Motor device

Abstract

The invention provides a motor device which can reduce the number of parts and can be easily assembled. The motor device includes: a motor case 31 to which a stator 32 is fixed; a housing (41) which is in contact with the motor housing (31); a rotating shaft 34 housed inside the motor case 31 and the case 41; a first metal piece BR1 which is arranged on the motor shell 31 and supports the axial direction base end side of the rotating shaft 34; a second metal piece BR2 which is provided in the housing 41 and supports the axial front end side of the rotating shaft 34; a ball bearing 36 provided between the first metal piece BR1 and the second metal piece BR2 in the axial direction of the rotating shaft 34 and supporting the rotating shaft 34; and a holder member (38) that is positioned by the ball bearing (36) and holds the plurality of conductive members (39), the holder member (38) being sandwiched between the motor case (31) and the ball bearing (36).

Description

Technical Field

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

[0002] For example, Patent Document 1 describes a skylight motor including a motor unit and a gear unit. A first radial bearing is provided in a yoke forming the motor unit, and a second radial bearing is provided in a brush holder installed in an opening of the yoke. Moreover, the armature shaft is rotatably supported by these first and second radial bearings.

[0003] On the other hand, a third radial bearing and a ball bearing are installed on a gear case forming the gear unit, and the worm shaft is rotatably supported by these third radial bearing and ball bearing. In addition, a connecting member is provided between the armature shaft and the worm shaft to connect the two so as to be able to transmit power to each other.

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: Japanese Patent Application Laid-Open No. 2019-129566 Summary of the Invention

[0007] Problems to be Solved by the Invention

[0008] However, in the technology described in Patent Document 1, the armature shaft is supported by a pair of bearings provided on the yoke, the worm shaft is supported by a pair of bearings provided on the gear case, and the armature shaft and the worm shaft are connected to each other by a connecting member. Therefore, in addition to the large number of parts, it is also necessary to accurately arrange and install the motor unit and the gear unit coaxially, and the assembly work is troublesome.

[0009] An object of the present invention is to provide a motor device that can reduce the number of parts and can be easily assembled.

[0010] Technical Means for Solving the Problems

[0011] An embodiment of the present invention is a motor device, comprising: a stator; and a rotor that rotates relative to the stator, the motor device including: a first housing in which the stator is fixed inside; a second housing that abuts against the first housing in the axial direction of the rotor; a rotating shaft that is provided on the rotor and is rotatably received inside the first housing and the second housing; a first bearing that is provided on the first housing and rotatably supports the axial base end side of the rotating shaft; a second bearing that is provided on the second housing and rotatably supports the axial front end side of the rotating shaft; a third bearing that is provided between the first bearing and the second bearing in the axial direction of the rotating shaft and rotatably supports the rotating shaft; and a holder member that is positioned by the third bearing and holds a plurality of conductive members, the holder member being clamped by the first housing and the third bearing in the axial direction of the rotor.

[0012] Effects of the Invention

[0013] Through the present invention, a motor device that can reduce the number of parts and can be easily assembled can be achieved. Description of the Drawings

[0014] Figure 1 is a schematic diagram of a sunroof device provided on the roof of a vehicle.

[0015] Figure 2 is a perspective view showing the output gear side of the sunroof motor.

[0016] Figure 3 is a perspective view showing the cover member side of the sunroof motor.

[0017] Figure 4 is a sectional view of the sunroof motor along the axial direction of the rotating shaft.

[0018] Figure 5 is a perspective view of the rotor viewed from the worm side.

[0019] Figure 6 is a perspective view of the holder member viewed from the reduction mechanism portion side.

[0020] Figure 7 is Figure 6 A arrow view of.

[0021] Figure 8 is a sectional view for explaining the first positioning portion.

[0022] Figure 9 is a sectional view for explaining the second positioning portion.

[0023] Figure 10 is a sectional view for explaining the third positioning portion.​​​​​​​​​​

[0024] Figure 11 is a diagram for explaining the assembly sequence (1) of the skylight motor.

[0025] Figure 12 is a diagram for explaining the assembly sequence (2) of the skylight motor. Detailed implementation mode

[0026] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0027] Figure 1 A schematic diagram showing a skylight device provided on the roof of a vehicle, Figure 2 A perspective view showing the output gear side of the skylight motor, Figure 3 A perspective view showing the cover member side of the skylight motor, Figure 4 A sectional view of the skylight 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 retainer member observed from the reduction mechanism part side, Figure 7 Showing Figure 6 The A arrow view of Figure 8 A sectional view for explaining the first positioning part, Figure 9 A sectional view for explaining the second positioning part, Figure 10 A sectional view for explaining the third positioning part.

