Rotary electric machine, method for manufacturing rotary electric machine, drive device for hybrid vehicle, and method for manufacturing drive device for

Abstract

Provided is a rotating electrical machine (40) in which annular holding parts (12, 12B) for holding a rotor (20) are connected to a rotating shaft and constitute a rotor shaft part (10) that rotates together with the rotor (20), the rotor shaft part (10) having a groove part (12GR) that is recessed from the circumferential surface to one side in the radial direction and a wall surface (12W) that extends from the circumferential surface to the other side in the radial direction, the groove part (12GR) being provided on the circumferential surface on one of the outer side and the inner side in the radial direction. A sensor rotor (50R) is fitted and disposed on the circumferential surface, an annular press-fitting member (60) is disposed, the press-fitting member sandwiches the sensor rotor (50R) between the press-fitting member and the wall surface (12W) from the axial direction, a first projection (60PR) is provided on the press-fitting member (60) so as to protrude in advance, and the sensor rotor (50R) is pressed by the first projection (60PR) in a state in which the first projection (60PR) is fitted into the groove (2GR). The press-fit member (60) and the rotor shaft part (10) are engaged and fixed.

Description

Technical Field

[0001] This application relates to a rotary electric motor, a method for manufacturing a rotary electric motor, a drive unit for a hybrid vehicle, and a method for manufacturing a drive unit for a hybrid vehicle. Background Technology

[0002] A common method for fixing the sensor rotor of an angle sensor assembled on the rotor of a rotary electric motor involves pressing a fixing ring into and fixing it to the rotor shaft, thereby clamping the sensor rotor axially. However, in recent automotive drive systems, the diameter of the rotary electric motor has increased due to higher output, necessitating a corresponding increase in the diameter of the angle sensor. Furthermore, from a layout perspective, automotive drive systems mostly employ external rotor-type angle sensors, resulting in an increased rotor diameter and weight, making it difficult to fix the sensor rotor using the pressing and frictional forces generated by the fixing ring. Therefore, to compensate for the fixing force on the sensor rotor, a fixing structure for an angle sensor in a rotary electric motor has been disclosed, which increases friction by clamping an elastic member between the fixing ring and the sensor rotor (see, for example, Patent Document 1).

[0003] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2007-64870 Summary of the Invention

[0004] The technical problem that the invention aims to solve However, in the existing fixed structure of the rotation angle sensor of the rotating electric machine, since the sensor rotor is fixed by using elastic members and fixing rings, it is necessary to ensure the space corresponding to the elastic members and fixing rings, which leads to technical problems such as increased cost and complicated structure and manufacturing process.

[0005] This application discloses a technology for solving the above-mentioned technical problems, the purpose of which is to provide a rotary motor, a method for manufacturing a rotary motor, a drive device for a hybrid vehicle including the rotary motor, and a method for manufacturing a drive device for a hybrid vehicle, wherein the rotary motor can ensure the secure fixing of the sensor rotor and has a simplified structure while saving space and reducing costs.

[0006] Technical solutions adopted to solve technical problems The rotary electric motor disclosed in this application includes a sensor that detects the rotation of a rotor that rotates integrally with the shaft. The annular retaining portion of the rotor is connected to the rotating shaft, forming a rotor shaft portion having the retaining portion and rotating together with the rotor. The rotor shaft portion includes a groove recessed into one radial side on one of its radially outer or radially inner sides, and a wall extending radially from the other radial side on its circumferential surface. The sensor rotor of the sensor is fitted into the circumferential surface and is disposed in axial contact with the wall surface. An annular press-in member is fitted into the circumferential surface, and the press-in member clamps the sensor rotor axially between the press-in member and the wall surface. The press-in member has a first protrusion pre-provided on a first surface facing the circumferential surface of the rotor shaft. When the first surface is pressed axially relative to the circumferential surface of the rotor shaft so that the first protrusion is embedded in the groove, the press-in member and the rotor shaft are locked and fixed.

[0007] Furthermore, the drive unit for hybrid vehicles disclosed in this application includes: Rotary electric motors configured as described above; and Engine, among which, In the rotary electric motor, the retaining portion of the rotor is connected to and disposed on a rotating shaft, such that the rotor is clamped between a gearbox arranged axially and the engine, the rotating shaft being a power transmission mechanism connecting the engine and the gearbox. The shaft is provided with a clutch mechanism for switching power transmission on and off at least one of the ends on the engine side or the gearbox side.

[0008] Furthermore, in the method for manufacturing a rotary electric machine disclosed in this application, in the rotary electric machine, An annular retaining portion that holds the rotor, which rotates integrally with the rotating shaft, is connected to the rotating shaft to form a rotor shaft portion having the retaining portion and rotating together with the rotor. The rotor shaft portion includes a groove recessed into one radial side on one of its radially outer or radially inner sides, and a wall extending radially from the other radial side on its circumferential surface. The sensor rotor, which detects the rotation of the rotor, is fitted with the circumferential surface and is disposed in axial contact with the wall surface. An annular press-in member is fitted into the circumferential surface, and the press-in member clamps the sensor rotor axially between the press-in member and the wall surface. The manufacturing method of the rotary electric motor includes a pressing process. In the pressing process, the first surface of the pressing member, which faces the circumferential surface of the rotor shaft, is fitted relative to the circumferential surface of the rotor shaft and pressed in from the axial side, so that the pressing member abuts against the sensor rotor, and a portion of one side of the first surface of the pressing member is embedded in the groove, thereby locking and fixing the pressing member to the rotor shaft.

