Motor device

Abstract

The invention provides a motor device which can realize miniaturization and improve layout performance relative to a fixed object. The cross-sectional shape of the motor housing along the radial direction of the rotor is formed in a square shape including first to fourth corners. The stator includes: a cylindrical core body; first to fourth core protrusions that come into contact with the first to fourth corners; a plurality of teeth; and a coil wound around the plurality of teeth for each phase, the rotor including a rotating shaft and a ring magnet provided on an outer peripheral portion of the rotating shaft, the ring magnet being provided between the rotor and the first to third corner portions in a radial direction of the rotor on first to third line segments connecting a rotation center of the rotor and the first to third corner portions, and the first to third line segments being provided between the rotor and the first to third corner portions. A U-phase connection terminal, a V-phase connection terminal, and a W-phase connection terminal electrically connected to each of the coils provided for each phase are disposed.

Description

Technical Field

[0001] This invention relates to a motor device having a stator and a rotor. Background Technology

[0002] For example, Patent Document 1 describes a brushless motor comprising a stator fixed to a housing and a rotor rotating relative to the stator. Furthermore, the brushless motor described in Patent Document 1 includes a molded busbar formed by molding three busbars using resin, and includes a terminal retainer and a cover equipped with a connector portion.

[0003] [Existing Technical Documents]

[0004] [Patent Literature]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 2023-125684 Summary of the Invention

[0006] [The problem the invention aims to solve]

[0007] However, in the brushless motor described in Patent Document 1, a thick-walled molded busbar overlaps along the axial direction of the stator, making it difficult to further miniaturize the brushless motor by shortening its shaft length. Furthermore, the connector portion located in the terminal retainer and cover protrudes partially in the radial direction of the housing, resulting in poor layout flexibility of the brushless motor relative to stationary objects.

[0008] The object of the present invention is to provide a motor device that can achieve further miniaturization and improve layout relative to a stationary object.

[0009] [Technical means to solve the problem]

[0010] In one embodiment of the motor device, it includes: a stator fixed inside a motor housing; and a rotor that rotates relative to the stator. The motor housing has a cross-sectional shape along the radial direction of the rotor that is a polygon including multiple corners. The stator has: a cylindrical core body; a core protrusion disposed on the outer periphery of the core body and abutting against the corners; multiple teeth disposed on the inner periphery of the core body; and coils wound around the multiple teeth according to each phase. The rotor includes: a rotating shaft for driving an object; and a magnet disposed on the outer periphery of the rotating shaft. In the radial direction of the rotor, between the rotor and the corners, and on a first line segment connecting the rotation center of the rotor to the corners, a connection terminal electrically connected to each of the coils arranged according to each phase is provided.

[0011] [The effects of the invention]

[0012] The present invention enables motor devices that can be further miniaturized and have improved layout relative to stationary objects. Attached Figure Description

[0013] Figure 1 This is a 3D diagram showing a motor used in a vehicle's seat.

[0014] Figure 2 yes Figure 1 A cross-sectional view of the motor for the seat along the axis of rotation.

[0015] Figure 3 yes Figure 2 A cross-sectional view along line AA.

[0016] Figure 4 This indicates the state where the cover component has been removed. Figure 2 The B-arrow view.

[0017] Figure 5 This is a three-dimensional view of the main body of the cover from the wiring unit side.

[0018] Figure 6 This is a three-dimensional view of the cover body from the sensor substrate side.

[0019] Figure 7 This is an exploded perspective view showing the rotor, the first planetary gear reducer, and the second planetary gear reducer.

[0020] Figure 8 It is a three-dimensional diagram representing a wiring unit.

[0021] Figure 9 This diagram illustrates the configuration structure of the U-phase connection terminal, V-phase connection terminal, W-phase connection terminal, and the connector connection part for the sensor.

[0022] Figure 10 This is an exploded perspective view of the electric motor section.

[0023] Figure 11 This diagram illustrates the power-on test of the electric motor section.

[0024] Figure 12 It is a three-dimensional view showing the electric motor section, wiring unit, and cover components.

[0025] Figure 13 This is a diagram showing the connection sequence of the wiring unit relative to the electric motor section.

[0026] Figure 14 This diagram shows the connection sequence of the speed reduction mechanism relative to the electric motor.

[0027] Explanation of icon numbers

[0028] 10: Seat motor (motor unit)

[0029] 11: First ball bearing

[0030] 11a: Outer ring

[0031] 11b: Inner circle

[0032] 11c: Steel ball

[0033] 12: Second ball bearing (bearing)

[0034] 12a: Outer ring

[0035] 12b: Inner circle

[0036] 12c: Steel ball

[0037] 13: Cover component (bearing retainer)

[0038] 14: Main body of the cover

[0039] 14a: Engagement recess

[0040] 14b: Hook and hook section

[0041] 15: Bottom wall of the cover

[0042] 15a: Bearing retainer

[0043] 15b: Power cord retaining claw

[0044] 16a: First cover sidewall

[0045] 16b: Second cover sidewall

[0046] 16c: Third cover sidewall

[0047] 16d: Fourth cover sidewall

[0048] 17a: First corner of the cover

[0049] 17b: Second corner of the cover

[0050] 17c: Third corner of the cover

[0051] 17d: Fourth corner of the cover

[0052] 18: Cover component

[0053] 18a: Incision site

[0054] 18b: Hook and claw

[0055] 20: Electric Motor Department

[0056] 21: Motor housing

[0057] 21a: Claw engagement

[0058] 22: Bottom wall

[0059] 22a: Bearing support sleeve

[0060] 22b: Threaded hole

[0061] 23a: First sidewall portion

[0062] 23b: Second sidewall portion

[0063] 23c: Third sidewall portion

[0064] 23d: Fourth sidewall

[0065] 24a: First corner (corner)

[0066] 24b: Second corner (corner)

[0067] 24c: Third corner (corner)

[0068] 24d: Fourth corner (corner)

[0069] 25: Opening

[0070] 26: Through hole

[0071] 27a, 27b, 27c: Hall effect elements (rotation sensors)

[0072] 30: Stator

[0073] 31: Stator core

[0074] 32: Core Body

[0075] 33a: First core protrusion (core protrusion)

[0076] 33b: Second core projection (core projection)

[0077] 33c: Third core projection (core projection)

[0078] 33d: Fourth core protrusion (core protrusion)

[0079] 34: Teeth

[0080] 35: Insulator

[0081] 36: Coil

[0082] 40: Rotor

[0083] 41: Rotation axis

[0084] 41a: Small diameter portion

[0085] 42: Rotor core

[0086] 42a: Fixing hole

[0087] 43: Ring magnet (magnet)

[0088] 44: Abutment component

[0089] 45: Opposing components

[0090] 50: Speed ​​Reduction Mechanism

[0091] 51: Gearbox housing

[0092] 51a: Engaging claw

[0093] 52: Annular bottom wall

[0094] 52a: Fitting tube

[0095] 53: Opening

[0096] 60: Planetary gear reducer (for driving objects)