[0028] <Sketch of the skylight device>

[0029] As Figure 1 shown, the skylight 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 of

[0030] ), a pair of shoes 15a, 15b are respectively fixed. Figure 1 In addition, on both sides in the vehicle width direction of the opening 14 of the roof 13, guide rails 16 extending in the front-rear direction of the vehicle 12 (

[0031] the left-right direction of Figure 1 the vehicle 12) are respectively fixed. Moreover, a pair of shoes 15a, 15b are respectively guided by a corresponding pair of guide rails 16, whereby the roof panel 11 moves in the front-rear direction of the vehicle 12. Figure 1 the left side of​​

[0032] 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 and 17b are engaged with an output gear 47a provided on the sunroof motor 20.

[0033] Thereby, when the sunroof motor 20 is driven, the pair of drive cables 17a and 17b move in opposite directions along their longitudinal directions. Accordingly, the roof panel 11 is pushed and pulled by the pair of drive cables 17a and 17b via a pair of shoes 15b, thereby opening / closing the opening 14.

[0034] In addition, the sunroof motor 20 corresponds to the motor device in the present invention.

[0035] <Sunroof Motor>

[0036] As Figures 2 to 4 shown, the sunroof motor 20 includes an electric motor unit 30 and a speed reduction mechanism unit 40. These electric motor unit 30 and speed reduction mechanism unit 40 are fixed to each other by a total of three fixing screws SC.

[0037] <Electric Motor Unit>

[0038] The electric motor unit 30 employs a brushless motor and has a motor housing 31 formed into a bottomed cylindrical shape by performing deep drawing or the like on 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.

[0039] <Stator>

[0040] 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 inside the motor housing 31 and includes a total of six teeth 32b (not shown in detail). Moreover, three-phase coils CL including a U phase, a V phase, and a W phase are respectively wound around these teeth 32b via insulators (insulating members) 32c.

[0041] In addition, the motor housing 31 corresponds to the first housing in the present invention.

[0042] <Rotor>

[0043] As Figure 4 and Figure 5As shown, inside the radial inner side of the stator 32, a rotor 33 is rotatably provided via a prescribed 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 laminating 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, each magnet MG is arranged at equal intervals (90° intervals) in the circumferential direction of the rotor core 33a.

[0044] In addition, the radial outer sides of the respective magnets MG fixed to the rotor core 33a are covered by a magnet holder 33b formed of a thin stainless steel plate or the like in a substantially cylindrical shape. The magnet holder 33b prevents the magnets MG from coming off the rotor core 33a. Thus, even when the rotor 33 rotates at high speed, the magnets MG will not disengage from the rotor core 33a due to the centrifugal force at this time.

[0045] <Rotating shaft>

[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. Thus, the rotating shaft 34 is provided on the rotor 33. In addition, in order to ensure sufficient strength, the rotating shaft 34 is made of a round steel bar.

[0047] Moreover, the axial base end side of the rotating shaft 34 ( Figure 4 the right side) is housed inside the motor housing 31 and is rotatably supported by a first metal member (radial bearing) BR1 provided on the bottom wall portion 31b of the motor housing 31. On the other hand, the axial front end side of the rotating shaft 34 ( Figure 4 the left side) is housed inside the housing 41 forming the speed reduction mechanism portion 40 and is rotatably supported by a second metal member (radial bearing) BR2 provided in the worm housing portion 49 of the housing 41.

[0048] That is, the rotating shaft 34 is rotatably housed inside the motor housing 31 and the housing 41. 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 axial front end 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 will not bend, and further, it reliably meshes with the worm wheel 46.

[0050] <Ball bearing>

[0051] Furthermore, a ball bearing 36 is installed at the axial center of the rotary shaft 34. That is, the ball bearing 36 is disposed between the first metal member BR1 and the second metal member BR2 in the axial direction of the rotary shaft 34, and the axial center of the rotary shaft 34 is supported to be rotatable freely. In the axial direction of the rotary shaft 34, the rotor core 33a fixed with the magnet MG and the ball bearing 36 are arranged side by side, and the rotor core 33a fixed with the magnet MG is disposed 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] The ball bearing 36, like the first metal member BR1 and the second metal member BR2, supports the rotary shaft 34 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 onto 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 or rotational speed, etc.

