furthermore, the second protrusion 64 is riveted, thereby riveting and fixing the substrate 10 to the retainer 6. Further, for example, the pin 9, the terminal 11b of the Hall sensor 11, and one end 12a of the terminal 12 are electrically connected to the substrate 10 by brazing. Finally, the cover 7 is installed on the retainer 6, thereby completing the motor 1.

[0074] [2. Effect]

[0075] (1) According to the motor 1 described above, the substrate 10 is axially separated from one end face 4a of the shaft 4. Therefore, it is not necessary to provide a hole for the shaft 4 to pass through in the substrate 10, so more electronic components can be arranged without increasing the size of the substrate 10. Therefore, the motor 1 can be equipped with more electronic components without making it larger. In addition, in the motor 1 described above, the winding 31 wound on the stator 3 and the substrate 10 are arranged axially separated, but the winding 31 is electrically connected to the substrate 10 via the connecting unit 9, so it can be connected to the substrate 10 at an accurate position. It should be noted that, as described above, if it is an external rotor type brushless motor 1, the surface area of ​​the magnet 21 can be increased compared with an internal rotor type brushless motor of the same size, so the motor performance can be improved.

[0076] (2) In the motor 1 described above, the connecting unit 9 is electrically connected to the substrate 10 at the outer periphery of the substrate 10, so the connecting unit 9 does not obstruct the arrangement of electronic components on the substrate 10. Therefore, the motor 1 can be mounted on more electronic components without making it larger.

[0077] (3) In the motor 1 described above, the connecting unit 9 is composed of a pin 9 fixed to the retaining member 6. In this case, the pin 9 can be reduced in size (by decreasing the outer diameter of the pin 9) within a range that can withstand the process of fixing the pin 9 to the retaining member 6 and the process of connecting the pin 9 to the winding 31. Therefore, the wire diameter, i.e., the winding wire diameter, in the state of binding the winding 31 to the pin 9 can be reduced, and the hole in the substrate 10 into which the pin 9 is inserted can be reduced. As a result, the substrate area can be further increased, and the effect of easy soldering and reduced defect rate is also achieved.

[0078] Furthermore, at least a portion of the pin 9 is configured not to overlap with the stator core 30 when viewed from the axial direction. In this way, the pin 9 is positioned on the outer periphery of the substrate 10 to a degree that it does not partially overlap with the stator core 30 when viewed from the axial direction, thereby further improving the freedom of mounting electronic components on the substrate 10.

[0079] (4) In the motor 1 described above, the rotor 2 and the base plate 10 are arranged to be axially separated, but a mounting hole 62 is provided in the retaining member 6, and a Hall sensor 11 is mounted in the mounting hole 62. Therefore, the Hall sensor 11 can be arranged at an appropriate distance from the rotor 2 and the magnet 21 that rotates integrally with it, ensuring detection accuracy. In addition, the Hall sensor 11 can be easily assembled, thus improving assembly ease. Furthermore, since the Hall sensor 11 is arranged in the mounting hole 62, the rigidity of the Hall sensor 11 can be improved, and vibration of the Hall sensor 11 can be prevented even if vibration occurs when the motor 1 is operating, thereby improving detection accuracy.

[0080] (5) The mounting hole portion 62 described above has a through hole 62a through which the retaining member 6 passes in the axial direction, and has a stepped shape in which the opening on the rotor 2 side is larger than the opening on the substrate 10 side. Therefore, when the Hall sensor 11 is inserted into the through hole 62a of the mounting hole portion 62 from the rotor 2 side, the Hall sensor 11 abuts against the stepped portion (the stepped portion 62b described above), and thus the axial positioning of the Hall sensor 11 can be easily performed.

[0081] (6) The motor 1 described above has a cover 7, which is mounted on the retainer 6 with the base plate 10 disposed between the cover 7 and the retainer 6, so that the base plate 10 can be protected by the cover 7. Furthermore, if the cover 7 is removed, only the base plate 10 can be replaced, so that the repair cost can be reduced.

[0082] (7) The motor 1 described above has a small housing plate 8, which is disposed on one end side (one direction side) closer to the stator core 30. Furthermore, the retaining member 6 described above has: a fixing portion 60, which is fixed to the small housing plate 8 at a position on the stator core 30 side; and a second protrusion 64, which protrudes from the fixing portion 60 towards one end side of the small housing plate 8. Further, the base plate 10 is supported on the retaining member 6 in a posture extending in a direction orthogonal to the axial direction, thus allowing for a compact structure. In addition, the base plate 10 is riveted to the second protrusion 64. Thus, the retaining member 6 is fixed to the small housing plate 8 and integrated with the stator 3, thereby improving the installation stability of the retaining member 6. On the other hand, since the base plate 10 is riveted to the second protrusion 64 protruding towards one end side of the axial direction compared to the small housing plate 8, it can be reliably fixed while maintaining a suitable gap from the stator 3. Furthermore, this gap separates the substrate 10 from the stator 3, thus protecting the electronic components from the heat generated by the stator 3. Furthermore, a small housing plate 8 is provided between the substrate 10 and the stator 3, which can block the heat generated from the stator 3, further protecting the electronic components from the adverse effects of heat.