[0009] Furthermore, the manufacturing method for the hybrid vehicle drive unit disclosed in this application is a manufacturing method for a vehicle drive unit configured as described above, including the following steps: In the rotary electric motor, the retaining portion of the rotor is connected to a rotating shaft, which is a power transmission mechanism connecting the engine and the gearbox, in a manner sandwiched between a gearbox arranged axially. A clutch mechanism for switching power transmission is provided at least one of the ends of the shaft, the engine side, or the gearbox side.

[0010] Invention Effects The rotary motor and drive unit for hybrid vehicles disclosed in this application can ensure the secure fixing of the sensor rotor and have a simplified structure while saving space and reducing costs.

[0011] Furthermore, based on the manufacturing method of the rotary motor and the manufacturing method of the drive unit for hybrid vehicles disclosed in this application, it is possible to manufacture a rotary motor and a drive unit for hybrid vehicles that ensure the secure fixing of the sensor rotor and have a simplified structure while saving space and reducing costs. Attached Figure Description

[0012] Figure 1 This is a cross-sectional view schematically showing the power transmission system including a rotary electric motor constituting part of the drive unit of the hybrid vehicle according to Embodiment 1.

[0013] Figure 2 This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for a hybrid vehicle according to Embodiment 1.

[0014] Figure 3 This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for a hybrid vehicle according to Embodiment 1.

[0015] Figure 4 This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for a hybrid vehicle according to Embodiment 1.

[0016] Figure 5This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for a hybrid vehicle according to Embodiment 1.

[0017] Figure 6 This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for the hybrid vehicle according to Embodiment 2.

[0018] Figure 7 This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for the hybrid vehicle according to Embodiment 2.

[0019] Figure 8 This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for the hybrid vehicle according to Embodiment 2.

[0020] Figure 9 This is a partially enlarged cross-sectional view showing the mounting portion of the rotation sensor in the drive unit for the hybrid vehicle according to Embodiment 2. Detailed Implementation

[0021] Implementation Method 1 This embodiment relates to a drive unit for a hybrid vehicle and a rotary motor constituting part of the drive unit, and particularly to a method for mounting an angle sensor to the rotary motor.

[0022] Figure 1 This is a schematic cross-sectional view of the power transmission system including the rotary motor 40 that constitutes part of the drive unit 100 for hybrid vehicles in this embodiment.

[0023] Figure 2 It is Figure 1 An enlarged cross-sectional view of part A.

[0024] Figure 3 It is Figure 2 The enlarged cross-sectional view of part B.

[0025] In the figure, the axial and radial directions of the rotary motor 40 are represented by arrows X and Y, respectively.

[0026] Furthermore, when referring to the inner side of the axis, it means the side closer to the center of the rotary motor than the two ends of the axis.

[0027] The hybrid vehicle drive unit 100 of this embodiment includes a rotary motor 40 and an on-board engine 1. Furthermore, a gearbox 2 and a shaft 11 are provided; the gearbox 2 is a transmission mechanism that transmits power from the engine 1 to the tires, and the shaft 11 is a rotating shaft that serves as a power transmission mechanism connecting the gearbox 2 to the engine 1.

[0028] In the aforementioned hybrid vehicle drive unit 100, a rotary motor 40 is positioned between an engine 1 and a transmission 2 arranged along the X-axis. Furthermore, one end of the shaft 11 along the X-axis is connected to the transmission 2 via a clutch mechanism 3B that switches power transmission on and off, while the other end is connected to the output shaft of the engine 1 via a clutch mechanism 3A that switches power transmission on and off.

[0029] Furthermore, regarding the clutch mechanism, it is not limited to a structure with the rotary motor 40 as the center and arranged on both sides of the rotor shaft along the axial direction X. It can also be arranged only on the engine 1 side or only on the gearbox 2 side.

[0030] Next, the structure of the rotary motor 40 will be explained.

[0031] like Figure 1 As shown, the rotary motor 40 includes an inner rotor (hereinafter simply referred to as rotor 20) and an outer stator (hereinafter simply referred to as stator 30) arranged concentrically with rotor 20 at a radially Y-side location.

[0032] The rotor 20 has a rotor core 20C and a magnet (not shown).

[0033] The stator 30 has a stator core 30C and a coil (not shown) mounted on the stator core 30C, and has coil ends (not shown) protruding from both sides of the axial end of the stator core 30C toward the axial direction X. The stator 30 is mounted on the inner circumferential surface of the peripheral wall 5IN of the housing 5 housing the rotary motor 40.

[0034] The rotor shaft portion 10 of the rotor 20 constituting the rotary motor 40 is configured to include a cylindrical portion 12, the aforementioned shaft portion 11, and a connecting portion 13. The cylindrical portion 12 is a holding portion that holds the rotor core 20C. The shaft portion 11 connects the engine 1 to the gearbox 2. The connecting portion 13 connects the shaft portion 11 to the cylindrical portion 12.

[0035] The cylindrical part 12 is formed by stacking multiple electromagnetic steel plates in the axial direction X, and the rotor core 20C is fixed on its radially outer peripheral surface 12OUT.

[0036] In this embodiment, the shaft 11 of the rotary motor 40 is shared with the drive shaft, which is a rotating shaft that connects the engine 1 and the gearbox 2 to the hybrid vehicle drive unit 100 as described above.

[0037] The housing 5 has an engine cover 5W1 and a support wall 5W2, the engine cover 5W1 being the wall on the other side of the axial direction X, and the support wall 5W2 extending from the engine cover 5W1 to one side of the axial direction X.

[0038] like Figure 2 As shown, a bearing 12B is provided as a retaining part in the support wall 5W2 of the outer casing 5.