[0097] 61: Gearbox

[0098] 61a: Internal gear

[0099] 61b: Large diameter part

[0100] 61c: Trail Department

[0101] 61d: Box opening

[0102] 62: Third ball bearing

[0103] 62a: Outer ring

[0104] 62b: Inner ring

[0105] 62c: Steel ball

[0106] 63: Closed component

[0107] 63a: Through hole

[0108] 70: First planetary gear reducer

[0109] 71: First Sun Gear

[0110] 72: First Planetary Gear

[0111] 73: First support frame

[0112] 80: Second planetary gear reducer

[0113] 81: Second Sun Gear

[0114] 82: Second Planetary Gear

[0115] 83: Second support frame

[0116] 84: Output shaft

[0117] 90: Wiring unit

[0118] 91: Connector connection part

[0119] 92: Power wiring

[0120] 92a: Sheath

[0121] 93: Signal wiring

[0122] 93a: Sheath

[0123] 94: Wiring Connector

[0124] BS: Boss for stacking and fixing

[0125] C: Rotor's center of rotation

[0126] CN: Connector connection part for sensor (controller connection part)

[0127] CR: Vehicle Controller (Controller)

[0128] HS: Screw through hole

[0129] Hc: Connector through hole

[0130] Hu: U-phase terminal insertion hole

[0131] Hv: V-phase terminal insertion hole

[0132] Hw: W-phase terminal insertion hole

[0133] L1: First line segment (first line segment)

[0134] L2: Second line segment (first line segment)

[0135] L3: Third line segment (first line segment)

[0136] L4: Fourth line segment (second line segment)

[0137] PN: Support pin

[0138] S: Fixing screw

[0139] SA: Stator assembly

[0140] SB: Sensor substrate

[0141] SC: Baseboard fixing screws

[0142] SH: Shoulder area

[0143] SNSR: Sensor wiring

[0144] SP: Coil Spring

[0145] SP1, SP2, SP3: Assembly fixture import space

[0146] ST: Sensor terminal

[0147] SW: Sensor line

[0148] TEST: Test setup

[0149] Tu: U-phase connection terminal (connection terminal)

[0150] Tv: V-phase connection terminal (connection terminal)

[0151] Tw: W-phase connection terminal (connection terminal)

[0152] U: U phase wiring

[0153] V: V phase wiring

[0154] W: W phase wiring

[0155] UL: U-phase power cord (power cord)

[0156] VL: V-phase power line (power cord)

[0157] WL: W-phase power cord (power cord)

[0158] WT: Connector Detailed Implementation

[0159] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0160] Figure 1 A perspective view showing a seat motor mounted in a vehicle is shown. Figure 2 Show Figure 1 A cross-sectional view of the motor used in the seat along the axis of rotation. Figure 3 Show Figure 2 A cross-sectional view along line AA. Figure 4 This shows the state indicating that the cover component has been removed. Figure 2 The B-arrow view, Figure 5 A perspective view of the main body of the cover is shown from the wiring unit side. Figure 6 This shows a perspective view of the cover body viewed from the sensor substrate side. Figure 7 An exploded perspective view showing the rotor, the first planetary gear reducer, and the second planetary gear reducer is shown. Figure 8 A three-dimensional view representing a wiring unit is shown. Figure 9The diagram illustrates the configuration structure of the U-phase connection terminal, V-phase connection terminal, W-phase connection terminal, and sensor connector connection part.

[0161] <Overview of Electric Seats>

[0162] Figure 1 The seat motor 10 shown is a drive source built into an electric seat installed in a vehicle such as an automobile. Specifically, the seat motor 10 drives the backrest tilting mechanism, the sliding mechanism that moves the electric seat back and forth, and the lifting mechanism that raises and lowers the seat. As a result, the driver can adjust the posture or position of the electric seat to match the driver's preferred driving position by operating the control switches located on the side of the electric seat.

[0163] The seat motor 10 has a wiring unit 90 including a connector connection portion 91. The connector connection portion 91 is electrically connected to the vehicle controller CR, and a power wiring 92 and a signal wiring 93 are arranged between the connector connection portion 91 and the electric motor portion 20 that forms the seat motor 10. Here, the power wiring 92 supplies drive current to the electric motor portion 20, and the signal wiring 93 sends sensor signals indicating the rotational state of the electric motor portion 20 to the vehicle controller CR.

[0164] Therefore, the vehicle controller CR can, for example, store multiple driving positions (electric seat postures) corresponding to drivers of different physiques. Moreover, the driver can recall the stored driving position according to their own preferences.

[0165] Furthermore, the seat motor 10 is equivalent to the motor device in this invention.

[0166] <Car seat motor>

[0167] like Figures 1 to 9 As shown, the seat motor 10 includes an electric motor section 20, a reduction gear section 50, and a wiring unit 90. Specifically, the electric motor section 20 and the reduction gear section 50 are respectively arranged on a coaxial axis. Moreover, the electric motor section 20 and the reduction gear section 50 are interconnected. Figure 1 and Figure 2 In the state shown, it forms a long, square, roughly rod-like shape.

[0168] <Electric Motor Section>

[0169] The electric motor unit 20 includes a motor housing 21 that forms its outer contour. The motor housing 21 is formed into a bottomed cylindrical shape by deep drawing or similar processes on a steel sheet, and... Figure 3 As shown, the cross-sectional shape along the direction orthogonal to the length direction is roughly square.

[0170] Specifically, along the length of the motor housing 21, on the side where the reduction gear section 50 is located ( Figure 2 A bottom wall portion 22 is provided on the left side. Additionally, as... Figure 3 , Figure 4 and Figure 9 As shown, the motor housing 21 includes a first sidewall portion 23a, a second sidewall portion 23b, a third sidewall portion 23c, and a fourth sidewall portion 23d.

[0171] Furthermore, the first sidewall portion 23a and the second sidewall portion 23b are connected to each other via the first corner portion 24a, and the second sidewall portion 23b and the third sidewall portion 23c are connected to each other via the second corner portion 24b. Furthermore, the third sidewall portion 23c and the fourth sidewall portion 23d are connected to each other via the third corner portion 24c, and the fourth sidewall portion 23d and the first sidewall portion 23a are connected to each other via the fourth corner portion 24d.

[0172] Thus, the cross-sectional shape of the motor housing 21 along the radial direction of the rotor 40 is formed as a regular polygon (square in this embodiment) including a total of four corners, namely the first corner 24a to the fourth corner 24d. Furthermore, the first corner 24a to the fourth corner 24d correspond to the corners in this invention.

[0173] Here, the first corner portion 24a to the fourth corner portion 24d are all arc-shaped, forming part of a circle of the same size centered on the rotation center C of the rotor 40. That is, when the motor housing 21 is viewed from the axial direction of the rotor 40, the first corner portion 24a to the fourth corner portion 24d are all formed in an arc shape. Moreover, the inner periphery of the arc-shaped portion inside the first corner portion 24a to the fourth corner portion 24d respectively abuts against the front end portions of the first core protrusion 33a, the second core protrusion 33b, the third core protrusion 33c, and the fourth core protrusion 33d that form the outer periphery of the stator core 31.

[0174] Here, the contact portions between the stator core 31 and the motor housing 21, i.e., the mutual abutment portions, are only four locations in total, consisting of the front ends of the first core protrusion 33a to the fourth core protrusion 33d. Furthermore, small gaps (not shown in detail) are formed in other portions between the stator core 31 and the motor housing 21. This prevents the pressing load on the stator core 31 relative to the motor housing 21 from becoming excessive, improving the assemblability of the electric motor section 20. In addition, the fixing strength of the stator core 31 relative to the motor housing 21 is sufficiently ensured by a certain degree of pressing load between the stator core 31 and the motor housing 21.

[0175] In addition, such as Figure 2 As shown, a bearing support cylinder 22a is integrally provided in the center of the bottom wall portion 22 of the motor housing 21. Furthermore, the outer ring 11a of the first ball bearing 11 is fixed to the bearing support cylinder 22a in the bottom wall portion 22 by pressing.

