Motor device and manufacturing method thereof

Abstract

The invention provides a motor device and a method for manufacturing the same, wherein the rotation balance of a rotor can be adjusted while the reduction of output torque is suppressed. The rotor 33 includes: a rotating shaft 34; a rotor core (33a) fixed to the rotating shaft (34); a magnet MG fixed to the rotor core 33a; and an adjustment member 37 that is fixed to the rotating shaft 34 and adjusts the rotational balance of the rotor 33, the separation distance L1 between the magnet MG in the axial direction of the rotating shaft 34 and the adjustment member 37 being longer than the separation distance L2 between the magnet MG in the radial direction of the rotating shaft 34 and the stator 32 (L1 > L2). As a result, the rotational balance of the rotor 33 can be adjusted, and the adjustment member 37 can be disposed further away from the magnet MG than the stator 32. Thus, the magnetic flux [Wb] of the magnet MG is suppressed toward the adjustment member 37 and efficiently faces the stator 32.

Description

Technical Field

[0001] The present invention relates to a motor device having a stator and a rotor that rotates relative to the stator, and a method for manufacturing the same. Background Art

[0002] For example, Patent Document 1 describes a brushless motor including a stator and a rotor that rotates relative to the stator. Specifically, a rotor is rotatably provided via a gap inside the radial direction of the stator, and metal balance correction portions are provided on both axial sides of a rotor core forming the rotor.

[0003] A pair of balance correction portions are fixed to a rotating shaft via bushings and are respectively disposed in close contact with end faces on both axial sides of the rotor core. Moreover, these balance correction portions have functions of preventing the permanent magnets provided inside the rotor core from flying out and correcting the rotational balance of the rotor by partially cutting off the outer peripheral portion.

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: Japanese Patent Application Laid-Open No. 2005-160196 Summary of the Invention

[0007] Problems to be Solved by the Invention

[0008] However, in the technology described in Patent Document 1, since the metal balance correction portion is provided in close contact with the permanent magnet, the following problem occurs: a part of the magnetic flux generated by the permanent magnet is directed toward the balance correction portion, and thus the magnetic flux directed toward the stator core is reduced. That is, as a result of providing the balance correction portion, problems such as a reduction in the output torque of the brushless motor occur.

[0009] An object of the present invention is to provide a motor device and a method for manufacturing the same that can adjust the rotational balance of a rotor while suppressing a reduction in output torque and the like.

[0010] Means for Solving the Problems

[0011] One embodiment of the present invention is a motor device including: a stator; and a rotor that rotates relative to the stator. In the motor device, the rotor includes: a rotating shaft; a rotor core fixed to the rotating shaft; a magnet fixed to the rotor core; and an adjustment member fixed to the rotating shaft and adjusting the rotational balance of the rotor. A separation distance between the magnet and the adjustment member in the axial direction of the rotating shaft is longer than a separation distance between the magnet and the stator in the radial direction of the rotating shaft.

[0012] Another embodiment of the present invention is a method for manufacturing a motor device, the motor device having: a stator; and a rotor that rotates relative to the stator. In the method for manufacturing the motor device, the rotor includes: a rotating shaft; a rotor core fixed to the rotating shaft; a magnet fixed to the rotor core; and an adjustment member fixed to the rotating shaft and adjusting the rotational balance of the rotor. The manufacturing method includes: a rotor core fixing step of fixing the rotor core to the rotating shaft; a magnet raw material fixing step of fixing the magnet raw material before magnetization to the rotor core; a rotational balance adjustment step of fixing the adjustment member at a position axially away from the magnet raw material on the rotating shaft and cutting the outer peripheral portion of the adjustment member; and a magnet magnetization step that is performed after the rotational balance adjustment step and magnetizes the magnet raw material.

[0013] Effects of the Invention

[0014] According to the present invention, a motor device including a structure capable of adjusting the rotational balance of a rotor while suppressing a decrease in output torque and the like, and a manufacturing method thereof can be realized. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a schematic diagram of a sunroof device provided on the roof of a vehicle.

[0016] Figure 2 is a perspective view showing the output gear side of the sunroof motor.

[0017] Figure 3 is a perspective view showing the cover member side of the sunroof motor.

[0018] Figure 4 is a sectional view of the sunroof motor along the axial direction of the rotating shaft.

[0019] Figure 5 is a perspective view of the rotor viewed from the worm side.

[0020] Figure 6 is a perspective view of the rotor viewed from the rotor core side.

[0021] Figure 7 is a perspective view of the bearing support member viewed from the motor part side.

[0022] Figure 8 is a perspective view of the bearing support member viewed from the speed reduction mechanism part side.

[0023] Figure 9 is a diagram for explaining the assembly sequence (1) of the rotor.

[0024] Figure 10 ​​​​​​​​​​is a diagram for explaining the assembly sequence (2) of the rotor.

[0025] Figure 11 is a diagram for explaining the assembly sequence (1) of the sunroof motor.

[0026] Figure 12 is a diagram for explaining the assembly sequence (2) of the sunroof motor. Detailed implementation mode

[0027] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0028] Figure 1 A schematic diagram showing a sunroof device provided on the roof of a vehicle, Figure 2 A perspective view showing the output gear side of the sunroof motor, Figure 3 A perspective view showing the cover member side of the sunroof motor, Figure 4 A sectional view of the sunroof motor along the axial direction of the rotation axis, Figure 5 A perspective view showing the rotor observed from the worm side, Figure 6 A perspective view showing the rotor observed from the rotor core side, Figure 7 A perspective view showing the bearing support member observed from the motor part side, Figure 8 A perspective view showing the bearing support member observed from the reduction gear mechanism part side.

[0029] <Summary of the sunroof device>

[0030] As Figure 1 shown, the sunroof device 10 includes a roof panel 11. The roof panel 11 opens / closes an opening 14 formed on the roof 13 of the vehicle 12. On both sides in the vehicle width direction of the roof panel 11 ( Figure 1 the upper and lower sides), a pair of shoes 15a, 15b are respectively fixed.