[0039] Furthermore, the cylindrical portion 12 supporting the rotor 20 has a bearing connection portion 12BS, which extends radially inward Y1 from the cylindrical portion 12. The bearing connection portion 12BS is connected to a bearing 12B provided in the support wall 5W2 of the housing 5, thereby enabling the rotor 20 to rotate by being supported by the bearing 12B, and to rotate integrally with the shaft portion 11.

[0040] In this embodiment, the rotor shaft 10 of the rotor 20 is an integral component consisting of a shaft 11 shared with the drive shaft, a cylindrical portion 12 that holds the rotor 20, and a connecting portion 13, as described above. Furthermore, all mechanisms, including the bearing 12B and the bearing connection portion 12BS, are considered as part of the rotor shaft 10. The bearing 12B holds the rotor 20 while integrally surrounding the shaft with the rotor 20, and supports the rotor 20 so that it can rotate.

[0041] Next, the angle sensor 50 installed on the aforementioned rotary motor 40 will be described.

[0042] like Figure 2 As shown, the angle sensor 50, which detects the rotation angle of the rotor 20, is configured to have an annular sensor rotor 50R and an annular sensor stator 50S. The sensor stator 50S is mounted on the support wall 5W2 of the engine cover 5W1 near the bearing 12B. The sensor rotor 50R is mounted and fixed to the inner circumferential surface 12IN of the cylindrical portion 12 in a manner described in detail below, so as to be opposite the sensor stator 50S in the radial Y direction.

[0043] In addition, according to Figure 1 It is evident that a structure is formed within the radially inner Y1 space of the cylindrical portion 12 of the rotary motor 40, housing and arranging the bearing 12B, bearing connection 12BS, sensor stator 50S, and sensor rotor 50R. Furthermore, the angle sensor 50 is disposed within the space extending axially inward from both axial ends of the rotor 20, as shown by X1, and is not disposed axially outward beyond the axial ends of the rotor 20. Thus, a space-saving structure is employed that effectively utilizes the space within the cylindrical portion 12.

[0044] Next, use Figure 1 And enlarged main parts Figure 3 The detailed structure of the sensor rotor 50R mounting portion of the rotary motor 40 of Embodiment 1, especially the cylindrical portion 12 that holds the rotor 20, will be described.

[0045] like Figure 3As shown, the cylindrical portion 12 that holds the rotor 20 is formed with a step 12S that changes the height of its inner circumferential surface 12IN in the radial direction Y. The wall surface that constitutes the step 12S and extends from the inner circumferential surface 12IN in the radially inward direction Y1 is designated as wall surface 12W.

[0046] The outer peripheral surface of the radially outer side Y2 of the sensor rotor 50R is mounted to the cylindrical portion 12 in a clearance fit manner, forming a predetermined gap GAP relative to the inner peripheral surface 12IN of the cylindrical portion 12. Furthermore, an annular retaining ring 60, serving as a press-fit member, is disposed and fixed at a predetermined position in the axial direction X, clamping the sensor rotor 50R between the retaining ring 60 and the wall surface 12W from the axial direction X. Thus, the sensor rotor 50R is fixed to the inner peripheral surface 12IN side of the cylindrical portion 12 constituting the rotor shaft portion 10.

[0047] Furthermore, a groove 12GR for locking and securing the fixing ring 60 is provided on the inner circumferential surface 12IN of the cylindrical portion 12. The groove 12GR is recessed radially outward Y2 from the inner circumferential surface 12IN of the cylindrical portion 12, with the radial Y direction as the depth direction. Figure 3 As shown, inside the aforementioned groove 12GR, part of the outer peripheral surface 60OUT, which is the first surface of the fixing ring 60, is in an engaged state, resulting in the fixing ring 60 being engaged with the groove 12GR. Thus, the fixing ring 60 and the cylindrical portion 12 constituting the rotor shaft portion 10 are engaged and fixed together.

[0048] Specifically, in the example of Embodiment 1, a portion of the retaining ring 60 that enters the interior of the groove 12GR is composed of a protrusion 60PR. This protrusion 60PR is a first protrusion that is pre-formed at the outer circumferential surface 60OUT of the retaining ring 60, opposite the inner circumferential surface 12IN of the cylindrical portion 12, before the retaining ring 60 is installed onto the cylindrical portion 12. That is, when the retaining ring 60 is pressed into the inner circumferential surface 12IN of the cylindrical portion 12, the protrusion 60PR pre-formed on the retaining ring 60 is embedded into the interior of the groove 12GR, thereby locking and securing the retaining ring 60 to the cylindrical portion 12.

[0049] More specifically, regarding the method of fixing the retaining ring 60, with the sensor rotor 50R abutting against the wall surface 12W, the retaining ring 60 is used to press the sensor rotor 50R along the axial X direction. In other words, with the retaining ring 60 installed and fixed to the cylindrical portion 12, a state of compressive stress is created. This compressive stress is generated by pressing the sensor rotor 50R along the axial X direction with a set pressure. The positions of the retaining ring 60 and the groove portion 12GR in the axial X direction are adjusted respectively to generate compressive stress relative to the sensor rotor 50R.

[0050] In addition, regarding the shape of the protrusion 60PR of the fixing ring 60, it is desirable that an inclined surface C1 be formed on the side of the protrusion 60PR that forms the front side when entering and is close to the step 12S and the sensor rotor 50R, so that the protrusion 60PR can be more easily pressed into the interior of the entry groove 12GR.

[0051] Here, at the edge of the inner wall constituting the groove 12GR, near the step 12S on the axial side, an inclined surface C3 is pre-formed that is inclined relative to the inner circumferential surface 12IN. Furthermore, if a structure is provided in which a gap is formed between the inclined surface C3 and the fixing ring 60, then the pressing force from the axial direction X generated by the fixing ring 60 pressing the sensor rotor 50R can be prevented from being dispersed on the cylindrical part 12 side, thereby ensuring a reliable pressing force from the axial direction X relative to the sensor rotor 50R.