[0083] [3. Other]

[0084] The motor 1 described above is one example, and the structure is not limited to the above. For example, the method of fixing the retainer 6 to the small housing plate 8 and the method of fixing the retainer 6 to the base plate 10 may not be riveting. In addition, the base plate 10 may not extend in a direction orthogonal to the axial direction, but rather at a slight inclination (along a direction other than orthogonal). It should be noted that the housing 5 and the cover 7 are not necessary and may be omitted or replaced by other components.

[0085] The shape of the connector portion 61 described above is also an example. For example, the connector portion may also be open in a direction orthogonal to the axial direction. Alternatively, if the lead wire is electrically connected to the substrate 10 instead of the terminal block 12, the connector portion 61 may be omitted, and the portion for bundling the lead wire may be provided in the retaining member.

[0086] The mounting structure of the Hall sensor 11 described above is also an example. The shape and configuration of the mounting hole 62 can also be changed. For example, a mounting part that is separate from the retainer 6 can also be provided.

[0087] In the motor 1 described above, a pin is used as a connecting unit, but the connecting unit is not limited to a pin as long as it can electrically connect the winding 31 to the substrate 10. Furthermore, the connecting unit is preferably located on the outer periphery of the substrate 10, but it is not limited to any location that does not obstruct the placement of electronic components. Even when a pin 9 is used as a connecting unit, it is not necessary to use a "binding pin" to secure the winding 31; instead of binding the winding 31 to the pin 9, a wire connection terminal can be used to connect the winding 31 to the pin 9. In this case, only the pin 9 needs to be electrically connected to the substrate 10, for example, by soldering.

[0088] The motor 1 described above is an external rotor type, but the above structure can also be applied to an internal rotor type brushless motor in which the stator 3 is arranged radially outside the rotor 2.

[0089] Explanation of reference numerals in the attached figures:

[0090] 1 motor (brushless motor)

[0091] 2 rotors

[0092] 3 stators

[0093] 4-axis

[0094] 4a One end face

[0095] 6 retainers

[0096] 7 masks

[0097] 8 small shell plates

[0098] 9 pins (connecting unit)

[0099] 10 substrates

[0100] 11 Hall effect sensor

[0101] 30 stator core (iron core)

[0102] 30a core outer circumference

[0103] 31 windings

[0104] 60 fixed part

[0105] 62 mounting holes

[0106] 62a Through Hole

[0107] 64 Second protrusion (protrusion)

[0108] The center line of the C-axis.

Claims

1. A brushless motor, characterized in that, The brushless motor has the following features: The rotor rotates integrally with the shaft. The stator is radially opposed to the rotor and has a core with windings. A substrate, which is axially separated from one end face of the axis and extends in a direction intersecting the axis; A retainer, which is fixed relative to the stator and holds the substrate; A connection unit that electrically connects the winding to the substrate; as well as A Hall effect sensor, comprising a detection unit and terminals, uses the detection unit to detect the rotational position of the rotor. The retainer is secured between a bottomed cylindrical housing that covers the rotor radially outward and a cover mounted on the retainer, and has mounting holes for mounting the Hall effect sensor. The Hall sensor is inserted through the rotor-side opening of the through hole of the retainer along the axial direction of the mounting hole, and the terminal passes through the through hole and is fixed by the detection part abutting against the mounting hole.

2. The brushless motor according to claim 1, characterized in that, The connection unit is electrically connected to the substrate at the outer periphery of the substrate.

3. The brushless motor according to claim 2, characterized in that, The connecting unit is a pin fixed to the retaining member. At least a portion of the pin does not overlap with the core when viewed from the axial direction.

4. The brushless motor according to claim 1, characterized in that, The mounting hole has a stepped shape in which the opening on the rotor side is larger than the opening on the substrate side.

5. The brushless motor according to claim 1, characterized in that, The cover is mounted on the retainer with the substrate disposed between it and the retainer.

6. The brushless motor according to claim 1, characterized in that, The brushless motor has a small, plate-shaped housing plate fixed relative to the stator and positioned on a side further away from the core than the substrate, i.e., in a direction separating the core from one end face. The retaining member has: a fixing portion fixed to a position on the core side of the small housing plate; and a protrusion extending from the fixing portion toward the small housing plate in one direction. The substrate extends in a direction orthogonal to the axial direction and is riveted to the protrusion.

7. The brushless motor according to any one of claims 1 to 6, characterized in that, The brushless motor is an external rotor type in which the stator is arranged radially inside the rotor.

Images