[0031] In addition, guide rails 16 extending in the front-rear direction of the vehicle 12 ( Figure 1 the left-right direction) are respectively fixed on both sides in the vehicle width direction of the opening 14 of the roof 13. Moreover, a pair of shoes 15a, 15b are respectively guided by the corresponding pair of guide rails 16, whereby the roof panel 11 moves in the front-rear direction of the vehicle 12.

[0032] One end of each of the drive cables 17a, 17b with gears is connected to the shoe 15b arranged on the rear side ( Figure 1 the right side) of the vehicle 12. The other ends of these drive cables 17a, 17b are arranged on the front side ( Figure 1 the left side) of the vehicle 12 closer to the opening 14.

[0033] ​​A sunroof motor 20 is provided inside the roof 13 on the front side of the vehicle 12 relative to the opening 14 and between the windshield FG. Moreover, the other ends of a pair of drive cables 17a, 17b are engaged with an output gear 47a provided on the sunroof motor 20.

[0034] Accordingly, when the sunroof motor 20 is driven, the pair of drive cables 17a, 17b move in opposite directions along their longitudinal directions. Therefore, the roof panel 11 is pushed and pulled by the pair of drive cables 17a, 17b via a pair of shoes 15b, thereby opening / closing the opening 14.

[0035] In addition, the sunroof motor 20 corresponds to the motor device in the present invention.

[0036] <Sunroof Motor>

[0037] As Figures 2 to 4 shown, the sunroof motor 20 includes an electric motor unit 30 and a reduction mechanism unit 40. These electric motor unit 30 and reduction mechanism unit 40 are fixed to each other by a total of three fixing screws SC.

[0038] <Electric Motor Unit>

[0039] The electric motor unit 30 uses a brushless motor and has a motor housing 31 formed in a bottomed cylindrical shape by deep drawing a steel plate or the like (magnetic body). The motor housing 31 forms the outer contour of the electric motor unit 30 and includes a side wall portion 31a having a substantially regular hexagonal cross section. In addition, one axial side ( Figures 2 to 4 the right side) of the side wall portion 31a is closed by a stepped bottom wall portion 31b.

[0040] <Stator>

[0041] As Figure 4 shown, a stator 32 is housed inside the motor housing 31. The stator 32 has a stator core 32a formed by laminating a plurality of thin steel plates (magnetic bodies). The stator core 32a is fixed to the motor housing 31 and includes a total of six teeth 32b (not shown in detail). Moreover, three-phase coils CL including U-phase, V-phase, and W-phase are respectively wound around these teeth 32b via insulators (insulating members) 32c.

[0042] <Rotor>

[0043] As Figures 4 to 6As shown in FIG. 1 , a rotor 33 is rotatably provided on the radial inner side of the stator 32 via a predetermined air gap AG. The rotor 33 rotates relative to the stator 32 and has a rotor core 33a formed in a substantially cylindrical shape. The rotor core 33a is formed by stacking a plurality of thin steel plates (magnetic bodies), and a total of four magnets MG are fixed to the radial outer side of the rotor core 33a using an adhesive or the like. Specifically, the magnets MG are arranged at equal intervals (90° intervals) in the circumferential direction of the rotor core 33a.

[0044] In addition, the radial outer side of each magnet MG fixed to the rotor core 33a is covered by a magnet holder 33b formed into a substantially cylindrical shape by a thin stainless steel plate or the like. The magnet holder 33b prevents the magnet MG from falling off the rotor core 33a. Thus, even if the rotor 33 rotates at a high speed, the magnet MG will not fall off from the rotor core 33a due to the centrifugal force at that time.

[0045] <Rotation axis>

[0046] The rotor core 33a is fixed to the rotating shaft 34. Specifically, the rotating shaft 34 is fixed to the rotation center of the rotor core 33a by press-fitting. In this way, the rotor 33 includes the rotating shaft 34, and the rotating shaft 34 is made of a round steel bar in order to ensure sufficient strength.

[0047] Furthermore, one axial side of the rotating shaft 34 ( Figure 4 The right side of the rotating shaft 34 is accommodated in the motor housing 31 and supported by the first metal member (radial bearing) BR1 installed on the bottom wall portion 31b of the motor housing 31 so as to be rotatable. Figure 4 The left side of the worm gear is accommodated in the housing 41 forming the speed reduction mechanism portion 40 and is supported rotatably by a second metal member (radial bearing) BR2 installed in the worm accommodation portion 49 of the housing 41.

[0048] In addition, the first metal member BR1 corresponds to the first bearing in the present invention, and the second metal member BR2 corresponds to the second bearing in the present invention.

[0049] In addition, a worm 35 forming a speed reduction mechanism SD is integrally provided on the other axial side of the rotating shaft 34. That is, the worm 35 is also made of a round steel bar. Thus, the rigidity of the worm 35 is improved, the worm 35 does not bend, and the worm 35 meshes with the worm wheel 46 reliably.

[0050] <Ball bearing>

[0051] Furthermore, a ball bearing 36 is provided at the axial center of the rotary shaft 34. That is, the ball bearing 36 supports the axial center of the rotary shaft 34 so as to be rotatable freely. In the axial direction of the rotary shaft 34, the rotor core 33a of the magnet MG and the ball bearing 36 are arranged in parallel, and the rotor core 33a of the magnet MG is arranged between the ball bearing 36 and the first metal member BR1.

[0052] In addition, the ball bearing 36 corresponds to the third bearing in the present invention.

[0053] Like the first metal member BR1 and the second metal member BR2, the ball bearing 36 supports the rotary shaft 34 so as to be rotatable freely, and includes: an inner ring (inner race) 36a formed of steel into a substantially cylindrical shape, and an outer ring (outer race) 36b formed of steel into a substantially cylindrical shape and having a diameter larger than that of the inner ring 36a. In addition, a plurality of balls (steel balls) 36c are provided between the inner ring 36a and the outer ring 36b.

[0054] Here, the inner ring 36a is fixed to the rotary shaft 34 by press-fitting. That is, the inner ring 36a rotates together with the rotary shaft 34. In addition, as Figure 4 shown, the outer diameter dimension D1 of the worm 35 is smaller than the outer diameter dimension D2 of the rotary shaft 34 (D1 < D2). Thus, the ball bearing 36 can be press-fitted into the rotary shaft 34 from the side of the worm 35 in the axial direction of the rotary shaft 34.