[0052] Furthermore, as explained above, it is desirable that at least one of the protrusion 60PR and the groove 12GR, on the side away from the step 12S and the sensor rotor 50R, forms an inclined surface C2, such that when the retaining ring 60 is installed and fixed to the rotor shaft 10, the retaining ring 60 engages with the cylindrical portion 12 while exerting a pressing force on the sensor rotor 50R along the axial direction X. The inclined surface C2 contacts the edge on the other side of the inner wall constituting the groove 12GR along the axial direction, thereby obtaining a pressing force that presses on the sensor rotor 50R along the axial direction X.

[0053] Furthermore, regarding the mating portion of the sensor rotor 50R and the inner circumferential surface 12IN of the cylindrical portion 12, as described above, it is designed to be mounted with a gap in the radial direction Y. In other words, it is designed to have a clearance fit size setting that ensures a gap fit within tolerance range. At the outer circumferential surface 12OUT of the cylindrical portion 12, the rotor core 20C is pressed in and mounted along the outer circumferential surface 12OUT. Through the above-described pressing process, the cylindrical portion 12 is pressed radially inward Y1, and therefore, sometimes, slight shape changes occur before and after this process. As a result, although it is assumed that the positional relationship between the inner circumferential surface 12IN of the radially inward Y1 of the cylindrical portion 12 and the sensor rotor 50R assembled therewith may change, the clearance fit size setting has taken into account the changes in the positional relationship and its manufacturing variations, and adopts a clearance fit design with a gap fit within tolerance range.

[0054] Furthermore, in the example of this embodiment 1, an example is shown in which the structure of the angle sensor 50 is set as an external rotor type. That is, an example is described in which a step 12S and a groove 12GR are provided on the inner circumferential surface 12IN of the cylindrical portion 12 constituting the rotor shaft portion 10, the sensor rotor 50R is mounted thereon, and the sensor stator 50S is provided on the radially inner side Y1 of the cylindrical portion 12.

[0055] However, the structure of the angle sensor 50 can also be set as an inner rotor type. That is, the sensor rotor 50R can be mounted by providing a step 12S and a groove 12GR on the outer peripheral surface 12OUT of the cylindrical part 12 that constitutes the rotor shaft part 10, and the sensor stator 50S is provided on the radially outer side Y2 of the cylindrical part 12.

[0056] In addition, the internal rotor type sensor rotor 50R can also be configured as shown in the figure below.

[0057] Figure 4 The configuration structure of the sensor rotor 50R of the angle sensor 50 of this embodiment is shown in a partially enlarged cross-sectional view of the drive unit 100 for hybrid vehicles.

[0058] Figure 5 yes Figure 4 An enlarged cross-sectional view of the main part of the hybrid vehicle drive unit 100 shown.

[0059] In this case, it is possible that a ring-shaped bearing 12B constituting the retaining portion of the rotor shaft portion 10 is provided on its outer peripheral surface, such as... Figure 5 As shown, a groove 12GR is recessed radially inward Y1 and the sensor rotor 50R is fixed thereon.

[0060] In this structure, although the step 12S described above is not formed, the wall surface 12BSW of the bearing connection portion 12BS, which extends radially outward Y2 from the outer periphery of the bearing 12B, constitutes a positioning portion for the axial position of the sensor rotor 50R. Furthermore, a fixing ring 60 is disposed and fixed at a predetermined position in the axial direction X to clamp the sensor rotor 50R between the fixing ring 60 and the wall surface 12BSW from the axial direction X.

[0061] As described above, the sensor rotor 50R can be disposed on the circumferential surface of the radially inner side Y1 or the radially outer side Y2 of each structural part constituting the rotor shaft portion 10.

[0062] Furthermore, in the case where the angle sensor 50 is an external rotor type, for example, the wall surface of the bearing connection 12BS extending in the radial Y direction can be used as a wall surface for positioning the sensor rotor 50R in the axial X direction.

[0063] Next, the manufacturing method of the rotary motor 40, which constitutes the drive unit portion of the hybrid vehicle drive unit 100 of this embodiment, will be described, and its effects will be explained where appropriate. In particular, the main part of the mounting method for mounting the angle sensor 50 to the rotor shaft portion 10 of the rotary motor 40, which constitutes a characteristic part of this embodiment, will be described below.

[0064] Regarding the installation method of mounting the angle sensor 50 to the rotor shaft portion 10 in this embodiment, based on the features described in the structural description above, the following structure will be described: A step 12S and a groove 12GR are provided on the radially inner side of the cylindrical portion 12 of the rotor shaft portion 10. The step 12S has a wall surface 12W that functions as a positioning part for the mounting position of the sensor rotor 50R in the axial direction X. The groove 12GR is provided to lock the fixing ring 60 and has the radial direction Y as the depth direction.

[0065] First, the installation process is carried out. In the installation process, the sensor rotor 50R is inserted along the axial direction X while fitting into the inner circumferential surface 12IN of the inner side of the cylindrical part 12 that constitutes the rotor shaft part 10, until it is near the position of the step 12S used for axial X positioning.

[0066] Furthermore, regarding the installation method of the angle sensor 50, it has been previously described that a portion of the fixing ring 60 enters the interior of the groove 12GR to form an embedded state. However, various installation methods can be envisioned, such as a locking method in which a portion of the outer peripheral surface 60OUT side of the fixing ring 60 is embedded in the interior of the groove 12GR.

[0067] In this embodiment 1, as the first example of the pressing process of embedding a portion of the outer peripheral surface 60OUT side of the fixing ring 60 into the groove 12GR, the method described below is used.