[0057] In addition, for the sensor magnet unit SMU, it also rotates together with the rotary shaft 34 in the same way as the inner ring 36a of the ball bearing 36. In addition, for the sensor magnet unit SMU, it can also be press-fitted onto 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 rotating shaft 34, an adjustment 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 adjustment 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 rotating shaft 34 by press-fitting.

[0060] In addition, the outer diameter dimension D3 of the adjustment member 37 (refer to Figure 12 ) is equal to or less than the outer diameter dimension D4 of the rotor 33 (refer to 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 in the axial direction of the rotating shaft 34 between the ball bearing 36 and the rotor core 33a and is arranged closer to the ball bearing 36 than the magnet MG. Thus, as Figure 4 shown, a relatively long first gap G1 is formed between the magnet MG and the adjustment member 37 in the axial direction of the rotating shaft 34.

[0062] Here, a relatively short second gap G2 is formed between the magnet MG and the stator 32 in the radial direction of the rotating shaft 34. Moreover, when the comparison object for comparing the separation distance L1 between the magnet MG and the adjustment member 37 in the axial direction of the rotating shaft 34 is the separation distance L2 between the magnet MG and the stator 32 in the radial direction of the rotating 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 fluxes (not shown) of the total four magnets MG are suppressed from heading toward the adjustment member 37. In other words, the magnetic flux of each magnet MG is efficiently directed toward 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 function of suppressing the rotational wobbling of the rotor 33 caused by, for example, minute deformation of the rotating shaft 34 that varies from product to product, or minute positional deviation between the rotation center of the rotating shaft 34 and the rotation center of the rotor core 33a. 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] Accordingly, the operating noise of the sunroof motor 20 can be reduced (improving quietness). In particular, since the sunroof motor 20 is disposed above the head of the driver or passengers, a loud operating noise would be harsh. Therefore, for the sunroof motor 20, it is necessary to further improve quietness.

[0066] <Fixing member>

[0067] Furthermore, as Figure 4 , Figure 6 and Figure 7 shown, the electric motor unit 30 includes a fixing member 38. The fixing member 38 is formed of a resin material such as plastic into a predetermined shape. The fixing member 38 includes a support main body 38a formed in a substantially flat plate shape and a plurality of wall portions 38b that enter the housing 41. That is, the fixing 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 fixing member 38. The ring-shaped support portion 38c includes a ring-shaped flat surface 38d facing the axial front end 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 mounting 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 fixing member 38 in the axial direction of the rotary shaft 34. Here, the motor housing 31 is fixed to the housing 41 by using a total of three fixing screws SC, and the fixing member 38 is fixed inside the housing 41 without wobbling. That is, the fixing member 38 is clamped by the motor housing 31 and the outer ring 36b in the axial direction of the rotor 33.

[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 along the circumferential direction of the ring-shaped support portion 38c and are formed in 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 from the ring-shaped support portion 38c toward the other axial side ( Figure 4 the left side). Moreover, the outer ring 36b of the ball bearing 36 is fitted inside the total of three positioning protrusions 38e.

[0071] Specifically, as Figure 7As shown, a pair of flat surfaces SF that are in point contact with the outer peripheral portion of the outer ring 36b are provided on the radially inner side of each positioning projection 38e. That is, a total of six flat surfaces SF are provided on the holder member 38. Moreover, the outer peripheral portion of the outer ring 36b is in point contact with the flat surfaces SF at a total of six contact points CP.

[0072] In addition, the total of six contact points CP are arranged at equal intervals (60-degree intervals) in the circumferential direction of the annular support portion 38c. Thus, when assembling the sunroof motor 20, the axis of the annular support portion 38c can be accurately aligned (centered) with the axis of the ball bearing 36.

[0073] In this way, the holder member 38 is positioned by the ball bearing 36 and supports the ball bearing 36 from one axial side. In other words, the ball bearing 36 has a function of positioning the holder member 38 in a proper position via a total of three positioning projections 38e.

[0074] Furthermore, a through small-diameter hole 38f and a through large-diameter hole 38g that penetrate axially along the annular support portion 38c and through which the rotary shaft 34 is inserted are provided on the radially inner side of the annular support portion 38c. Here, the inner diameter dimension D5 (refer to Figure 12 ) of the through small-diameter hole 38f is smaller than the inner diameter dimension D6 (refer to Figure 12 ) of the through large-diameter hole 38g (D5 < D6).

[0075] In addition, the through small-diameter hole 38f corresponds to the insertion hole in the present invention.

[0076] Here, as Figure 4 shown, an adjustment member 37 is arranged 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.