[0055] <Sensor magnet unit>

[0056] In addition, in the axial direction of the rotary shaft 34, a sensor magnet unit SMU is provided between the worm 35 and the ball bearing 36. The sensor magnet unit SMU has: a cylindrical bracket member BK fixed to the rotary shaft 34 by press-fitting, and a sensor magnet SM held by the bracket member BK. Here, the sensor magnet SM is used to detect the rotation state of the rotary shaft 34 (rotor 33), specifically, to detect the rotation direction, rotation speed, etc.

[0057] In addition, for the sensor magnet unit SMU, it also rotates together with the rotary shaft 34 like the inner ring 36a of the ball bearing 36. In addition, for the sensor magnet unit SMU, it can also be press-fitted into the rotary shaft 34 from the side of the worm 35 in the axial direction of the rotary shaft 34.

[0058] <Adjusting member>

[0059] Furthermore, in the axial direction of the rotary shaft 34, an adjusting member 37 for adjusting the rotational balance of the rotor 33 is provided between the ball bearing 36 and the rotor core 33a (magnet MG). The adjusting member 37 is formed into a substantially cylindrical shape by laminating a plurality of thin steel plates (magnetic bodies) 37a, and is fixed to the rotary shaft 34 by press-fitting.

[0060] In addition, the outer diameter dimension D3 of the adjustment member 37 (see Figure 12 ) is set to be less than the outer diameter dimension D4 of the rotor 33 (see Figure 12 ) (D3 < D4). Here, the outer diameter dimension D4 of the rotor 33 becomes the portion with the largest radial dimension of the magnet holder 33b.

[0061] The adjustment member 37 is arranged axially on the rotary shaft 34 between the ball bearing 36 and the rotor core 33a, and is arranged closer to the ball bearing 36 (the part closer to the ball bearing 36) than the magnet MG. Thus, as Figure 4 shown, a relatively long first gap G1 is formed axially on the rotary shaft 34 between the magnet MG and the adjustment member 37.

[0062] Here, a relatively short second gap G2 is formed radially on the rotary shaft 34 between the magnet MG and the stator 32. Moreover, when the comparison object for comparing the separation distance L1 between the magnet MG and the adjustment member 37 axially on the rotary shaft 34 is the separation distance L2 between the magnet MG and the stator 32 radially on the rotary shaft 34, the separation distance L1 is longer than the separation distance L2 (L1 > L2). Specifically, the separation distance L1 is "about 7 times" the separation distance L2 (L1 ≒ L2 × 7).

[0063] By arranging the adjustment member 37 to be farther from the magnet MG than the stator 32 in this way, the magnetic flux [Wb] of the total four magnets MG is suppressed from heading towards the adjustment member 37. In other words, the magnetic flux [Wb] of each magnet MG is efficiently directed towards the stator 32. Therefore, even if an adjustment member 37 containing a magnetic body is provided between the ball bearing 36 and the magnet MG, a decrease in the output torque of the sunroof motor 20 can be suppressed.

[0064] In addition, the adjustment member 37 has the following functions, that is, the function of suppressing the slight deformation of the rotary shaft 34 that varies for each product, or the slight positional deviation between the rotation center of the rotary shaft 34 and the rotation center of the rotor core 33a, etc., which causes rotational wobbling of the rotor 33. Specifically, when assembling the rotor 33, while rotating the rotor 33, a part of the outer periphery of the adjustment member 37 is cut to optimize the rotational balance of the rotor 33 (suppress rotational wobbling).

[0065] Thereby, the operating noise of the sunroof motor 20 can be reduced (the quietness can be improved). In particular, since the sunroof motor 20 is arranged above the driver or the passengers, it will be harsh when the operating noise is large. Therefore, for the sunroof motor 20, it is necessary to further improve the quietness. In addition, the assembly sequence of the rotor 33 regarding the adjustment of the rotational balance of the rotor 33 will be described in detail later.

[0066] <Bearing support member>

[0067] Furthermore, as Figure 4 , Figure 7 and Figure 8 shown, the electric motor unit 30 includes a bearing support member 38. The bearing support member 38 is formed into a prescribed shape from a resin material such as plastic. The bearing support member 38 includes a support main body 38a formed into a substantially flat plate shape, and a plurality of wall portions 38b that enter the housing 41. That is, the bearing support member 38 becomes a part installed in the housing 41.

[0068] A ring-shaped support portion 38c is integrally provided on the support main body 38a of the bearing support member 38. The ring-shaped support portion 38c includes a ring-shaped flat surface 38d facing the other axial side of the rotary shaft 34 ( Figure 4 the left side), and the ring-shaped flat surface 38d abuts against the outer ring 36b of the ball bearing 36 from one axial side thereof ( Figure 4 the right side). That is, the ring-shaped support portion 38c supports the entire circumference on one axial side of the outer ring 36b. In addition, the other axial side of the outer ring 36b ( Figure 4 the left side) is supported by a bearing installation portion 50 provided in the housing 41.

[0069] In this way, the outer ring 36b of the ball bearing 36 is clamped between the housing 41 and the bearing support member 38 in the axial direction of the rotary shaft 34. Here, by fixing the motor housing 31 to the housing 41 using a total of three fixing screws SC, the bearing support member 38 is fixed inside the housing 41 without wobbling. That is, the bearing support member 38 is clamped between the outer ring 36b and the motor housing 31 in the axial direction of the rotary shaft 34.

[0070] In addition, a total of three positioning protrusions 38e are integrally provided on the ring-shaped support portion 38c. These positioning protrusions 38e extend in the circumferential direction of the ring-shaped support portion 38c and are formed into a substantially arc shape. In addition, these positioning protrusions 38e are arranged at equal intervals (120-degree intervals) in the circumferential direction of the ring-shaped support portion 38c. Furthermore, each positioning protrusion 38e protrudes toward the other axial side of the ring-shaped support portion 38c ( Figure 4 the left side). Moreover, the outer ring 36b of the ball bearing 36 enters the inside of the total of three positioning protrusions 38e in a contacting manner.