[0176] Specifically, the first ball bearing 11 has an electric motor section 20 disposed on one side along its axial direction. Figure 2 Approximately two-thirds of the right side of the first ball bearing 11 is pressed into the bearing support cylinder 22a. In addition, approximately one-third of the axial portion of the first ball bearing 11 on the side where the speed reduction mechanism 50 is located protrudes from the bearing support cylinder 22a toward the side where the speed reduction mechanism 50 is located.

[0177] Here, the first ball bearing 11 supports the side of the rotating shaft 41 where the speed reduction mechanism 50 is located in the axial direction, allowing it to rotate freely. The inner ring 11b of the first ball bearing 11 is mounted on the side of the rotating shaft 41 where the speed reduction mechanism 50 is located. Specifically, the inner ring 11b of the first ball bearing 11 is mounted on the rotating shaft 41 in a manner that allows it to move only in the axial direction of the rotating shaft 41.

[0178] In addition, such as Figure 2 As shown, in the radial direction of the first ball bearing 11, a plurality of steel balls 11c are arranged between the outer ring 11a, which is located on the outer side of the radial direction, and the inner ring 11b, which is located on the inner side of the radial direction. As a result, the outer ring 11a and the inner ring 11b can rotate smoothly relative to each other via the steel balls 11c.

[0179] Here, on the axial direction of the rotating shaft 41 (rotor 40), the side of the seat motor 10 equipped with the wiring unit 90 is positioned ( Figure 2 The right side) is defined as the "axial (length direction) side", and the side of the seat motor 10 equipped with the reduction mechanism 50 is defined as the side of the seat motor 10. Figure 2 The left side is defined as "the other side of the axial (length direction) direction".

[0180] like Figure 2 As shown, a pair of threaded holes 22b are provided on the bottom wall portion 22 (only one is shown in the figure). Specifically, the pair of threaded holes 22b are arranged facing each other with the bearing support sleeve 22a as the center. Moreover, each threaded hole 22b is threaded with a fixing screw S for fixing the reduction mechanism portion 50 to the electric motor portion 20 (see reference). Figure 14 ).

[0181] In addition, such as Figure 2 As shown, an opening 25 is provided on the axial side of the motor housing 21, that is, on the side opposite to the bottom wall 22. The stator 30 or the rotor 40 is assembled into the inside of the motor housing 21 through the opening 25.

[0182] <Stator>

[0183] like Figures 2 to 4 and Figure 9As shown, a stator (fixed element) 30 is fixed inside the motor housing 21. Specifically, the stator 30 includes a stator core 31, which is formed into a generally cylindrical shape by laminating thin steel plates containing ferromagnetic materials. The stator core 31 is fixed by pressing it into the inside of the motor housing 21.

[0184] like Figure 3 and Figure 9 As shown, the stator core 31 includes a core body 32 formed in a cylindrical shape. In addition, a first core protrusion 33a, a second core protrusion 33b, a third core protrusion 33c, and a fourth core protrusion 33d (a total of four) are integrally provided on the outer periphery of the core body 32, which are formed in a generally triangular shape when the core body 32 is viewed from the axial direction.

[0185] Furthermore, the first core protrusion 33a to the fourth core protrusion 33d correspond to the core protrusions in this invention.

[0186] Furthermore, the front ends of these first core protrusions 33a to fourth core protrusions 33d respectively abut against the inner periphery of the first corner portion 24a to fourth corner portion 24d. Specifically, the front ends of the first core protrusions 33a to fourth core protrusions 33d contact the arc-shaped inner periphery of the inner side of the first corner portion 24a to fourth corner portion 24d.

[0187] Therefore, when the stator core 31 is pressed into and fixed to the motor housing 21, damage to the inner circumference of the first corner portion 24a to the fourth corner portion 24d can be prevented from being sheared off. On the other hand, the fixing strength of the stator core 31 relative to the motor housing 21 can be ensured to be sufficient. Furthermore, in Figure 3 and Figure 9 In the middle, a dashed line (baseline) is drawn at the boundary between the core body 32 and the first core protrusion 33a to the fourth core protrusion 33d.

[0188] Here, the stator 30, including the stator core 31, is inserted into the motor housing 21 through the opening 25. An automatic assembly device (not shown) can be used during this insertion operation. Therefore, the stator 30 is positioned precisely in the specified position relative to the axial direction of the motor housing 21.

[0189] Furthermore, each of the first core protrusion 33a to the fourth core protrusion 33d is provided with a stacking and fixing boss BS. That is, the stacked thin steel plates forming the stator core 31 are firmly fixed to each other by a total of four bosses BS. Thus, the first core protrusion 33a to the fourth core protrusion 33d, which have a relatively large area when viewed from the axial direction and are close to the outer periphery of the stator core 31, are provided with stacking and fixing bosses BS. In addition, as Figure 9As shown, a total of four bosses BS are arranged on the first line segment L1 to the fourth line segment L4. Therefore, during the forming of the bosses BS, i.e., during the assembly of the stator core 31, the misalignment of the core body 32 or the teeth 34 is suppressed.

[0190] like Figure 3 As shown, a plurality of teeth 34 protruding toward the rotor 40 are integrally provided on the inner side, i.e., the inner circumference, in the radial direction of the core body 32. Here, the number of teeth 34 is equal to the number of slots in the stator core 31, which is 6 in this embodiment. Of course, the number of teeth 34 can be arbitrarily set according to the specifications of the electric motor unit 20.

[0191] An insulator 35, comprising a resin material such as plastic, is installed on each of the six teeth 34. Furthermore, a coil 36 is wound around each tooth 34 via the insulator 35. Here, a coil 36 of the same phase is wound around each pair of teeth 34 facing each other with the rotor 40 as the center. That is, the coils 36 are arranged at equal intervals (60-degree intervals) relative to the circumference of the stator 30 in the order of U phase, V phase, W phase, U phase, V phase, W phase. Thus, each coil 36 is wound around each tooth 34 according to each phase.

[0192] In addition, such as Figure 4 As shown, two coils 36 corresponding to each of the U, V, and W phases are electrically connected via tie wires WT to the corresponding U-phase connection terminals Tu, V-phase connection terminals Tv, and W-phase connection terminals Tw. These U-phase connection terminals Tu, V-phase connection terminals Tv, and W-phase connection terminals Tw are formed into approximately plate-like shapes from highly conductive materials such as brass and are positioned on one axial side of the stator 30. That is, the U-phase connection terminals Tu, V-phase connection terminals Tv, and W-phase connection terminals Tw are positioned near the opening 25 along the length of the motor housing 21.

[0193] Furthermore, the U-phase connection terminal Tu, the V-phase connection terminal Tv, and the W-phase connection terminal Tw are equivalent to the connection terminals in this invention.

[0194] Specifically, such as Figure 9 As shown, the U-phase connection terminal Tu is arranged axially on the rotor 40, overlapping the core body 32 on one side of the core body 32. Furthermore, the U-phase connection terminal Tu is arranged radially on the rotor 40 between the rotor 40 and the first corner portion 24a (radial direction region AR1). Moreover, the U-phase connection terminal Tu is arranged radially on the rotor 40 on the first line segment L1 connecting the rotation center C of the rotor 40 to the circumferential center of the first corner portion 24a in the motor housing 21.