[0077] By effectively using the dead angle DS, the adjustment member 37 is arranged in the dead angle DS. Therefore, by arranging the adjustment member 37 on the rotary shaft 34, the overall size of the housing 41 or the sunroof motor 20 is not increased.

[0078] In addition, on the support body 38a, a plurality of conductive members 39 (refer to Figure 4 ) are installed corresponding to the three-phase coil CL (refer to Figure 6 and Figure 7)。Specifically, a total of three conductive members 39 are provided corresponding to the U-phase, V-phase, and W-phase. That is, the retainer member 38 holds a total of three conductive members 39. The total of three conductive members 39 mounted on the retainer member 38 are formed of brass or the like with excellent conductivity into a substantially rod shape and extend along the axial direction of the rotor 33.

[0079] Moreover, on one side in the long side direction of the total of three conductive members 39 ( Figure 6 the right side), they are respectively electrically connected to the three-phase coils CL provided in the stator 32 (refer to Figure 4 and Figure 12 ). In contrast, on the other side in the long side direction of the total of three conductive members 39 ( Figure 6 the left side), they are supported by the conductive member support portion 49a provided in the housing 41 (refer to Figure 4 and Figure 12 ). Here, the connection terminals (not shown) of the external connector provided on the vehicle 12 (refer to Figure 1 ) side are electrically connected to the other side in the long side direction of the conductive member 39.

[0080] Thereby, a drive current is supplied from an in-vehicle controller or the like to the three-phase coils CL of the skylight motor 20, and further, the rotating shaft 34 is rotated forward or backward. Thus, the retainer member 38 supports the outer ring 36b of the ball bearing 36 and holds a total of three conductive members 39.

[0081] <Reduction mechanism portion>

[0082] 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 of a resin material such as plastic into a substantially flat rectangular parallelepiped shape and abuts against the motor housing 31 in the axial direction of the rotor 33. Specifically, the housing 41 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.

[0083] In addition, the housing 41 corresponds to the second housing in the present invention.

[0084] As Figure 4 shown, a worm housing portion 45 is provided inside the housing 41. The worm housing portion 45 is disposed in a portion close to the third wall portion 44. Moreover, a worm 46 forming the reduction mechanism SD is rotatably housed inside the worm housing portion 45. Here, the worm 46 includes a resin material such as plastic and is made lightweight. A tooth portion 46a is provided on the worm 46, and the tooth portion 46a meshes with the worm gear 35 inside the housing 41.

[0085] 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.

[0086] In addition, the axial base end side of the output shaft 47 including the round steel bar is fixed at the rotation center of the worm wheel 46. In contrast, on the axial front end side of the output shaft 47, an output gear 47a (refer to Figure 1 ) for meshing with a pair of drive cables 17a, 17b (refer to Figure 2 ) is integrally provided.

[0087] Therefore, the high-speed rotation of the rotary shaft 34 is reduced by the speed reduction mechanism SD, and the rotational force that has been reduced and has become high 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.

[0088] Here, the side of the worm wheel housing portion 45 opposite to the first wall portion 42 side is open (not shown). And, 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.

[0089] 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.

[0090] The worm housing portion 49 extends in the axial direction of the rotary shaft 34, and on the other axial side of the worm housing portion 49 ( Figure 4 the left side), a second metal member BR2 that rotatably supports the axial front end side of the rotary shaft 34 is housed.

[0091] Furthermore, a conductive member support portion 49a is provided between the worm housing portion 49 and the second wall portion 43. The conductive member support portion 49a has a function of supporting the other long side direction ( Figure 4 the left side) of the total three conductive members 39 held by the holder member 38 without shaking. Thereby, each conductive member 39 can be electrically connected to a connection terminal (not shown) of an external connector provided on the vehicle 12 (refer to Figure 1 ) side in a stable state.

[0092] In addition, a bearing mounting portion 50 is provided inside the housing 41. The bearing mounting portion 50 is disposed on the axial side of the worm accommodating portion 49 ( Figure 4 on the right side), and opens toward the motor housing 31. A ball bearing 36 is accommodated inside the bearing mounting portion 50, and the entire circumference on the other axial side ( Figure 4 on the left side) of the outer ring 36b is supported by the bearing mounting portion 50.

[0093] Furthermore, 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, for example, a sintered material obtained by compacting metal powder. Also, 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 of the ball bearing 36 (refer to Figure 12 ) is larger than the inner diameter dimension D5 of the through small diameter hole 38f in the annular support portion 38c (refer to Figure 12 )(D7 > D5).

[0094] 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 (meshing disengagement from each other) can be suppressed, and thus power can be reliably transmitted to each other.