[0068] First, in the state before being installed on the rotor shaft 10, a first protrusion forming process is performed to prepare a structure in which a protrusion 60PR is formed on the outer peripheral surface 60OUT of the fixing ring 60.

[0069] In the first protrusion forming process, when the fixing ring 60 abuts against the sensor rotor 50R, a protrusion 60PR is formed at the position of the outer peripheral surface 60OUT opposite to the groove 12GR.

[0070] Next, a pressing process is performed. In the pressing process, the fixing ring 60 with the above-mentioned protrusion 60PR is inserted from the axial direction X along the inner circumferential surface 12IN of the cylindrical part 12 of the rotor shaft 10. At this time, the fixing ring 60 is pressed in from the axial direction X until it reaches the position where the sensor rotor 50R abuts against the step 12S of the rotor shaft 10.

[0071] As a result, the following state is achieved: the protrusion 60PR of the retaining ring 60 is pushed in relative to the inner circumferential surface 12IN of the cylindrical portion 12, and its axial position is fixed when the protrusion 60PR is pushed in and locked within the groove 12GR of the cylindrical portion 12. At this time, a large reaction force in the axial direction X is generated at the protrusion 60PR. This reaction force is applied as a compressive stress set relative to the sensor rotor 50R, thereby forming a frictional force that prevents the sensor rotor 50R from rotating around its axis.

[0072] In this installation method, by applying a load only to the axial direction X, the fixing ring 60, the sensor rotor 50R, and the rotor shaft 10 can be fixed simultaneously. Furthermore, since the fixing ring 60 is engaged with the cylindrical portion 12 of the rotor shaft 10, the movement of the sensor rotor 50R in the axial direction X can be physically suppressed, thus preventing the sensor rotor 50R from falling off.

[0073] Furthermore, with the retaining ring 60 fixed relative to the cylindrical portion 12 of the rotor shaft 10, a compressive stress is generated relative to the sensor rotor 50R, pressing it in the axial direction X. As a result, a large frictional force can be generated at the contact surface between the cylindrical portion 12 of the rotor shaft 10 and the sensor rotor 50R, thereby suppressing the rotation of the retaining ring 60 around its axis.

[0074] Furthermore, as explained above, when the mounting method of the fixing ring 60 to the cylindrical portion 12 of the rotor shaft 10 is adopted by pressing and fixing, the combined effect of the clearance fit between the sensor rotor 50R and the cylindrical portion 12 means that even after the rotor core 20C is pressed in and fixed to the outer peripheral surface 12OUT side of the cylindrical portion 12 as described above, the installation can still be achieved by setting the gap by setting the dimensional tolerance. Therefore, performance degradation caused by deformation and compressive stress of the sensor rotor 50R can be avoided.

[0075] Furthermore, even in the process of installing the sensor rotor 50R near the step 12S before fixing it with the retaining ring 60, a dimensional design with a gap in the radial Y direction is always employed. This ensures that the sensor rotor 50R will not get stuck during its movement in the axial X direction, making installation of the sensor rotor 50R easier.

[0076] In particular, when the rotor setting process of pressing the rotor 20 into the outer peripheral surface 12OUT of the cylindrical portion 12 of the rotor shaft portion 10 is performed, since the shape of the cylindrical portion 12 may change before and after this process, the sensor rotor 50R is clamped between the fixing ring 60 and the wall surface 12W at a position that forms a clearance fit with the inner peripheral surface 12IN of the cylindrical portion 12 by the fixing ring 60.

[0077] Next, based on the manufacturing method of the rotary motor 40 of Embodiment 1 and its modified example described above, the manufacturing method of the final hybrid vehicle drive device and its resulting effects will be briefly explained below.

[0078] Regarding the rotary motor 40 manufactured by the manufacturing method of Embodiment 1 and its variations, the rotary motor 40 is positioned between the engine 1 and the gearbox 2 in the axial direction X, and, in particular, the rotor 20 in the rotary motor 40 is connected to the drive shaft of the rotor shaft portion 10 constituting the rotating shaft and the drive shaft constituting the power transmission mechanism between the gearbox 2 and the engine 1.

[0079] Furthermore, in the case where a portion of the rotor shaft 10 also serves as the drive shaft, as in Embodiment 1, it is also possible to assemble a portion of the rotor 20, on which the angle sensor is mounted, to the drive shaft. In the example of Embodiment 1, the drive shaft, which is integrally formed by the connecting structural member and the shaft portion, is assembled to the cylindrical portion 12 of the rotor shaft 10 constituting the rotor 20. Moreover, the clutch mechanism is then assembled to the rotary motor 40. The clutch mechanism is assembled on either the engine side or the transmission side. Alternatively, in the case where the clutch mechanism is arranged on both the engine side and the transmission side, it is obviously sufficient to assemble the clutch mechanism on both sides.

[0080] In the above-mentioned processes, the order of operations can be appropriately optimized based on factors such as the ease of assembly of each component to be assembled and the generalizability of the components. By appropriately combining the above-mentioned processes and executing them in sequence, the hybrid vehicle drive device of this embodiment can be manufactured.

[0081] According to the hybrid vehicle drive unit and its manufacturing method described above, in the fixing of the angle sensor relative to the rotary motor, the sensor rotor can be firmly fixed, thereby reliably preventing the sensor from moving in the axial direction from a structural point of view, suppressing component costs and manufacturing costs, and simplifying the structure and manufacturing process, etc.

[0082] Furthermore, when using an external rotor type sensor rotor with a larger diameter and greater weight, this heavier sensor rotor can be secured more firmly and reliably. As a result, the overall manufacturing method for the drive unit of a hybrid vehicle can achieve an excellent manufacturing method, while also significantly reducing manufacturing costs and achieving the high reliability and space efficiency necessary for a vehicle drive unit.