[0071] Thereby, when assembling the sunroof motor 20, the axis of the ball bearing 36 can be accurately aligned (centered) with the axis of the ring-shaped support portion 38c. In other words, the ball bearing 36 has a function of positioning the bearing support member 38 at a regular position via each positioning protrusion 38e.

[0072] Furthermore, on the radially inner side of the annular support portion 38c, there are provided a through small-diameter hole 38f and a through large-diameter hole 38g that penetrate axially along the annular support portion 38c. In addition, the inner diameter dimension D5 of the through small-diameter hole 38f is smaller than the inner diameter dimension D6 of the through large-diameter hole 38g (D5 < D6).

[0073] Here, as Figure 4 shown, an adjustment member 37 is disposed on the radially inner side of the through small-diameter hole 38f and the through large-diameter hole 38g. Moreover, since the annular support portion 38c has a size capable of supporting the outer ring 36b of the ball bearing 36 from one axial side, a relatively large dead angle DS is formed on the radially inner side of the through small-diameter hole 38f and the through large-diameter hole 38g.

[0074] By effectively utilizing the dead angle DS, the adjustment member 37 is disposed in the dead angle DS. Therefore, by providing the adjustment member 37 on the rotary shaft 34, the overall size of the housing 41 or the skylight motor 20 is not increased.

[0075] In addition, on the support main body 38a, a total of three conductive members 39 (refer to Figure 4 ) are provided corresponding to the three-phase coil CL (refer to Figure 8 ). These conductive members 39 are formed in a substantially rod shape from brass or the like with excellent conductivity, and one side in the long side direction thereof ( Figure 7 the near front side) is electrically connected to the three-phase coil CL respectively. In contrast, the other side in the long side direction of the conductive member 39 ( Figure 8 the left side) can be electrically connected to the connection terminals (not shown) of the external connector provided on the vehicle 12 (refer to Figure 1 ) side. Thereby, a drive current is supplied from an in-vehicle controller or the like to the three-phase coil CL of the skylight motor 20, and further the rotary shaft 34 is rotated forward or backward.

[0076] Thus, the bearing support member 38 has, on the basis of the function of supporting the ball bearing 36, the function of holding a total of three conductive members 39.

[0077] <Reduction mechanism portion>

[0078] As Figures 2 to 4 shown, the reduction mechanism portion 40 includes a housing 41 that houses the reduction mechanism SD. The housing 41 is formed in a substantially flat rectangular parallelepiped shape from a resin material such as plastic, and has a first wall portion 42, a second wall portion 43, and a third wall portion 44. Among the first wall portion 42, the second wall portion 43, and the third wall portion 44, the proportion of the first wall portion 42 is the largest.

[0079] As Figure 4As shown, a worm wheel housing portion 45 is provided inside the housing 41. The worm wheel housing portion 45 is disposed in a portion close to the third wall portion 44. Moreover, a worm wheel 46 forming a speed reduction mechanism SD is rotatably housed inside the worm wheel housing portion 45. Here, the worm wheel 46 is made of a resin material such as plastic and is lightweight. A tooth portion 46a is provided on the worm wheel 46, and the tooth portion 46a meshes with the worm 35 inside the housing 41.

[0080] That is, the speed reduction mechanism SD becomes a worm reducer capable of obtaining a relatively large speed reduction ratio. Specifically, in the present embodiment, the speed reduction ratio of the speed reduction mechanism SD is [1:67]. That is, it becomes a speed reduction ratio such that when the worm 35 rotates 67 turns, the worm wheel 46 finally rotates 1 turn. Of course, other speed reduction ratios can also be set.

[0081] In addition, the axial base end side of an output shaft 47 including a round steel bar is fixed to the rotation center of the worm wheel 46. In contrast, an output gear 47a for meshing with a pair of drive cables 17a, 17b (refer to Figure 1 ) is integrally provided on the axial front end side of the output shaft 47 (refer to Figure 2 ).

[0082] Therefore, the high-speed rotation of the rotating shaft 34 is decelerated by the speed reduction mechanism SD, and the rotational force decelerated and increased in torque is transmitted to the pair of drive cables 17a, 17b via the output shaft 47 and the output gear 47a. In addition, the speed reduction mechanism SD is formed by the worm 35 and the worm wheel 46.

[0083] Here, the side of the worm wheel housing portion 45 opposite to the first wall portion 42 side is open (not shown). Moreover, as Figure 3 shown, the opening portion of the worm wheel housing portion 45 is closed by a cover member 48 formed by pressing a steel plate or the like into a substantially circular plate shape.

[0084] In addition, as Figure 4 shown, a worm housing portion 49 is provided inside the housing 41. The worm housing portion 49 is disposed in a portion close to the second wall portion 43. Moreover, the worm housing portion 49 is disposed near the worm wheel housing portion 45, and the interiors of these housing portions 49, 45 communicate with each other. Thereby, the worm 35 and the tooth portion 46a can mesh with each other.

[0085] The worm housing portion 49 extends in the axial direction of the rotating shaft 34, and a second metal member BR2 that rotatably supports the other axial side of the rotating shaft 34 is housed on the other axial side of the worm housing portion 49 ( Figure 4 the left side).

[0086] Furthermore, a bearing mounting portion 50 is provided inside the housing 41. The bearing mounting portion 50 is disposed on one axial side of the worm housing portion 49 ( Figure 4to the right), opening toward the motor housing 31. A ball bearing 36 is housed inside the bearing mounting portion 50, and the entire circumference on the other axial side ( Figure 4 to the left) of the outer ring 36b is supported by the bearing mounting portion 50.

[0087] In addition, a support ring SR formed in a substantially cylindrical shape is fixed to the bearing mounting portion 50 by press-fitting. The support ring SR is formed of a sintered material obtained by compacting metal powder, for example. Further, the outer ring 36b is disposed via a minute gap (not shown) on the radially inner side of the support ring SR. Here, the outer diameter dimension D7 (see Figure 12 ) of the ball bearing 36 is larger than the inner diameter dimension D5 (see Figure 12 ) of the through small-diameter hole 38f in the annular support portion 38c (D7 > D5).