[0195] The V-phase connection terminal Tv is also configured axially on the rotor 40, overlapping the core body 32 on one side of the core body 32. Furthermore, the V-phase connection terminal Tv is configured radially on the rotor 40 between the rotor 40 and the second corner portion 24b (a region with the same width as the radial region AR1). Moreover, the V-phase connection terminal Tv is configured radially on the rotor 40 on the second line segment L2 connecting the rotation center C of the rotor 40 to the circumferential center of the second corner portion 24b in the motor housing 21.

[0196] The W-phase connection terminal Tw is also configured in the axial direction of the rotor 40 to overlap with the core body 32 on one side of the core body 32. Furthermore, the W-phase connection terminal Tw is disposed in the radial direction of the rotor 40 between the rotor 40 and the third corner portion 24c (a region with the same width as the radial direction region AR1). Moreover, the W-phase connection terminal Tw is disposed in the radial direction of the rotor 40 on the third line segment L3 that connects the rotation center C of the rotor 40 to the circumferential center of the third corner portion 24c in the motor housing 21.

[0197] Furthermore, the first line segment L1, the second line segment L2, and the third line segment L3 configured for the U-phase connection terminal Tu, the V-phase connection terminal Tv, and the W-phase connection terminal Tw respectively correspond to the first line segment in this invention. Additionally, in Figure 9 The diagram only shows the motor housing 21 (dark shaded) and the stator core 31 (light shaded).

[0198] Furthermore, the U-phase connection terminal Tu, the V-phase connection terminal Tv, and the W-phase connection terminal Tw extend from one axial side of the stator 30 toward the wiring unit 90. On the wiring unit 90 side of the U-phase connection terminal Tu, the V-phase connection terminal Tv, and the W-phase connection terminal Tw, respectively, are electrically connected the U-phase power line UL, the V-phase power line VL, and the W-phase power line WL forming the power wiring 92 (see reference). Figure 8 Specifically, the U-phase connection terminal Tu, V-phase connection terminal Tv, W-phase connection terminal Tw, and U-phase power lines UL, V-phase power lines VL, and W-phase power lines WL are soldered together (see reference). Figure 13 They are electrically connected to each other.

[0199] Here, as Figure 4 and Figure 9As shown, in the radial direction of the rotor 40, assembly fixture guide spaces SP1, SP2, and SP3 are respectively formed between the U-phase connection terminal Tu and the first corner portion 24a, between the V-phase connection terminal Tv and the second corner portion 24b, and between the W-phase connection terminal Tw and the third corner portion 24c. Specifically, these assembly fixture guide spaces SP1, SP2, and SP3 face the first core protrusion 33a, the second core protrusion 33b, and the third core protrusion 33c in the axial direction of the stator 30.

[0200] In addition, such as Figure 13 As shown, when assembling the seat motor 10, the soldering iron TL, which serves as an assembly fixture, enters the assembly fixture guide space SP1, assembly fixture guide space SP2, and assembly fixture guide space SP3. Thus, the assembly fixture guide space SP1, assembly fixture guide space SP2, and assembly fixture guide space SP3 have the function of easily soldering (connecting) the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw to the U-phase power line UL, V-phase power line VL, and W-phase power line WL, respectively.

[0201] In addition, such as Figure 9 As shown, in the radial direction of the rotor 40, between the rotor 40 and the fourth corner 24d (a region with the same width as the radial direction region AR1) and on the fourth line segment L4 connecting the rotation center C of the rotor 40 and the fourth corner 24d of the motor housing 21, a sensor substrate SB (see reference) is disposed. Figure 6 The sensor connector CN (refer to) Figure 5 Part of the sensor connector connection CN. Furthermore, the sensor connector connection CN faces the fourth core protrusion 33d in the axial direction of the stator 30. That is, the sensor connector connection CN is disposed near the fourth corner 24d in the motor housing 21. Therefore, in the axial direction of the rotor 40, the sensor connector connection CN can be disposed at the same position as the positions where the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw are disposed, thereby suppressing the increase in the axial dimension of the seat motor 10.

[0202] Furthermore, the fourth line segment L4, which is configured as a part of the connector connection part CN for the sensor, corresponds to the second line segment in this invention.

[0203] <Rotor>

[0204] like Figures 2 to 4 and Figure 7As shown, a rotor (rotor) 40 is rotatably disposed within a small gap (air gap) on the inner radial side of the stator 30. That is, the rotor 40 rotates relative to the stator 30. The rotor 40 includes a rotating shaft 41 comprising a stepped round steel bar. Specifically, on the other axial side of the rotating shaft 41 ( Figure 2 A small-diameter portion 41a is integrally provided on the left side, and a first sun gear 71 forming a first planetary gear reducer 70 is fixed to the small-diameter portion 41a. That is, the rotating shaft 41 drives the first planetary gear reducer 70.

[0205] Furthermore, on one axial side of the rotating shaft 41 ( Figure 2 The right side of the rotating shaft 41 is rotatably supported by the second ball bearing 12, and the other axial side of the rotating shaft 41 is rotatably supported by the first ball bearing 11. That is, the rotating shaft 41 is rotatably supported by the first ball bearing 11 and the second ball bearing 12 fixed to the motor housing 21 and the cover member 13.

[0206] In addition, a rotor core 42, which is formed by stacking multiple steel plates containing ferromagnetic materials, is installed on the outer periphery of the rotating shaft 41. Specifically, by pressing the rotating shaft 41 into the fixing hole 42a of the rotor core 42, the rotor core 42 is firmly fixed at a predetermined position in the axial direction of the rotating shaft 41.

[0207] Furthermore, an annular magnet 43 is fixed to the outer periphery of the rotor core 42 via an adhesive (not shown). That is, the annular magnet 43 is disposed on the outer periphery of the rotating shaft 41, and is, for example, a neodymium magnet, and is formed in a generally cylindrical shape. Additionally, the annular magnet 43 is magnetized in a manner where S poles, N poles, S poles, N poles (a total of 4 poles) are alternately arranged in its circumferential direction. In other words, the electric motor unit 20 becomes a 4-pole, 6-slot brushless motor. Of course, the number of poles of the annular magnet 43 can be arbitrarily set according to the specifications of the electric motor unit 20.

[0208] Furthermore, the ring magnet 43 is equivalent to the magnet in this invention.

[0209] like Figure 2 As shown, the other axial side of the annular magnet 43 abuts against the abutting member 44 fixed to the rotating shaft 41. On the other hand, one axial side of the annular magnet 43 abuts against the opposing member 45 fixed to the rotating shaft 41. Thus, the annular magnet 43 is precisely positioned in the axial direction of the rotating shaft 41 at a predetermined position between the abutting member 44 and the opposing member 45.

[0210] Here, the other axial side of the abutting member 44 abuts against the inner ring 11b of the first ball bearing 11. That is, the axial position of the rotating shaft 41, to which the abutting member 44 is fixed, is defined by the first ball bearing 11. Furthermore, on one axial side of the abutting member 44, in addition to abutting against the annular magnet 43, it also abuts against the other axial side of the rotor core 42. Thus, the axial positions of the rotor core 42 and the annular magnet 43 are defined via the abutting member 44 and the first ball bearing 11.

[0211] In contrast, an opposing member 45 is fixed on one axial side of the rotating shaft 41, the opposing member 45 being disposed axially between the second ball bearing 12 and the annular magnet 43. Furthermore, a helical spring SP is disposed on one axial side of the opposing member 45, the helical spring SP being disposed between the opposing member 45 and the inner ring 12b of the second ball bearing 12 in a state where an initial load has been applied.