[0083] Furthermore, the output shaft that transmits rotational torque to the engine, the drive shaft on the transmission side, and the rotor shaft that constitutes the rotor of the rotary motor are all shared. Additionally, the angle sensor is positioned within a space defined from both axial ends of the rotor inwards, and not positioned further outwards than the axial ends of the rotor. That is, a structure is adopted in which the bearing portion serving as the retainer, the sensor stator of the angle sensor, and the sensor rotor are housed within the space inside the cylindrical portion that forms part of the rotor shaft. Therefore, in hybrid vehicle drive systems where space is limited in the narrow area between the engine and transmission for accommodating the clutch, rotary motor, and angle sensor, as described above, efficient utilization of the rotor's inner space and high motor output can be simultaneously achieved. This effect is common to both the outer rotor type and the inner rotor type, which is a variation thereof.

[0084] Furthermore, when the angle sensor is configured as an external rotor type, by adopting a structure in which the sensor rotor is fitted and mounted on the circumferential surface of the inner circumferential side of the cylindrical part that holds the rotor core, in addition to the previously described effect of efficiently utilizing space, it is also possible to more firmly and reliably fix the external rotor type sensor rotor with a larger diameter and greater weight, and it is also possible to reduce manufacturing costs.

[0085] Furthermore, since the rotor is supported by the bearing connection and bearing and the support wall of the housing to enable rotation, stable rotation can be ensured even when the rotor is heavy.

[0086] Implementation Method 2 Hereinafter, with the help of the accompanying drawings, Embodiment 2 of this application will be described focusing on the parts that differ from Embodiment 1 described above. Parts identical to those in Embodiment 1 are labeled with the same symbols and their descriptions are omitted.

[0087] In this second embodiment, as a second example of the pressing process of embedding a portion of the outer peripheral surface 60OUT side of the fixing ring 60 into the groove 12GR, the method described below is used.

[0088] Figure 6The configuration structure of the sensor rotor 50R of the angle sensor 50 of this embodiment is shown in a partially enlarged cross-sectional view of the drive unit for hybrid vehicles.

[0089] Regarding the other installation method, firstly, the following steps are performed in the same manner as described in Embodiment 1: the sensor rotor 50R is inserted axially X along the inner circumferential surface 12IN of the cylindrical portion 12 of the rotor shaft portion 10, and positioned to abut against the step 12S of the rotor shaft portion 10. Furthermore, similar to the previously described installation method, since the mating portion between the sensor rotor 50R and the cylindrical portion 12 of the rotor shaft portion 10 is set to a clearance fit, the installation of the sensor rotor 50R near the step 12S of the cylindrical portion 12 is facilitated.

[0090] Next, with the retaining ring 60 abutting against the sensor rotor 50R, as follows: Figure 6 As shown, a tool 70 with an acute angle is used to press and deform the annular retaining ring 60 from the side of the retaining ring 60 that abuts against the sensor rotor 50R on the opposite side in the axial direction X. Ideally, the pressing position, as shown, should be radially outward from the center of the cross-section of the retaining ring 60. The resulting flow portion 60FL is forced into the groove 12GR, thereby creating a state where a portion of the outer peripheral surface 60OUT of the retaining ring 60 is embedded inside the groove 12GR.

[0091] Specifically, as explained above, by pressing the tool 70 to a position radially outward from the center of the cross-section of the retaining ring 60, it is easier to embed the flow portion 60FL into the interior of the groove portion 12GR. As a result, the retaining ring 60 is locked and fixed to the cylindrical portion 12 of the rotor shaft portion 10 while the sensor rotor 50R is being pressed down.

[0092] Furthermore, regarding the fixing ring 60, since it is deformed by being pressed from the axial direction X, a portion of its outer peripheral surface 60OUT side, namely the flow portion 60FL, enters the groove 12GR. Therefore, the first protrusion forming process, which involves setting a pre-set protrusion 60R as described above, can be omitted.

[0093] In addition, in this alternative installation method, for the fixing ring 60, it is pressed in the direction of the sensor rotor 50R along the axial direction X, and a state is formed in which a part of the outer peripheral surface 60OUT side of the fixing ring 60 enters the inside of the groove portion 12GR, thereby completing the locking and fixing. Therefore, in the state where the sensor rotor 50R abuts and is provided on the wall surface 12W, by using the structure of pressing the sensor rotor 50R from the axial direction X with the fixing ring 60, in other words, in the state where the fixing ring 60 is installed and fixed to the cylindrical portion 12, a state is formed in which a compressive stress is generated, and the compressive stress is generated by pressing the sensor rotor 50R along the axial direction X with a set pressure. Therefore, the same structure as that in the case of using the method of locking and fixing by press-fitting described above can be achieved. As a result, it functions in a manner that also suppresses the rotation of the fixing ring 60.

[0094] In this manufacturing method, since there is no need to provide a first convex portion forming process such as forming a convex portion 60PR on the outer periphery of the fixing ring 60 in advance, the component cost can be suppressed. In addition, since there is no need to strictly manage the positional relationship between the convex portion 60PR and the groove portion 12GR in the axial direction X, the manufacturing becomes easy.

[0095] Other desired modes related to the manufacturing method will be described.

[0096] Figure 7 The configuration structure of the sensor rotor 50R of the rotation angle sensor 50 of the present embodiment is shown, which is a partial enlarged cross-sectional view of a drive device for a hybrid vehicle.