[0088] As Figure 4 shown, the rotating shaft 34 is supported at three points by the first metal member BR1, the second metal member BR2, and the ball bearing 36. Thereby, when the skylight motor 20 operates, the situation where the worm 35 moves away from the tooth portion 46a of the worm wheel 46 (mutual meshing disengagement) can be suppressed, and thus power can be reliably transmitted to each other.

[0089] Further, the inner ring 36a is fixed to the rotating shaft 34, and the outer ring 36b is clamped between the bearing mounting portion 50 and the bearing support member 38. Therefore, the rotating shaft 34 does not move in its axial direction. Accordingly, it is not necessary to provide thrust bearings on both axial sides of the rotating shaft 34, thereby achieving a reduction in the number of parts.

[0090] On the other hand, in order to smoothly rotate the rotating shaft 34 with three-point support, it is necessary to improve the accuracy of the parts forming the skylight motor 20. However, such an improvement in part accuracy leads to complication of the manufacturing process or an increase in the product cost, and thus is not practical. Therefore, in the present embodiment, the ball bearing 36 (outer ring 36b) is disposed via a minute gap on the radially inner side of the support ring SR.

[0091] Thereby, the minute gap absorbs the manufacturing error of the parts or the difference in linear expansion between the parts. Therefore, smooth rotation of the rotating shaft 34 can be ensured. As described above, the minute gap between the support ring SR and the outer ring 36b has a function of absorbing the manufacturing error of the parts forming the skylight motor 20 or the difference in linear expansion between the parts.

[0092] <Motor housing portion>

[0093] In addition, as Figure 4 , Figure 11 and Figure 12 shown, a motor housing portion 51 formed in a substantially box shape is provided inside the housing 41. The motor housing portion 51 is disposed on the motor housing 31 side of the bearing mounting portion 50 in the axial direction of the rotating shaft 34Figure 4 to the right side).

[0094] A part of the electric motor unit 30 is housed in the motor housing portion 51. Specifically, as Figure 4 shown, the wall portion 38b of the bearing support member 38 forming the electric motor unit 30 enters the motor housing portion 51.

[0095] <Metal sheath>

[0096] Here, as Figure 2 and Figure 3 shown, a metal sheath 60 formed by bending a thin steel plate is partially installed on the outer side of the housing 41. The metal sheath 60 has a function of preventing the electrical noise generated inside the housing 41 from radiating to the outside of the housing 41. Thus, the electrical noise cannot reach in-vehicle audio etc. (not shown) mounted on the vehicle 12 (refer to Figure 1 ), and the generation of radio noise etc. can be suppressed.

[0097] <Assembly sequence>

[0098] Next, the assembly sequence of the rotor 33 and the assembly sequence (manufacturing method) of the sunroof motor 20 formed as described above will be described in detail with reference to the drawings.

[0099] Figure 9 FIG. shows the assembly sequence (1) of the rotor, Figure 10 FIG. shows the assembly sequence (2) of the rotor, Figure 11 FIG. shows the assembly sequence (1) of the sunroof motor, Figure 12 FIG. shows the assembly sequence (2) of the sunroof motor.

[0100] <Assembly sequence of the rotor>

[0101] As Figure 9 and Figure 10 shown, when assembling the rotor 33, a rotating shaft 34, a rotor core 33a, a magnet raw material MM before magnetization, a magnet holder 33b, an adjustment member 37, a ball bearing 36, and a sensor magnet unit SMU are prepared.

[0102] <Knurling>

[0103] Then, as Figure 9 shown, a knurling process of forming a knurl K along the axial direction on the surface of the rotating shaft 34 is performed. Here, the knurling process is a process of forming serrations (knurls) on the surface, and thereby, the rotor core 33a and the adjustment member 37 can be firmly fixed to the rotating shaft 34 by press-fitting.

[0104] <Press-fitting of the rotor core>

[0105] Next, perform the operation of pressing and fixing the rotor core 33a onto the rotating shaft 34. Specifically, as shown by the arrow M1 in Figure 9 , perform the operation of pressing the rotor core 33a onto the rotating shaft 34 from the other axial side of the rotating shaft 34, that is, from the side of the worm 35. Then, position the rotor core 33a at a specified position in the axial direction of the rotating shaft 34. Here, the process of fixing the rotor core 33a to the rotating shaft 34 corresponds to the rotor core fixing process in the present invention.

[0106] <Installation of magnet raw material>

[0107] Thereafter, perform the operation of fixing the magnet raw material MM before magnetization to the radially outer side of the rotor core 33a fixed to the rotating shaft 34. Specifically, apply an adhesive (not shown) to the inside of a total of four magnet raw materials MM, and as shown by the arrow M2 in Figure 9 , install each magnet raw material MM on the outer peripheral portion of the rotor core 33a. Here, since the magnet raw material MM is before magnetization, it does not have magnetic force and thus the installation operation of the magnet raw material MM onto the rotor core 33a can be easily performed. Here, the process of fixing the magnet raw material MM before magnetization to the rotor core 33a corresponds to the magnet raw material fixing process in the present invention.

[0108] <Installation of magnet retainer>

[0109] Next, as shown by the arrow M3 in Figure 9 , perform the operation of installing the magnet retainer 33b on the outer peripheral portion of each magnet raw material MM. Specifically, install the magnet retainer 33b from the axial side of the rotating shaft 34 ( Figure 9 the upper side). Then, position the magnet retainer 33b at a specified position in the axial direction of the rotating shaft 34, that is, at a position that completely covers the outer peripheral portion of the magnet raw material MM.

[0110] <Balancing adjustment operation>

[0111] Thereafter, as shown by the arrow M4 in Figure 10 , fix the adjustment member 37 to the rotating shaft 34 by pressing. Specifically, perform the operation of pressing the adjustment member 37 onto the rotating shaft 34 from the side of the worm 35 in the axial direction of the rotating shaft 34. Here, fix the adjustment member 37 at a position in the axial direction of the rotating shaft 34 that is separated from the magnet raw material MM by a separation distance L1 (refer to Figure 4 ).