[0212] Therefore, the rotor 40 and the helical spring SP are arranged to support each other between the inner ring 11b of the first ball bearing 11 and the inner ring 12b of the second ball bearing 12. This suppresses axial wobble of the inner ring 11b of the first ball bearing 11 and the inner ring 12b of the second ball bearing 12 relative to their respective outer rings 11a and 12a. In other words, the spring force of the helical spring SP has the function of suppressing axial wobble of the first ball bearing 11 and the second ball bearing 12, and reducing the operating noise of the seat motor 10.

[0213] <Cover Components>

[0214] like Figure 2 As shown, the opening 25 of the motor housing 21 is closed by the cover member 13. This prevents dust and other contaminants from entering the inside of the motor housing 21. Specifically, the cover member 13 includes a cover body 14 and a cover member 18.

[0215] like Figure 5 and Figure 6 As shown, the cover body 14 is formed into a roughly square bowl shape from a resin material such as plastic. The cover body 14 includes a cover bottom wall 15 formed into a roughly square shape, and a first cover side wall 16a, a second cover side wall 16b, a third cover side wall 16c, and a fourth cover side wall 16d integrally formed with the cover bottom wall 15.

[0216] Furthermore, with the electric motor unit 20 assembled, the first cover sidewall 16a and the first sidewall portion 23a (see reference) Figure 4 Arranged axially on rotor 40, the second cover sidewall 16b and the second sidewall portion 23b (refer to...) Figure 4 Arranged axially on rotor 40, the third cover sidewall 16c and the third sidewall portion 23c (refer to...) Figure 4Arranged axially on rotor 40, the fourth cover sidewall 16d and the fourth sidewall portion 23d (refer to...) Figure 4 They are arranged axially on rotor 40.

[0217] Furthermore, the first cover sidewall 16a and the second cover sidewall 16b are connected to each other via the first cover corner 17a, and the second cover sidewall 16b and the third cover sidewall 16c are connected to each other via the second cover corner 17b. Furthermore, the third cover sidewall 16c and the fourth cover sidewall 16d are connected to each other via the third cover corner 17c, and the fourth cover sidewall 16d and the first cover sidewall 16a are connected to each other via the fourth cover corner 17d.

[0218] Here, engaging recesses 14a are respectively provided on the first cover sidewall 16a and the third cover sidewall 16c, which are arranged facing each other with the second ball bearing 12 as the center. Figure 4 As shown, in these engaging recesses 14a, a total of four engaging claws 21a engage with two motor housings 21 each. As a result, the cover body 14 (cover member 13) is in a state that prevents it from wobbling relative to the motor housings 21 and thus prevents it from falling off.

[0219] like Figure 5 As shown, a bearing retainer 15a is integrally provided in the center of the bottom wall 15 of the cover body 14, and the bearing retainer 15a extends along the axial direction of the rotor 40. Furthermore, the outer ring 12a of the second ball bearing 12 (see reference) is pressed into and fixed to the inner side of the bearing retainer 15a. Figure 2 That is, a bearing retainer 15a is provided in the cover member 13, and the bearing retainer 15a holds the second ball bearing 12 in its inner circumference.

[0220] Furthermore, the second ball bearing 12 supports one axial side of the rotating shaft 41 for free rotation, and the inner ring 12b of the second ball bearing 12 is mounted on one axial side of the rotating shaft 41. Specifically, the inner ring 12b of the second ball bearing 12 is mounted on the rotating shaft 41 in a manner that allows it to move only in the axial direction of the rotating shaft 41.

[0221] Here, in the radial direction of the second ball bearing 12, a plurality of steel balls 12c are arranged between the outer ring 12a, which is located on the outer side of the radial direction, and the inner ring 12b, which is located on the inner side of the radial direction. Thus, the outer ring 12a and the inner ring 12b can rotate smoothly relative to each other via the steel balls 12c. Furthermore, both the first ball bearing 11 and the second ball bearing 12 are general-purpose products and use the same type of bearing. This improves assemblability while facilitating parts management.

[0222] Thus, the cover member 13 that closes the opening 25 supports the second ball bearing 12, which is equivalent to the bearing retainer in this invention. Furthermore, the second ball bearing 12 held in the cover member 13 is equivalent to the bearing in this invention.

[0223] like Figure 5 As shown, on one axial side of the bearing retainer 15a ( Figure 2 On the right side of the bearing retainer 15a, a total of three power cable retaining claws 15b are integrally provided. These power cable retaining claws 15b protrude outward in the radial direction of the bearing retainer 15a at a specified height on the axial side of the bearing retainer 15a. That is, a total of three power cable retaining claws 15b are provided on the outer periphery of the bearing retainer 15a.

[0224] Furthermore, the three power line retaining claws 15b have U-phase power line UL, V-phase power line VL, and W-phase power line WL (see reference) provided along the outer periphery of the bearing retaining sleeve 15a. Figure 8 Specifically, each power line retaining claw 15b has the function of restricting the axial movement of the U-phase power line UL, V-phase power line VL, and W-phase power line WL within the bearing retaining sleeve 15a.

[0225] Here, as Figure 2 As shown, when viewing the second ball bearing 12, which is held inside the bearing retainer 15a, from the radial direction of the rotor 40, a portion of the U-phase power line UL, V-phase power line VL, W-phase power line WL, and the sensor connector connection part CN overlaps with the second ball bearing 12. That is, a portion of the U-phase power line UL, V-phase power line VL, W-phase power line WL, and the sensor connector connection part CN extends into the inner side of the axial region AR2 of the second ball bearing 12.

[0226] Thus, the second ball bearing 12, the U-phase power line UL, the V-phase power line VL, the W-phase power line WL, and the sensor connector CN are efficiently and well configured in the designated positions of the cover body 14, thereby suppressing the axial increase of the cover body 14.

[0227] In addition, such as Figure 5 and Figure 6 As shown, the bottom wall 15 of the cover body 14 is provided with terminals Tu for U-phase connection, Tv for V-phase connection, and Tw for W-phase connection along the axial direction of the rotor 40 (see reference). Figure 4The rotor 40 has U-phase terminal insertion holes Hu, V-phase terminal insertion holes Hv, and W-phase terminal insertion holes Hw, which are respectively inserted through. These U-phase terminal insertion holes Hu, V-phase terminal insertion holes Hv, and W-phase terminal insertion holes Hw are each formed in a generally rectangular shape. Furthermore, in the radial direction of the rotor 40, the U-phase terminal insertion hole Hu is disposed between the bearing retaining sleeve 15a and the first cover corner portion 17a, the V-phase terminal insertion hole Hv is disposed between the bearing retaining sleeve 15a and the second cover corner portion 17b, and the W-phase terminal insertion hole Hw is disposed between the bearing retaining sleeve 15a and the third cover corner portion 17c.

[0228] Furthermore, a connector insertion hole Hc is provided on the bottom wall 15 of the cover body 14, through which the sensor connector connection part CN is inserted in the axial direction of the rotor 40. The connector insertion hole Hc is also generally rectangular in shape, similar to the U-phase terminal insertion hole Hu, the V-phase terminal insertion hole Hv, and the W-phase terminal insertion hole Hw. Moreover, in the radial direction of the rotor 40, the connector insertion hole Hc is disposed between the bearing retaining sleeve 15a and the fourth cover side wall 16d and the fourth cover corner 17d.