[0095] Also, an inner ring 36a is fixed to the rotating shaft 34, and the outer ring 36b is clamped by the bearing mounting portion 50 and the retainer member 38. Therefore, the rotating shaft 34 does not move in its axial direction. Therefore, 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.

[0096] 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.

[0097] Thereby, the minute gap absorbs the manufacturing error of the parts or the linear expansion difference between the parts. Therefore, smooth rotation of the rotating shaft 34 can be ensured. In this way, 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 linear expansion difference between the parts.

[0098] <Motor accommodating portion>

[0099] In addition, as Figure 4 , Figure 9 , Figure 11 and Figure 12As shown, a motor housing portion 51 formed in a substantially box shape is provided inside the housing 41. The motor housing portion 51 is arranged on the motor housing 31 side of the bearing mounting portion 50 in the axial direction of the rotating shaft 34 ( Figure 4 on the right side).

[0100] 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 holder member 38 forming the electric motor unit 30 enters the motor housing portion 51.

[0101] <Metal sheath>

[0102] Here, as Figure 2 and Figure 3 shown, a metal sheath 60 formed by bending a thin steel plate is partially installed outside 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.

[0103] <Positioning structure>

[0104] As Figures 8 to 10 shown, in the skylight motor 20 of the present embodiment, the motor housing 31, the housing 41, and the holder member 38 are respectively positioned with reference to the single rotating shaft 34 (axis CT) forming the rotor 33. Thus, the assembled skylight motor 20 can rotate the rotating shaft 34 smoothly without deviation due to product differences. Specifically, through the positioning structure at the following three locations, compared with the prior art, it is possible to easily assemble while reducing the number of parts.

[0105] <First positioning portion>

[0106] As Figure 8 shown, through the first positioning portion PP1, the motor housing 31 (stator 32) is positioned with respect to the rotating shaft 34. Specifically, a first metal member BR1 is installed on the bottom wall portion 31b of the motor housing 31, and the rotating shaft 34 is rotatably supported by the first metal member BR1. That is, the first positioning portion PP1 is formed by the bottom wall portion 31b, the first metal member BR1, and the rotating shaft 34.

[0107] Thus, the motor housing 31 and the stator 32 are accurately positioned at the regular position with reference to the rotating shaft 34 (axis CT) via the first metal member BR1.

[0108] <Second positioning portion>

[0109] As Figure 9As shown, the housing 41 is positioned relative to the rotary shaft 34 by the second positioning portion PP2. Specifically, a second metal member BR2 is installed in the worm housing portion 49 of the housing 41, and the rotary shaft 34 is rotatably supported by the second metal member BR2. That is, the second positioning portion PP2 is formed by the worm housing portion 49, the second metal member BR2, and the rotary shaft 34 (on the side of the worm 35).

[0110] Thus, the housing 41 is accurately positioned at a regular position with the rotary shaft 34 (axis CT) as a reference via the second metal member BR2.

[0111] In addition, there is a small gap (not shown) between the outer ring 36b of the ball bearing 36 and the support ring SR to absorb the manufacturing error of the parts or the linear expansion difference between the parts. Therefore, the ball bearing 36 fixed to the rotary shaft 34 does not contribute to the positioning of the housing 41.

[0112] <Third positioning portion>

[0113] As Figure 10 shown, the retainer member 38 is positioned relative to the rotary shaft 34 by the third positioning portion PP3. Specifically, the inner ring 36a of the ball bearing 36 is installed on the rotary shaft 34, and a total of three positioning protrusions 38e of the outer ring 36b of the ball bearing 36 and the retainer member 38 are engaged. That is, the third positioning portion PP3 is formed by the rotary shaft 34, the ball bearing 36, and the positioning protrusion 38e.

[0114] Thus, the retainer member 38 is accurately positioned at a regular position with the rotary shaft 34 (axis CT) as a reference via the ball bearing 36.

[0115] In addition, the ball bearing 36 has an inner ring 36a, an outer ring 36b, and a plurality of balls 36c, and is a precision part without clearance between the respective parts. Therefore, the retainer member 38 is accurately positioned on the rotary shaft 34 via the ball bearing 36.

[0116] In this way, in the sunroof motor 20 of the present embodiment, the motor housing 31, the stator 32, the housing 41, and the retainer member 38 are accurately positioned with the rotary shaft 34 as a reference by a total of three positioning portions PP1, PP2, and PP3. That is, by positioning other constituent parts with the rotary shaft 34 (axis CT) as a reference, the assembly accuracy of the sunroof motor 20 is improved, and further, the rotational resistance of the rotary shaft 34 is suppressed from deviating due to different products.