[0097] In this example, regarding the setting of each tolerance in the axial direction X of the positions of the sensor rotor 50R, the fixing ring 60, the groove portion 12GR, etc., it is desirable that, as Figure 7 shown, a structure (L1 < L2) is adopted in which the position of the groove portion 12GR of the rotor shaft portion 10 is set so as to be within the fitting range of the fixing ring 60. Thereby, it is possible to prevent the flowing portion 60FL generated when pressing the pressing tool 70 from not entering the groove portion 12GR and escaping in the axial direction X, and thus it is possible to suppress insufficient fixing force and deviation.

[0098] Hereinafter, a modification example in which a partial structure of the above manufacturing method is changed will be described.

[0099] Figure 8 The configuration structure of the sensor rotor 50R of the rotation angle sensor 50 of the present embodiment is shown, which is a partial enlarged cross-sectional view of a drive device for a hybrid vehicle.

[0100] In the first modification example, the sensor rotor 50R is configured to have a plurality of through holes 50RH that are holes penetrating in the axial direction X on the surface facing the fixing ring 60. In addition, as Figure 8 As shown, a tool 70 is used to press near the extension line of the axial direction X from the center of the through hole 50RH. Consequently, when the retaining ring 60 deforms, a portion of the retaining ring 60 opposite to the sensor rotor 50R is generated as a flow portion 60FL2, which is forced into the through hole 50RH, thus creating a state where the flow portion 60FL2 is embedded within the through hole 50RH. As a result, the retaining ring 60 is locked onto the sensor rotor 50R.

[0101] By means of the aforementioned locking mechanism, the movement of the sensor rotor 50R in the rotational direction is not only suppressed by the frictional force from the fixing ring 60, but also by physical suppression, thereby completely fixing the sensor rotor 50R and the rotor shaft 10 in the axial and rotational directions via the fixing ring 60.

[0102] Figure 9 The configuration structure of the sensor rotor 50R of the angle sensor 50 of this embodiment is shown in a partially enlarged cross-sectional view of the drive unit for hybrid vehicles.

[0103] In the second modified example, which will be described next, the through hole 50RH in the rotor 20 of the rotating electric machine is changed to a recess 50RGR as the hole portion, compared to the first modified example. Specifically, since the sensor rotor 50R is composed of stacked electromagnetic steel plates, therefore, as Figure 9 As shown, the recess 50RGR can be formed by drilling a hole only in one of the stacked steel plates (cutting core) that contacts the fixing ring 60. Therefore, compared to drilling holes in all the steel plates, this offers the advantage of a longer mold life. In particular, if a straight section perpendicular to the circumferential direction is provided in the recess 50RGR for effective locking in the rotational direction, corners will be created, leading to increased mold wear. Based on this, drilling only in the cutting core is also effective in increasing the shape freedom of the recess 50RGR.

[0104] In addition, the example shown above is that the recess 50RGR is formed by opening a hole in only one stacked steel plate. However, it is also possible to form the recess 50RGR by forming through holes in at least a predetermined number of steel plates on the other side of the axial direction of the sensor rotor.

[0105] Furthermore, while the above description illustrates a method for embedding the flow portion 60FL2 generated when the tool 70 is pressed against the retaining ring 60, causing the retaining ring 60 to deform, into the through hole 50RH or the recess 50RGR, the method is not limited thereto. For example, a second protrusion forming process may be performed, in which a second protrusion is pre-formed on the surface of the retaining ring 60 corresponding to the side of the sensor rotor 50R on the axial side, and this second protrusion may be pushed into the through hole 50RH or the recess 50RGR during the pressing process.

[0106] In this embodiment, the sensor rotor can also be securely fixed, thereby reliably preventing the sensor rotor from moving in the axial direction from a structural perspective, suppressing component and manufacturing costs, and simplifying the structure and manufacturing process.

[0107] Although this application describes various exemplary implementation methods and embodiments, the various features, methods and functions described in one or more implementation methods are not limited to specific implementation methods, but can also be applied to implementation methods individually or in various combinations to implementation methods.

[0108] Therefore, it is considered that numerous variations not illustrated are also included within the scope of the technology disclosed in this application. For example, this includes variations, additions, or omissions of at least one constituent element, as well as cases where at least one constituent element is extracted and combined with constituent elements of other embodiments.

[0109] Symbol Explanation 1 Engine; 2 Gearbox; 3A, 3B Clutch mechanism; 10 Rotor shaft; 12 Cylindrical section (holding section); 12B Bearing (holding section); 12W Wall; 20 Rotor; 60OUT Outer peripheral surface (first surface); 60PR Protrusion (first protrusion); 50R Sensor rotor; 100 Drive unit for hybrid vehicles.

Claims

1. A rotary motor, the rotary motor comprising a sensor that detects the rotation of a rotor that rotates integrally with a rotating shaft, characterized in that, The annular retaining portion of the rotor is connected to the rotating shaft, forming a rotor shaft portion having the retaining portion and rotating together with the rotor. The rotor shaft portion includes a groove recessed into one radial side on one of its radially outer or radially inner sides, and a wall extending radially from the other radial side on its circumferential surface. The sensor rotor of the sensor is fitted into the circumferential surface and is disposed in axial contact with the wall surface. An annular press-in member is fitted into the circumferential surface, and the press-in member clamps the sensor rotor axially between the press-in member and the wall surface. The press-in member has a first protrusion pre-provided on a first surface facing the circumferential surface of the rotor shaft. When the first surface is pressed axially relative to the circumferential surface of the rotor shaft so that the first protrusion is embedded in the groove, the press-in member and the rotor shaft are locked and fixed.

2. The rotary motor as described in claim 1, characterized in that, The axial positions of the first protrusion and the groove of the press-in member are adjusted such that the press-in member applies a predetermined compressive stress relative to the sensor rotor in the axial direction.