[0229] like Figure 6 As shown, on one side of the bottom wall 15 of the cover, an electric motor section 20 is provided ( Figure 2 A sensor substrate SB is fixed to the left side of the housing. Specifically, the sensor substrate SB is fixed to the bottom wall 15 of the housing via substrate fixing screws SC. A through hole 26 is provided in the center of the sensor substrate SB, extending through one side of the axial direction of the rotation shaft 41. Three Hall elements 27a, 27b, and 27c, corresponding to the U phase, V phase, and W phase, are arranged around the through hole 26. Furthermore, these Hall elements 27a, 27b, and 27c are arranged at equal intervals (120-degree intervals) in the circumferential direction of the through hole 26.

[0230] In addition, a total of three Hall elements 27a, 27b, and 27c are positioned axially on the rotor 40 and connected to the annular magnet 43 (see reference). Figure 2 The axial sides of the Hall elements 27a, 27b, and 27c face each other. Thus, each Hall element 27a, Hall element 27b, and Hall element 27c generates a rectangular wave signal at each time point according to the change of the magnetic poles accompanying the rotation of the annular magnet 43 (rotor 40).

[0231] Here, a total of three Hall elements 27a, 27b, and 27c are electrically connected to a total of five sensor terminals ST forming the sensor connector connection portion CN. Furthermore, the wiring connector 94 of the wiring unit 90 is electrically connected to the sensor connector connection portion CN of the sensor substrate SB (see reference). Figure 8 Thus, the rectangular wave signals generated by each Hall element 27a, Hall element 27b, and Hall element 27c are transmitted via a total of five sensor lines SW forming signal wiring 93 (see reference). Figure 8 And sent to the vehicle controller CR (refer to) Figure 1 Therefore, the vehicle controller CR can simultaneously monitor the rotational state of the rotor 40 and control its rotational direction, speed, and ultimately, its stopping position.

[0232] Thus, a sensor substrate SB is mounted on the cover body 14 of the cover member 13. The sensor substrate SB has Hall elements 27a, 27b, and 27c for detecting the rotation state of the rotating shaft 41 (rotor 40), and a sensor connector connection part CN for connecting to the vehicle controller CR. Furthermore, Hall elements 27a, 27b, and 27c correspond to the rotation sensor in this invention, the vehicle controller CR corresponds to the controller in this invention, and the sensor connector connection part CN corresponds to the controller connection part in this invention.

[0233] <Deceleration Mechanism Section>

[0234] like Figure 2 As shown, the reduction mechanism 50 includes a reducer housing 51. The reducer housing 51 is formed into a bottomed cylindrical shape by deep drawing or other processes on a steel plate, and its cross-sectional shape along a direction orthogonal to its length direction is approximately square.

[0235] An annular bottom wall 52 is provided on one axial side of the reducer housing 51, abutting against the bottom wall portion 22 of the motor housing 21 in the axial direction of the rotating shaft 41. A fitting sleeve 52a is integrally provided in the center of the annular bottom wall 52 for fitting into the bearing support sleeve 22a of the motor housing 21. Thus, the reducer housing 51 is coaxially arranged with respect to the motor housing 21.

[0236] In addition, a pair of screw insertion holes HS are provided on the annular bottom wall 52 (see reference). Figure 14 The pair of screw through holes HS are for inserting fixing screws S for fixing the reduction mechanism 50 to the electric motor 20. Specifically, the pair of screw through holes HS are respectively oriented in the axial direction of the rotating shaft 41 towards a pair of threaded holes 22b provided on the bottom wall portion 22 of the motor housing 21.

[0237] Additionally, an opening 53 is provided on the opposite side of the reducer housing 51, i.e., the side opposite to the annular bottom wall 52. The planetary gear reducer 60 is inserted into the inner side of the reducer housing 51 through this opening 53. Furthermore, a locking shoulder SH is provided on the opposite side of the planetary gear reducer 60, and a locking pawl 51a of the reducer housing 51 engages with this locking shoulder SH. Thus, the planetary gear reducer 60 is prevented from wobbling and disengaging relative to the reducer housing 51.

[0238] The planetary gear reducer 60 includes a gearbox 61, which is generally box-shaped and has an internal gear 61a formed on its inner side in the radial direction. The gearbox 61 is made of resin material such as plastic and includes a large-diameter portion 61b and a small-diameter portion 61c. Specifically, the large-diameter portion 61b is disposed on one axial side of the gearbox 61, and the small-diameter portion 61c is disposed on the other axial side of the gearbox 61. Furthermore, the internal gear 61a is provided throughout the entire axial region of the large-diameter portion 61b.

[0239] In contrast, a third ball bearing 62, having an outer ring 62a, an inner ring 62b, and steel balls 62c, is housed inside the small diameter portion 61c. Specifically, the outer ring 62a of the third ball bearing 62 is fixed to the inside of the small diameter portion 61c by pressing, and the inner ring 62b of the third ball bearing 62 supports the output shaft 84 of the second planetary gear reducer 80 to rotate freely.

[0240] An annular sealing member 63 is provided on one axial side of the gearbox 61 to close the gearbox opening 61d of the gearbox 61. Furthermore, the sealing member 63 is fixed to the gearbox opening 61d by pressing. Additionally, a through hole 63a is provided in the center of the sealing member 63, which fits into approximately one-third of the portion on one axial side of the first ball bearing 11.

[0241] Therefore, the axis of the enclosed member 63 (planetary gear reducer 60) and the axis of the first ball bearing 11 are aligned without offset from each other. Thus, the driving force of the rotating shaft 41, which is rotatably supported by the first ball bearing 11, is efficiently transmitted to the planetary gear reducer 60. Furthermore, the first planetary gear reducer 70, disposed on the input side (the side where the electric motor 20 is located), and the second planetary gear reducer 80, disposed on the output side (the side where the tilting mechanism, etc., is located), are housed inside the gearbox 61 and the enclosed member 63.

[0242] Specifically, the first planetary gear reducer 70 and the second planetary gear reducer 80 are arranged axially along the rotating shaft 41 in a manner that enables them to transmit power to each other, and the planetary gear reducer 60 performs two-stage reduction. This achieves a reduction in the diameter of the planetary gear reducer 60.

[0243] <First Planetary Gear Reducer>

[0244] like Figure 2 and Figure 7As shown, the first planetary gear reducer 70 has a first sun gear 71, which is mounted on the minor diameter portion 41a of the rotating shaft 41 and functions as the input portion of the first planetary gear reducer 70. The first sun gear 71 is pressed and fixed to the minor diameter portion 41a by the rotation of the rotating shaft 41, and is precisely configured on the coaxial axis relative to the minor diameter portion 41a.

[0245] In addition, the first planetary gear reducer 70 includes three first planetary gears 72 (in Figure 7 (Only two are shown in the image). The three first planetary gears 72 mesh with the internal gear 61a and the first sun gear 71 disposed in the gearbox 61, and rotate around the first sun gear 71. These first planetary gears 72 are each rotatably supported by a first support frame 73 forming the first planetary gear reducer 70. Specifically, the three first planetary gears 72 are arranged at equal intervals (120-degree intervals) in the circumferential direction of the first support frame 73.

[0246] Furthermore, a second sun gear 81 is integrally provided on the other side of the first support frame 73 along its axial direction. The second sun gear 81 functions as the output part of the first planetary gear reducer 70 and as the input part of the second planetary gear reducer 80. The second sun gear 81 is hollow and is disposed at the axis of the first support frame 73.

[0247] <Second Planetary Gear Reducer>

[0248] like Figure 2 and Figure 7 As shown, the second planetary gear reducer 80 has a second sun gear 81 integrally mounted on the first support frame 73 of the first planetary gear reducer 70.