[0112] Next, install the rotating shaft 34 equipped with the magnet retainer 33b and the adjustment member 37 on a balancing adjustment device (not shown in detail), and rotate the rotating shaft 34 as shown by the arrow RT in Figure 10 . At this time, as shown by the arrow in Figure 10As shown by arrow M5, a pair of support arms AM provided in the balance adjustment device is inserted into the first gap G1 between the magnet raw material MM (magnet holder 33b) and the adjustment member 37, and the rotating shaft 34 is supported by the pair of support arms AM.

[0113] Thereafter, while the rotating shaft 34 is rotated as indicated by the arrow RT, Figure 10 As shown by the arrow M6, the cutting blade CB provided in the balance adjustment device is brought into contact with the outer periphery of the adjustment member 37 and moved, thereby partially cutting the outer periphery of the adjustment member 37. In this way, the rotational shaking of the rotor 33 caused by the slight deformation of the rotating shaft 34 that is different for each product or the slight positional deviation between the rotation center of the rotating shaft 34 and the rotation center of the rotor core 33a can be suppressed.

[0114] Here, the steel plate 37a (see Figure 5 and Figure 6 ) is determined by the specifications of the sunroof motor 20, specifically, by the length or weight of the rotating shaft 34 (rotor 33). That is, by adjusting the number of steel plates 37a according to the adjusting member 37, a rough adjustment can be made, and the reduction work of the adjusting member 37 as described above can be completed with a minimum in the subsequent fine adjustment. Therefore, the operation time of the reduction work can be shortened, and the discharge amount of the cut chips can be suppressed to a minimum.

[0115] In addition, during the balancing operation, due to the different magnet raw materials MM (refer to Figure 9 ) does not have magnetic force, so the cut chips (cutting chips) of the adjustment member 37 will not adhere to the magnet raw material MM or the magnet holder 33b. By performing the balance adjustment operation before magnetization, the assembly workability can be improved.

[0116] Here, the step of fixing the adjustment member 37 at a position separated from the magnet material MM by the separation distance L1 in the axial direction of the rotating shaft 34 and trimming the outer periphery of the adjustment member 37 to perform balance adjustment corresponds to the rotation balance adjustment step in the present invention.

[0117] <Magnetic work>

[0118] After completing the balancing operation, Figure 10 As shown, the <magnetization operation> is performed. Specifically, the rotor 33 after the balance adjustment is completed is installed in the magnetization device (not shown in detail). At this time, a total of four magnet raw materials MM (magnet holders 33b) are installed on the radial inner side of the air-core coil AC forming the magnetization device. Then, a magnetization current is passed through the air-core coil AC to generate a magnetic field MF on the radial inner side thereof (refer to Figure 10The hollow arrow). Thus, each magnet raw material MM (refer to Figure 9 ) is magnetized and becomes a magnet MG (refer to Figure 4 ) with magnetic force. Here, the process of magnetizing a total of four magnet raw materials MM corresponds to the magnet magnetization process in the present invention.

[0119] <Other Component Installation>

[0120] After that, as shown by the arrow M7 in Figure 10 , the operation of installing the ball bearing 36 and the sensor magnet unit SMU with respect to the rotary shaft 34 from the worm 35 side of the rotary shaft 34 is performed. In addition, both the ball bearing 36 and the sensor magnet unit SMU are fixed to the rotary shaft 34 by press-fitting.

[0121] In addition, the ball bearing 36 uses a high-precision ball bearing as a general-purpose product, and the sensor magnet unit SMU has a small diameter and is lightweight. Therefore, even after the balance adjustment, the rotational balance of the rotor 33 (rotary shaft 34) will not collapse. Thus, as shown in Figure 10 <Completion> of

[0122] <Assembly Sequence of Sunroof Motor>

[0123] Next, the assembly sequence of the rotor 33 (rotor assembly RA) after the assembly is completed into the housing 41, that is, the assembly sequence of the sunroof motor 20, will be described in detail with reference to the drawings.

[0124] Here, referring to Figure 12 , the size relationship of the outer diameter dimension D3 of the adjusting member 37, the outer diameter dimension D4 of the rotor 33, the inner diameter dimension D5 of the through small-diameter hole 38f, the inner diameter dimension D6 of the through large-diameter hole 38g, and the outer diameter dimension D7 of the ball bearing 36 is D6≒D7>D5>D4>D3.

[0125] Thus, the rotor 33 and the adjusting member 37 can be inserted radially inside the annular support portion 38c, and the annular flat surface 38d can be brought into contact with the entire circumference on the axial side of the outer ring 36b. Therefore, as shown in Figure 11 and Figure 12 , the sunroof motor 20 can be easily assembled.

[0126] <Assembly Sequence (1)>

[0127] As shown in Figure 11 , first, the housing 41, the second metal member BR2, the support ring SR, and the rotor assembly RA are prepared. Here, the rotor assembly RA is Figure 10 the rotor 33 after the assembly is completed as shown in <Completion> of

[0128] Then, along the dotted line, first mount the second metal part BR2 on the worm housing part 49. Next, mount the support ring SR on the bearing mounting part 50. After that, turn the worm 35 side in the axial direction of the rotor assembly RA towards the motor housing part 51. Then, house the worm 35 of the rotor assembly RA in the worm housing part 49 and mount the ball bearing 36 on the bearing mounting part 50.

[0129] At this time, support the worm 35 side of the rotating shaft 34 with the second metal part BR2 and insert the outer ring 36b into the support ring SR. In addition, since a minute gap (not shown) is provided between the outer ring 36b and the support ring SR, the operation of mounting the rotor assembly RA on the housing 41 can be easily performed.

[0130] Thus, the operation of mounting the rotor assembly RA on the housing 41 is completed. Here, the housing 41 on which the rotor assembly RA is mounted through <Assembly sequence (1)> is defined as the housing assembly HA.