3. The rotary motor as described in claim 1 or 2, characterized in that, The edge of the inner wall constituting the groove has an inclined surface that is inclined relative to the circumferential surface on the axial side, i.e. the wall surface side, and a gap is formed between the inclined surface and the press-in member.

4. The rotary electric motor as described in any one of claims 1 to 3, characterized in that, The press-in member has a second protrusion pre-formed on one side of the axial direction, i.e., the side opposite to the sensor rotor. The sensor rotor has a hole formed on the other side of the axial direction, that is, on the side opposite to the second protrusion. The second protrusion of the press-in member is embedded in the hole of the sensor rotor, thereby locking and fixing the press-in member to the sensor rotor.

5. The rotary electric motor as described in any one of claims 1 to 4, characterized in that, The axial width of the groove is configured to be smaller than the axial width of the press-in member.

6. The rotary electric motor as described in any one of claims 1 to 5, characterized in that, In the structure where the groove and the wall are located on the radially inner side of the rotor shaft, The sensor rotor is positioned axially inward from both ends of the rotor.

7. A drive unit for a hybrid vehicle, comprising: The rotary motor according to any one of claims 1 to 6; as well as engine, Its features are, In the rotary electric motor, the retaining portion of the rotor is connected to and disposed on a rotating shaft, such that the rotor is clamped between a gearbox arranged axially and the engine, the rotating shaft being a power transmission mechanism connecting the engine and the gearbox. The shaft is provided with a clutch mechanism for switching power transmission on and off at least one of the ends on the engine side or the gearbox side.

8. A method for manufacturing a rotary electric motor, wherein in the rotary electric motor, An annular retaining portion that holds the rotor, which rotates integrally with the rotating shaft, is connected to the rotating shaft to form a rotor shaft portion having the retaining portion and rotating together with the rotor. The rotor shaft portion includes a groove recessed into one radial side on one of its radially outer or radially inner sides, and a wall extending radially from the other radial side on its circumferential surface. The sensor rotor, which detects the rotation of the rotor, is fitted with the circumferential surface and is disposed in axial contact with the wall surface. An annular press-in member is fitted into the circumferential surface, and the press-in member clamps the sensor rotor axially between the press-in member and the wall surface. The manufacturing method of the rotary electric motor is characterized by including a pressing process. In the pressing process, the first surface of the pressing member, which faces the circumferential surface of the rotor shaft, is fitted relative to the circumferential surface of the rotor shaft and pressed in from the axial side, so that the pressing member abuts against the sensor rotor, and a portion of one side of the first surface of the pressing member is embedded in the groove, thereby locking and fixing the pressing member to the rotor shaft.

9. The method for manufacturing a rotary electric motor as described in claim 8, characterized in that, A first protrusion forming process is included before the pressing-in process. In the first protrusion forming process, when the pressing-in member abuts against the sensor rotor, a first protrusion is pre-formed at the position of the first surface opposite the groove. In the pressing process, By pushing the first protrusion into the groove, the first protrusion, which is part of one side of the first surface, is embedded in the groove.

10. The method for manufacturing a rotary electric motor as described in claim 8, characterized in that, In the pressing process, With the pressing member in contact with the sensor rotor, the pressing member is pressed from the side opposite in the axial direction to the side of the pressing member that is in contact with the sensor rotor. The pressing deforms the pressing member so that a portion of the first side is squeezed into the groove, thereby setting the state in which a portion of the first side is embedded in the groove.

11. The method for manufacturing a rotary electric motor as described in any one of claims 8 to 10, characterized in that, In the structure where the sensor rotor has a hole on the other side of the axial direction, i.e., the side opposite to the press-in member, A second protrusion forming process is included before the pressing-in process. In the second protrusion forming process, a second protrusion is pre-formed on the axial side of the pressing-in member, that is, on the side opposite to the hole of the sensor rotor. In the pressing process, By pushing the second protrusion into the hole, the second protrusion is positioned as being embedded in the groove.

12. The method for manufacturing a rotary electric motor as described in any one of claims 8 to 10, characterized in that, In the structure where the sensor rotor has a hole on the other side of the axial direction, i.e., the side opposite to the press-in member, Pressing is performed on the pressing member from the side opposite in the axial direction to the side of the pressing member that is opposite to the side of the sensor rotor. This pressing deforms the pressing member so that a portion of the pressing member on the side opposite to the sensor rotor is squeezed into the hole, thereby setting it to a state in which a portion of the side opposite to the sensor rotor is embedded in the hole.

13. The method for manufacturing a rotary electric machine as described in any one of claims 8 to 12, characterized in that, In the structure where the groove and the wall are located on the radially inner circumferential surface of the rotor shaft, In the pressing process, At a position where a clearance fit is formed on the circumferential surface relative to the radial inner side of the rotor shaft, the sensor rotor is clamped between the press-in member and the wall surface by the press-in member.

14. The method for manufacturing a rotary electric machine as described in any one of claims 8 to 13, characterized in that, In the structure where the sensor rotor has a hole on the other side of the axial direction, i.e., the side opposite to the press-in member, The sensor rotor is formed by stacking multiple steel plates axially. The hole is formed by forming through holes in at least a predetermined number of the steel plates that constitute the axial side of the sensor rotor.

15. A method for manufacturing a drive unit for a hybrid vehicle. It is the manufacturing method of the drive unit for hybrid vehicles as described in claim 7. Its features are, Includes the following processes: In the rotary electric motor, the retaining portion of the rotor is connected to a rotating shaft, which is a power transmission mechanism connecting the engine and the gearbox, in a manner sandwiched between a gearbox arranged axially. A clutch mechanism for switching power transmission is provided at least one of the ends of the shaft, the engine side, or the gearbox side.

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