[0249] Additionally, the second planetary gear reducer 80 includes three second planetary gears 82 (in... Figure 7 (Only two are shown in the image). The three second planetary gears 82 mesh with the internal gear 61a and the second sun gear 81 disposed in the gearbox 61, and rotate around the second sun gear 81. These second planetary gears 82 are rotatably supported by the second support frame 83 forming the second planetary gear reducer 80. Specifically, the three second planetary gears 82 are arranged at equal intervals (120-degree intervals) in the circumferential direction of the second support frame 83.

[0250] Furthermore, an output shaft 84, which functions as the output section of the second planetary gear reducer 80, is integrally provided on the other axial side of the second support frame 83. Here, the output shaft 84 is rotatably supported on the inner ring 62b of the third ball bearing 62, and tilting mechanisms (not shown) are connected to the output shaft 84 in a manner that enables power transmission.

[0251] Here, the support pin PN is mounted on the other axial side of the axis of the second support frame 83. On the other hand, the support pin PN is mounted on the axial side of the axis of the first support frame 73. Furthermore, the support pin PN aligns the axis of the first support frame 73 (second sun gear 81) with the axis of the second support frame 83 (output shaft 84) and supports them so that they can rotate relative to each other.

[0252] Thus, the planetary gear reducer 60 performs two-stage speed reduction through the first planetary gear reducer 70 and the second planetary gear reducer 80 arranged on the same shaft, reducing the rotational speed of the high-speed rotating rotor 40 (rotating shaft 41) to a specified rotational speed, and the high-torque rotational force after speed reduction is output from the output shaft 84 to the tilting mechanism, etc. (not shown).

[0253] Furthermore, the planetary gear reducer 60 is driven by the rotating shaft 41, which corresponds to the driving object in this invention.

[0254] <Wiring Unit>

[0255] like Figure 8 As shown, the wiring unit 90 has a connection with the vehicle controller CR (refer to...). Figure 1 The connector connection portion 91 is connected to the connector (not shown). Additionally, the wiring unit 90 includes a power wiring 92 and a signal wiring 93, with one side of the power wiring 92 and signal wiring 93 along their length direction ( Figure 8 The right side) is connected to the connector connection part 91. On the other hand, the power cable 92 and the signal cable 93 are connected on the other side along their length direction ( Figure 8 (The left side) is connected to the cover component 13.

[0256] The power wiring 92 has a sheath 92a containing flame-retardant ethylene polymer, etc., and a total of three U-phase power lines UL, V-phase power lines VL, and W-phase power lines WL disposed inside the sheath 92a. Furthermore, as... Figure 8 As shown, the other side of the U-phase power line UL, V-phase power line VL, and W-phase power line WL is stripped of its outer sheath, and the exposed U-phase power line UL, V-phase power line VL, and W-phase power line WL are soldered to the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw (see reference). Figure 4 Electrical connection.

[0257] Thus, the U-phase power line UL, V-phase power line VL, and W-phase power line WL are electrically connected to the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw, supplying driving current to each coil 36. The U-phase power line UL, V-phase power line VL, and W-phase power line WL are equivalent to the power lines in this invention.

[0258] Additionally, the signal wiring 93 includes the same sheath 93a as the power wiring 92, and a total of five sensor lines SW are provided inside the sheath 93a. Furthermore, as... Figure 8 As shown, the other side of the length direction of the five sensor wires SW is connected to the wiring connector 94. Thus, simply inserting the wiring connector 94 into the sensor connector connection part CN (see reference)... Figure 5 This allows for easy connection of each sensor line SW to the sensor substrate SB (see reference). Figure 5 Electrical connection.

[0259] Assembly steps for the seat motor

[0260] Next, the assembly sequence of the seat motor 10 formed as described above will be explained in detail using the accompanying drawings.

[0261] Figure 10 An exploded perspective view of the electric motor section is shown. Figure 11 A diagram illustrating the energization test of the electric motor section is shown. Figure 12 A perspective view showing the electric motor section, wiring unit, and cover assembly is provided. Figure 13 The diagram shows the connection sequence of the wiring unit relative to the electric motor section. Figure 14 The diagram shows the connection sequence of the speed reduction mechanism relative to the electric motor.

[0262] Assembly of the electric motor section

[0263] First, such as Figure 10 As shown, the stator assembly SA, rotor 40, and cover body 14 are prepared to be assembled in different assembly processes. Additionally, a first planetary gear reducer 70 is prepared to be formed (see reference). Figure 7 The first sun gear 71.

[0264] Furthermore, along the dotted line in the figure, the rotor 40 is installed inside the stator assembly SA. At this time, the side of the rotor 40 with the abutment member 44, that is, the side with the small-diameter portion 41a of the rotating shaft 41, faces the opening 25 of the motor housing 21. Then, the other axial side of the rotating shaft 41 forming the rotor 40 is inserted into the first ball bearing 11 fixed to the bearing support sleeve 22a (see reference). Figure 2 ).

[0265] Thus, the installation of rotor 40 relative to stator assembly SA is completed. Furthermore, stator assembly SA refers to the first ball bearing 11 (see reference...). Figure 2 The components that fix the stator 30 to the motor housing 21.

[0266] Next, along the dotted line in the figure, the cover body 14 on which the sensor substrate SB is mounted is installed in the opening 25 of the motor housing 21. At this time, the side of the cover body 14 on which the sensor substrate SB is mounted faces the opening 25, and the axial side of the rotating shaft 41 is inserted into the second ball bearing 12 installed inside the bearing retainer 15a.

[0267] Then, the engaging claw 21a of the motor housing 21 engages with the engaging recess 14a of the cover body 14. Thus, the installation of the cover body 14 relative to the motor housing 21 is completed. Then, the first sun gear 71 is pressed into and fixed to the bottom wall portion 22 of the motor housing 21 (see reference). Figure 2 The small diameter portion 41a of the protruding rotating shaft 41.

[0268] Alternatively, the first sun gear 71 can be pressed into and fixed to the small diameter portion 41a before the cover body 14 is installed in the opening portion 25.

[0269] Thus, the assembly of the electric motor section 20 is completed.

[0270] <Operational Test of Electric Motor Section>

[0271] Next, a check is performed to ensure the assembled electric motor unit 20 is functioning correctly, i.e., an operational test (power-on test) of the electric motor unit 20. Specifically, such as... Figure 11 As shown, the test device TEST is connected to the electric motor section 20 for operation testing.

[0272] Then, using connectors (not shown), connect the U-phase wiring U, V-phase wiring V, and W-phase wiring W installed in the TEST test apparatus to the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw of the electric motor unit 20, respectively. Additionally, connect the sensor wiring SNSR (with connector) installed in the TEST test apparatus to the sensor connector connection part CN of the electric motor unit 20.

[0273] Then, the test apparatus TEST is operated in test mode to confirm the drive status of the electric motor unit 20 and determine whether the electric motor unit 20 is qualified (qualified / unqualified). Thus, in this embodiment, the connection wiring unit 90 (see reference 1) can be easily and independently tested. Figure 8 The previously compact electric motor unit 20 was tested for operation. Thus, the electric motor unit 20 can be tested for operation independently because the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw are arranged in an exposed manner inside the cover body 14, and the sensor connector connection part CN is arranged inside the cover body 14.

[0274] Thus, the operation test of the electric motor unit 20 is completed.