[0131] <Assembly sequence (2)>

[0132] Next, as Figure 12 shown, prepare the housing assembly HA, the bearing support member 38, the motor assembly MA, and a total of three fixing screws SC. In addition, a total of three conductive members 39 are mounted on the bearing support member 38. The so-called motor assembly MA is an assembly in which the first metal part BR1 is mounted on the bottom wall part 31b of the motor housing 31 and the stator 32 is fixed to the side wall part 31a of the motor housing 31.

[0133] Then, along the dotted line, first turn the housing 41 side of the bearing support member 38 towards the motor housing part 51. Next, insert the plurality of wall parts 38b provided on the bearing support member 38 into the motor housing part 51. At this time, since the outer diameter dimension D3 of the adjustment member 37 and the outer diameter dimension D4 of the rotor 33 are smaller than the inner diameter dimension D5 of the through-hole small diameter hole 38f in the annular support part 38c (D3 < D4 < D5), the adjustment member 37 and the rotor 33 can be easily inserted through the radial inner side of the through-hole small diameter hole 38f.

[0134] After that, the outer ring 36b enters the inside of a total of three positioning protrusions 38e provided on the bearing support member 38. Moreover, since the inner diameter dimension D5 of the through-hole small diameter hole 38f is smaller than the outer diameter dimension D7 of the outer ring 36b (D5 < D7), the entire circumference of the annular flat surface 38d in the annular support part 38c abuts against one axial side of the outer ring 36b. In addition, the adjustment member 37 is arranged in the dead angle DS (refer to Figure 4 ) formed on the radial inner side of the annular support part 38c.

[0135] In this way, the other axial side of the outer ring 36b ( Figure 12The entire circumference on the left side) is supported by the bearing mounting portion 50, and the entire circumference on the axial side ( Figure 12 the right side) of the outer ring 36b is supported by the annular flat surface 38d of the annular support portion 38c. Therefore, tilting of the ball bearing 36 (rotating shaft 34) can be suppressed.

[0136] Next, the motor assembly MA is faced toward the motor housing portion 51. At this time, the bearing support member 38 side of the motor housing 31 is faced toward the motor housing portion 51. Then, while inserting the rotor 33 inside the stator 32 radially, the opening side of the motor housing 31 is brought into contact with the housing 41. At this time, the first metal member BR1 supports the axial side of the rotating shaft 34.

[0137] At this time, the bearing support member 38 is positioned by the outer ring 36b, and the motor assembly MA is positioned by the rotating shaft 34. In addition, the ball bearing 36 and the rotating shaft 34 are arranged coaxially with good mutual precision. Therefore, the bearing support member 38 and the motor assembly MA are also arranged coaxially with good mutual precision. Thereby, it is possible to easily and accurately position the total three conductive members 39 and the three-phase coil CL, and they can be easily electrically connected to each other (improve the assemblability).

[0138] Thereafter, using a fastening tool such as a cross screwdriver (not shown), a total of three fixing screws SC are screwed to the housing 41. Thereby, the motor housing 31 and the housing 41 are firmly fixed to each other. Thus, after the rotor assembly RA is installed in the housing 41, the bearing support member 38 and the motor assembly MA are installed in the housing assembly HA, and the fixing operation of the bearing support member 38 and the motor assembly MA to the housing assembly HA is completed.

[0139] In addition, after <Assembly sequence (2)>, the worm wheel 46 (refer to Figure 4 ) is housed in the worm wheel housing portion 45 of the housing 41, and the opening portion of the worm wheel housing portion 45 is closed by the cover member 48 (refer to Figure 3 ). Thereby, the assembly operation of the sunroof motor 20 is completed.

[0140] As described in detail above, according to the present embodiment, the rotor 33 includes: a rotating shaft 34; a rotor core 33a fixed to the rotating shaft 34; a magnet MG fixed to the rotor core 33a; and an adjustment member 37 fixed to the rotating shaft 34 and adjusting the rotational balance of the rotor 33, and the separation distance L1 between the magnet MG and the adjustment member 37 in the axial direction of the rotating shaft 34 is longer than the separation distance L2 between the magnet MG and the stator 32 in the radial direction of the rotating shaft 34 (L1 > L2).

[0141] Accordingly, the rotational balance of the rotor 33 can be adjusted, and the adjusting member 37 can be arranged to be farther from the magnet MG than the stator 32. Therefore, it is possible to suppress the magnetic flux [Wb] of the magnet MG from reaching the adjusting member 37, and the magnetic flux [Wb] of the magnet MG can efficiently reach the stator 32. As a result, a decrease in the output torque of the sunroof motor 20 can also be suppressed.

[0142] In addition, according to the present embodiment, since the adjusting member 37 is formed in a cylindrical shape by laminating a plurality of steel plates 37a, a rough adjustment can be performed by adjusting the number of the steel plates 37a, and the reduction operation of the adjusting member 37 in subsequent fine adjustment can be minimized. Therefore, the operation time of the reduction operation can be shortened, and the discharge amount of cutting chips can be suppressed to the minimum.

[0143] Furthermore, according to the present embodiment, since the outer diameter dimension D3 of the adjusting member 37 is equal to or less than the outer diameter dimension D4 of the rotor 33, the bearing support member 38 having a through small-diameter hole 38f with an inner diameter dimension D5 (D5 > D4 > D3) can be easily installed from the axial side (the side opposite to the worm 35 side) of the rotary shaft 34 (see Figure 12 ). Therefore, the assemblability of the sunroof motor 20 is not deteriorated.

[0144] In addition, according to the present embodiment, in the rotary shaft 34, the axial side is rotatably supported by the first metal member BR1, the axial other side is rotatably supported by the second metal member BR2, and the axial center portion is rotatably supported by the ball bearing 36, and the adjusting member 37 is arranged between the ball bearing 36 and the rotor core 33a. Accordingly, a relatively large space in the axial direction of the rotary shaft 34 can be effectively used for the arrangement of the adjusting member 37, and further, an increase in the overall size of the sunroof motor 20 can be suppressed.