[0117] <Assembly sequence of the sunroof motor>

[0118] Next, the assembly sequence of the sunroof motor 20 formed as described above will be described in detail with reference to the drawings.

[0119] Figure 11 Figure showing the assembly sequence (1) of the skylight motor Figure 12 Figure showing the assembly sequence (2) of the skylight motor.

[0120] Here, as Figure 12 shown, the size relationship of the outer diameter dimension D3 of the adjustment 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.

[0121] Thus, the rotor 33 and the adjustment 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 Figure 11 and Figure 12 shown, the skylight motor 20 can be easily assembled.

[0122] <Assembly sequence (1)>

[0123] As Figure 11 shown, first, prepare the housing 41, the second metal part BR2, the support ring SR, and the rotor assembly RA. Here, the rotor assembly RA is an assembly in which a rotor 33, a ball bearing 36, a sensor magnet unit SMU, and an adjustment member 37 are installed on the rotating shaft 34.

[0124] Then, along the dotted line, first fix the second metal part BR2 to the worm housing portion 49. Next, fix the support ring SR to the bearing installation portion 50. After that, orient the worm 35 side of the rotor assembly RA axially toward the motor housing portion 51. Then, house the worm 35 of the rotor assembly RA in the worm housing portion 49 and install the ball bearing 36 in the bearing installation portion 50.

[0125] At this time, let the second metal part BR2 support the worm 35 side of the rotating shaft 34 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 installation operation of the rotor assembly RA to the housing 41 can be easily performed.

[0126] Thus, the installation operation of the rotor assembly RA to the housing 41 is completed, and the housing 41 is positioned on the rotating shaft 34 via the second metal part BR2 (refer to Figure 9 ). In addition, the housing 41 with the rotor assembly RA installed through <Assembly sequence (1)> is designated as the housing assembly HA.

[0127] <Assembly sequence (2)>

[0128] Next, as Figure 12As shown, prepare the housing assembly HA, the holder member 38, the motor assembly MA, and a total of three fixing screws SC. In addition, a total of three conductive members 39 are installed on the holder member 38. Further, the motor assembly MA is an assembly in which a first metal piece BR1 is installed on the bottom wall portion 31b of the motor housing 31 and a stator 32 is fixed to the side wall portion 31a of the motor housing 31.

[0129] Then, along the dotted line, first, the housing 41 side surface of the holder member 38 is faced toward the motor receiving portion 51. Next, the plurality of wall portions 38b provided on the holder member 38 are inserted into the motor receiving portion 51. At this time, since the inner diameter dimension D5 of the through-hole small diameter hole 38f in the annular support portion 38c is larger than the outer diameter dimension D3 of the adjustment member 37 and the outer diameter dimension D4 of the rotor 33 (D5 > D4 > D3), the adjustment member 37 and the rotor 33 can be easily inserted radially inside the through-hole small diameter hole 38f.

[0130] Thereafter, the conductive member support portion 49a supports the other long side direction of the total of three conductive members 39 installed on the holder member 38 ( Figure 12 the left side), and the outer ring 36b is fitted inside the total of three positioning protrusions 38e provided on the holder member 38.

[0131] At this time, since the inner diameter dimension D5 of the through-hole small diameter hole 38f is smaller than the outer diameter dimension D7 of the ball bearing 36 (D5 < D7), the entire circumference of the annular flat surface 38d in the annular support portion 38c abuts against the axial one side of the outer ring 36b. Further, the adjustment member 37 is disposed in the dead angle DS (refer to Figure 4 ) formed radially inside the annular support portion 38c.

[0132] In this way, the entire circumference of the axial other side of the outer ring 36b ( Figure 12 the left side) is supported by the bearing mounting portion 50, and the entire circumference of the axial one side of the outer ring 36b ( Figure 12 the right side) 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.

[0133] Next, the motor assembly MA is faced toward the motor receiving portion 51. At this time, the holder member 38 side of the motor housing 31 is faced toward the motor receiving portion 51. Then, while the rotor 33 is inserted radially inside the stator 32, the opening side of the motor housing 31 is brought into contact with the housing 41. At this time, the first metal piece BR1 supports the axial base end side of the rotating shaft 34.

[0134] At this time, the holder member 38 is positioned by the outer ring 36b (refer to Figure 10 ), and the motor assembly MA is positioned by the rotating shaft 34 (refer to Figure 8)。In addition, the ball bearing 36 and the rotating shaft 34 are arranged coaxially with good mutual precision.