[0145] Furthermore, according to the present embodiment, the rotor 33 can be assembled through a rotor core fixing process, a magnet raw material fixing process, a rotational balance adjustment process, and a magnet magnetization process. The rotor core fixing process is to fix the rotor core 33a to the rotary shaft 34, the magnet raw material fixing process is to fix the magnet raw material MM before magnetization to the rotor core 33a, the rotational balance adjustment process is to fix the adjusting member 37 at a position axially away from the magnet raw material MM on the rotary shaft 34 and cut the outer peripheral portion of the adjusting member 37, and the magnet magnetization process is performed after the rotational balance adjustment process and magnetizes the magnet raw material MM.

[0146] Accordingly, it is completed without allowing the cutting chips of the adjusting member 37 to adhere to the magnet raw material MM or the magnet holder 33b. Thus, by performing the balance adjustment operation before magnetization, an improvement in assemblability can be achieved.

[0147] In addition, according to the present embodiment, as described above, for example, the operation time of the reduction operation can be shortened, and the discharge amount of the reduced chips can be suppressed to the minimum, so that manufacturing energy conservation can be achieved, and thus the Sustainable Development Goals (SDGs) established by the United Nations, in particular Goal 7 (Ensure access for all to affordable, reliable and sustainable modern energy) and Goal 13 (Take urgent action to combat climate change and its impacts), can be achieved.

[0148] The present invention is not limited to the above-described embodiment, and of course, various modifications can be made without departing from its gist. In the above embodiment, an example of applying the present invention to the sunroof motor 20 used in the sunroof device 10 of the vehicle 12 is shown, but the present invention is not limited thereto. For example, it can also be applied to in-vehicle motors (motor devices) used in sliding door devices, electric window devices, wiper devices, etc. mounted on vehicles.

[0149] In addition, the material, shape, size, number, installation position, etc. of each component in the above embodiment are arbitrary as long as the object of the present invention can be achieved, and are not limited to the above embodiment.

[0150] Explanation of reference numerals

[0151] 10: Sunroof device

[0152] 11: Roof panel

[0153] 12: Vehicle

[0154] 13: Roof

[0155] 14: Opening

[0156] 15a, 15b: Shoe

[0157] 16: Guide rail

[0158] 17a, 17b: Drive cable

[0159] 20: Sunroof motor (motor device)

[0160] 30: Electric motor part

[0161] 31: Motor housing

[0162] 31a: Side wall part

[0163] 31b: Bottom wall part

[0164] 32: Stator

[0165] 32a: Stator core

[0166] 32b: Tooth

[0167] 33: Rotor

[0168] 33a: Rotor core

[0169] 33b: Magnet holder

[0170] 34: Rotating shaft

[0171] 35: Worm

[0172] 36: Ball bearing (third bearing)

[0173] 36a: Inner ring

[0174] 36b: Outer ring

[0175] 37: Adjusting member

[0176] 37a: Steel plate

[0177] 38: Bearing support member

[0178] 38a: Support body

[0179] 38b: Wall portion

[0180] 38c: Annular support portion

[0181] 38d: Annular flat surface

[0182] 38e: Positioning protrusion

[0183] 38f: Through-hole with small diameter

[0184] 38g: Through-hole with large diameter

[0185] 39: Conductive member

[0186] 40: Reduction gear mechanism portion

[0187] 41: Housing

[0188] 42: First wall portion

[0189] 43: Second wall portion

[0190] 44: Third wall portion

[0191] 45: Worm wheel housing portion

[0192] 46: Worm wheel

[0193] 46a: Tooth portion

[0194] 47: Output shaft

[0195] 47a: Output gear

[0196] 48: Cover member

[0197] 49: Worm housing part

[0198] 50: Bearing installation part

[0199] 51: Motor housing part

[0200] 60: Metal sheath

[0201] AC: Air-core coil

[0202] AG: Air gap

[0203] AM: Support arm

[0204] BK: Bracket member

[0205] BR1: First metal part (first bearing)

[0206] BR2: Second metal part (second bearing)

[0207] CB: Cutting tool

[0208] CL: Coil

[0209] DS: Dead angle

[0210] FG: Windshield

[0211] G1: First gap

[0212] G2: Second gap

[0213] HA: Housing assembly

[0214] K: Knurling

[0215] L1, L2: Separation distance

[0216] MA: Motor assembly

[0217] MF: Magnetic field

[0218] MG: Magnet

[0219] MM: Magnet raw material

[0220] RA: Rotor assembly

[0221] SC: Fixing screw

[0222] SD: Reduction mechanism

[0223] SM: Sensor magnet

[0224] SMU: Sensor magnet unit

[0225] SR: Support ring

Claims

1. A motor device, comprising: stator; as well as The rotor rotates relative to the stator, and in the motor device, The rotor comprises: Axis of rotation; A rotor core fixed to the rotating shaft; a magnet fixed to the rotor core; and an adjusting member, fixed to the rotating shaft, and adjusting the rotational balance of the rotor, A separation distance between the magnet and the adjustment member in the axial direction of the rotating shaft is longer than a separation distance between the magnet and the stator in the radial direction of the rotating shaft.

2. The motor device according to claim 1, wherein: The adjustment member is formed into a cylindrical shape by laminating a plurality of steel plates.

3. The motor device according to claim 2, wherein: The outer diameter of the adjustment member is smaller than the outer diameter of the rotor.

4. The motor device according to claim 1, wherein: The rotating shaft is rotatably supported by a first bearing on one axial side, rotatably supported by a second bearing on the other axial side, and rotatably supported by a third bearing on the axial center. The adjustment member is arranged between the third bearing and the rotor core.

5. A method for manufacturing a motor device, the motor device comprising: stator; as well as The rotor rotates relative to the stator. In the method for manufacturing the motor device, The rotor comprises: Axis of rotation; A rotor core fixed to the rotating shaft; a magnet fixed to the rotor core; and an adjusting member, fixed to the rotating shaft, and adjusting the rotational balance of the rotor, The manufacturing method has the following features: a rotor core fixing step of fixing the rotor core to the rotating shaft; A magnet raw material fixing step, fixing the magnet raw material before magnetization on the rotor core; a rotation balance adjustment step of fixing the adjustment member at a position away from the magnet raw material in the axial direction of the rotating shaft and trimming the outer periphery of the adjustment member; and The magnet magnetizing step is performed after the rotation balance adjusting step and magnetizes the magnet material.

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