[0135] Therefore, the retainer member 38 and the motor assembly MA are also arranged coaxially with good mutual precision. Thus, 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 (improving the assemblability).

[0136] 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. Thus, the motor housing 31 and the housing 41 are firmly fixed to each other. In this way, after the rotor assembly RA is installed on the housing 41, the retainer member 38 and the motor assembly MA are installed on the housing assembly HA, and the fixing operation of the retainer member 38 and the motor assembly MA to the housing assembly HA is completed.

[0137] In addition, after <Assembly Sequence (2)>, the worm wheel 46 is housed in the worm wheel housing portion 45 of the housing 41 (refer to Figure 4 ), and the opening portion of the worm wheel housing portion 45 is closed by the cover member 48 (refer to Figure 3 ). Thus, the assembly operation of the sunroof motor 20 is completed.

[0138] As described in detail above, according to the present embodiment, it includes: a motor housing 31 in which a stator 32 is fixedly installed; a housing 41 that abuts against the motor housing 31 in the axial direction of the rotor 33; a rotating shaft 34 that is provided on the rotor 33 and is rotatably housed inside the motor housing 31 and the housing 41; a first metal member BR1 that is provided on the motor housing 31 and rotatably supports the axial base end side of the rotating shaft 34; a second metal member BR2 that is provided on the housing 41 and rotatably supports the axial front end side of the rotating shaft 34; a ball bearing 36 that is provided between the first metal member BR1 and the second metal member BR2 in the axial direction of the rotating shaft 34 and rotatably supports the rotating shaft 34; and a retainer member 38 that is positioned by the ball bearing 36 and holds a plurality of conductive members 39, and the retainer member 38 is clamped by the motor housing 31 and the ball bearing 36 in the axial direction of the rotor 33.

[0139] Thus, with a single rotating shaft 34 (axis CT) as a reference, the motor housing 31, the stator 32, the housing 41, and the retainer member 38 can be accurately positioned. Therefore, compared with the prior art, a sunroof motor 20 that can reduce the number of parts and can be easily assembled can be realized.

[0140] In addition, according to the present embodiment, a plurality of conductive members 39 extend in the axial direction of the rotor 33. One side in the long side direction of each of the plurality of conductive members 39 is respectively connected to the three-phase coils CL provided in the stator 32, and the other side in the long side direction of the plurality of conductive members 39 is supported by a conductive member support portion 49a provided in the housing 41.

[0141] Since the constituent parts of the sunroof motor 20 are positioned with respect to the rotation shaft 34 as a reference, by only assembling the sunroof motor 20, it is possible to easily connect one side in the long side direction of the conductive member 39 to the coil CL, and it is possible to cause the conductive member support portion 49a to support the other side in the long side direction of the conductive member 39 (improving the assemblability).

[0142] Furthermore, according to the present embodiment, a through small-diameter hole 38f through which the rotation shaft 34 is inserted is provided in the retainer member 38, and the inner diameter dimension D5 of the through small-diameter hole 38f (refer to Figure 12 ) is smaller than the outer diameter dimension D7 of the ball bearing 36 (refer to Figure 12 )(D5 < D7) and larger than the outer diameter dimension D4 of the rotor 33 (refer to Figure 12 )(D5 > D4).

[0143] Accordingly, when assembling the sunroof motor 20, the rotor 33 can be easily inserted through the through small-diameter hole 38f of the retainer member 38. In addition, the outer ring 36b can be supported over the entire circumference of the annular flat surface 38d.

[0144] In addition, according to the present embodiment, an adjustment member 37 for adjusting the rotational balance of the rotor 33 is provided between the ball bearing 36 and the rotor 33 in the axial direction of the rotation shaft 34, and the outer diameter dimension D3 of the adjustment member 37 (refer to Figure 12 ) is equal to or less than the outer diameter dimension D4 of the rotor 33 (refer to Figure 12 )(D3 < D4).

[0145] Accordingly, when assembling the sunroof motor 20, the rotor 33 and the adjustment member 37 can be easily inserted through the through small-diameter hole 38f of the retainer member 38. Thereby, the assemblability of the sunroof motor 20 can also be improved.

[0146] Furthermore, according to the present embodiment, compared with the prior art, the number of parts can be reduced, and assembly can be easily performed. Therefore, energy savings in manufacturing can be achieved. Accordingly, it is possible to achieve the Sustainable Development Goals (SDGs) established by the United Nations, particularly Goal 7 (Ensure access to affordable, reliable, sustainable and modern energy for all) and Goal 13 (Take urgent action to combat climate change and its impacts).

[0147] The present invention is not limited to the described embodiments, and various modifications can be made without departing from its gist. In the described embodiments, an example of applying the present invention to the sunroof motor 20 used in the sunroof device 10 of the vehicle 12 is shown. However, 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.

[0148] In addition, the materials, shapes, dimensions, quantities, installation positions, etc. of the respective components in the described embodiments are arbitrary as long as the present invention can be achieved, and are not limited to the described embodiments.

[0149] Explanation of reference numerals

[0150] 10: Sunroof device

[0151] 11: Roof panel

[0152] 12: Vehicle

[0153] 13: Roof

[0154] 14: Opening

[0155] 15a, 15b: Shoes

[0156] 16: Guide rail

[0157] 17a, 17b: Drive cable

[0158] 20: Sunroof motor (motor device)

[0159] 30: Electric motor part

[0160] 31: Motor housing (first housing)

[0161] 31a: Side wall part

[0162] 31b: Bottom wall part

[0163] 32: Stator

[0164] 32a: Stator core

[0165] 32b: Tooth

[0166] 32c: Insulator (insulating member)

[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] 36c: Ball

[0176] 37: Adjusting member

[0177] 37a: Steel plate

[0178] 38: Fixing member

[0179] 38a: Support body

[0180] 38b: Wall portion

[0181] 38c: Annular support portion

[0182] 38d: Annular flat surface

[0183] 38e: Positioning projection

[0184] 38f: Through small-diameter hole (insertion through-hole)

[0185] 38g: Through large-diameter hole

[0186] 39: Conductive member

[0187] 40: Reduction mechanism portion

[0188] 41: Housing (second housing)

[0189] 42: First wall portion

[0190] 43: Second wall portion

[0191] 44: Third wall portion

[0192] 45: Worm housing portion

[0193] 46: Worm

[0194] 46a: Tooth portion

[0195] 47: Output shaft

[0196] 47a: Output gear

[0197] 48: Cover member

[0198] 49: Worm shaft housing portion

[0199] 49a: Conductive member support portion

[0200] 50: Bearing installation portion

[0201] 51: Motor housing part

[0202] 60: Metal sheath

[0203] AG: Air gap

[0204] BK: Bracket member

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

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

[0207] CL: Coil

[0208] CP: Contact point

[0209] CT: Axis

[0210] DS: Dead angle

[0211] FG: Windshield

[0212] G1: First gap

[0213] G2: Second gap

[0214] HA: Housing assembly

[0215] MA: Motor assembly

[0216] MG: Magnet

[0217] PP1: First positioning part

[0218] PP2: Second positioning part

[0219] PP3: Third positioning part

[0220] RA: Rotor assembly

[0221] SC: Fixing screw

[0222] SD: Reduction mechanism

[0223] SF: Flat surface

[0224] SM: Sensor magnet

[0225] SMU: Sensor magnet unit

[0226] SR: Support ring

Claims

1. A motor device having: a stator ； and a rotor that rotates relative to the stator, the motor device comprising: a first housing in which the stator is fixed inside; a second housing that abuts against the first housing in the axial direction of the rotor; a rotating shaft provided on the rotor and rotatably housed inside the first housing and the second housing; a first bearing provided in the first housing and rotatably supporting the axial base end side of the rotating shaft; a second bearing provided in the second housing and rotatably supporting the axial front end side of the rotating shaft; a third bearing provided between the first bearing and the second bearing in the axial direction of the rotating shaft and rotatably supporting the rotating shaft; and a holder member positioned by the third bearing and holding a plurality of conductive members, the holder member being clamped between the first housing and the third bearing in the axial direction of the rotor.

2. The motor device according to claim 1, wherein the plurality of conductive members extend in the axial direction of the rotor, one side in the long side direction of the plurality of conductive members is connected to a coil provided on the stator, the other side in the long side direction of the plurality of conductive members is supported by a conductive member support portion provided in the second housing.

3. The motor device according to claim 1, wherein a through hole for inserting the rotating shaft is provided in the holder member, the inner diameter dimension of the through hole is smaller than the outer diameter dimension of the third bearing and larger than the outer diameter dimension of the rotor.

4. The motor device according to any one of claims 1 to 3, wherein an adjustment member for adjusting the rotational balance of the rotor is provided between the third bearing and the rotor in the axial direction of the rotating shaft, the outer diameter dimension of the adjustment member is equal to or less than the outer diameter dimension of the rotor.

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