[0275] <Connection work of wiring unit>

[0276] Next, as Figure 12 As shown, the operation of electrically connecting the wiring unit 90 to the electric motor unit 20 is performed. First, the wiring unit 90, which will be assembled in different assembly processes, is prepared, and the cover member 18 is prepared. Then, along the dotted line in the figure, the wiring unit 90 is connected to the electric motor unit 20, and the cover member 18 is installed on the cover body 14.

[0277] Then, as Figure 13 As shown, the U-phase power line UL, V-phase power line UV, and W-phase power line UW of the wiring unit 90 are respectively soldered to the U-phase connection terminal Tu, the V-phase connection terminal Tv, and the W-phase connection terminal Tw. Furthermore, in Figure 13 The image only shows the soldering of the U-phase power line UL to the U-phase connection terminal Tu. The V-phase power line UV and the W-phase power line UW are also soldered to the V-phase connection terminal Tv and the W-phase connection terminal Tw in the same way as the U-phase power line UL.

[0278] Specifically, the front end of the stripped U-phase power cable UL is installed on the U-phase connection terminal Tu. In this state, as shown by the solid arrow M1, a soldering iron TL is inserted into the assembly fixture guide space SP1. Thus, the U-phase power cable UL and the U-phase connection terminal Tu are soldered together and electrically connected to each other.

[0279] Next, as shown by the dashed arrow M2, the U-phase power line UL is arranged to hook onto the power line retaining claw 15b and simultaneously wound around the bearing retaining sleeve 15a. Furthermore, the V-phase power lines UV and W-phase power lines UW are also arranged around the bearing retaining sleeve 15a in the same manner as the U-phase power line UL.

[0280] Then, as indicated by the dashed arrow M3, the wiring connector 94 of the wiring unit 90 is inserted into the sensor connector connection part CN to achieve electrical connection. Thus, the electrical connection between the wiring unit 90 and the electric motor part 20 is completed.

[0281] In addition, such as Figure 12 As shown, when the cover component 18 is installed on the cover body 14, the U-phase power line UL, V-phase power line VL, W-phase power line WL, and a total of 5 sensor lines SW (refer to) are connected from the cutout 18a provided in the cover component 18. Figure 13 The cover member 18 is extended to the outside. Additionally, the cover member 18 is hooked onto the hook portion 14b of the cover body 14 by a plurality of hook claws 18b provided on the cover member 18 (see reference). Figure 13 It is fixed to the main body 14 of the cover.

[0282] <Connection Operation of the Speed ​​Reduction Mechanism>

[0283] Next, as Figure 14 As shown, the operation of connecting the reduction gear unit 50 and the electric motor unit 20 is performed. First, the planetary gear reducer 60, which will be assembled in different assembly processes, is prepared, along with the reducer housing 51 and a pair of fixing screws S. Then, along the dotted line in the figure, the annular bottom wall 52 of the reducer housing 51 is aligned with the bottom wall 22 of the motor housing 21 (see reference). Figure 2 ) Abutting. At this time, the fitting sleeve 52a is fitted into the bearing support sleeve 22a (refer to Figure 2 ).

[0284] Then, a pair of fixing screws S are inserted from the inside of the reducer housing 51 into a pair of screw insertion holes HS, and screwed into a pair of threaded holes 22b provided in the bottom wall portion 22 of the motor housing 21 (see reference). Figure 2 Thus, the fixing of the reducer housing 51 to the electric motor unit 20 is completed.

[0285] Next, from the opening 53 of the reducer housing 51 (refer to...) Figure 2 The planetary gear reducer 60 is inserted into the inner side of the reducer housing 51. At this time, the side of the planetary gear reducer 60 with the sealing member 63 faces the opening 53. Furthermore, in the axial direction of the rotor 40, the position of the engagement shoulder SH in the planetary gear reducer 60 is aligned with the position of the engagement pawl 51a in the reducer housing 51. Then, the first sun gear 71 (refer to...) fixed to the small diameter portion 41a... Figure 7 ) and the three first planetary gears 72 forming the first planetary gear reducer 70 (refer to Figure 7 ) meshing.

[0286] Then, the engaging claw 51a of the reducer housing 51 engages with the engaging shoulder SH of the planetary gear reducer 60. Thus, the connection between the reducer unit 50 and the electric motor unit 20 is completed, and the assembly of the seat motor 10 is finished.

[0287] As detailed above, according to this embodiment, the cross-sectional shape of the motor housing 21 along the radial direction of the rotor 40 is formed as a square including the first corner portion 24a to the fourth corner portion 24d. The stator 30 has: a cylindrical core body 32; first core protrusions 33a to the fourth core protrusions 33d, disposed on the outer periphery of the core body 32 and abutting against the first corner portions 24a to the fourth corner portions 24d; a plurality of teeth 34, disposed on the inner periphery of the core body 32; and coils 36, wound and mounted on the plurality of teeth 34 according to each phase. The rotor 4 The device includes: a rotating shaft for driving the planetary gear reducer 60; and an annular magnet 43 disposed on the outer periphery of the rotating shaft 41. In the radial direction of the rotor 40, between the rotor 40 and the first corner portion 24a to the third corner portion 24c, and on the first line segment L1 to the third line segment L3 connecting the rotation center C of the rotor 40 with the first corner portion 24a to the third corner portion 24c, a U-phase connection terminal Tu, a V-phase connection terminal Tv, and a W-phase connection terminal Tw electrically connected to each of the coils 36 arranged according to each phase are disposed.

[0288] Therefore, the axial dimension of the seat motor 10 can be shortened without having to overlap the molded busbars with respect to the rotor 40 as before. This allows for further miniaturization of the seat motor 10.

[0289] Furthermore, within the radial direction of the motor housing 21, the power wiring 92 (U-phase power line UL, V-phase power line VL, W-phase power line WL) and signal wiring 93 (a total of 5 sensor lines SW) can be electrically connected and configured. Therefore, local protrusions in the radial direction of the motor housing 21 can be eliminated, improving the layout relative to stationary objects.

[0290] Furthermore, in the radial direction of the rotor 40, assembly fixture guide spaces SP1, SP2, and SP3 can be formed between the U-phase connection terminal Tu and the first corner portion 24a, between the V-phase connection terminal Tv and the second corner portion 24b, and between the W-phase connection terminal Tw and the third corner portion 24c, respectively. Therefore, it is easy to perform electrical connection operations (improved assemblability) between the soldering iron TL and the U-phase connection terminal Tu, V-phase connection terminal Tv, W-phase connection terminal Tw and the U-phase power line UL, V-phase power line VL, and W-phase power line WL.

[0291] Furthermore, according to this embodiment, an arc-shaped inner peripheral portion is provided on the inner side of the first corner portion 24a to the fourth corner portion 24d, and the first core protrusion portion 33a to the fourth core protrusion portion 33d are in contact with the inner peripheral portion surface.

[0292] Therefore, when the stator core 31 is pressed into and fixed to the motor housing 21, damage to the inner circumference of the first corner portion 24a to the fourth corner portion 24d can be prevented from being cut off. In addition, the fixing strength of the stator core 31 relative to the motor housing 21 can be ensured to be sufficient.

[0293] Furthermore, according to this embodiment, the motor housing 21 is provided with an opening 25 closed by a cover member 13, which holds the second ball bearing 12 that supports the rotating shaft 41 to rotate freely. A U-phase connection terminal Tu, a V-phase connection terminal Tv, and a W-phase connection terminal Tw are arranged near the opening 25. A sensor substrate SB is mounted on the cover member 13. The sensor substrate SB has: Hall elements 27a, 27b, and 27c to detect the rotation state of the rotating shaft 41; and a sensor connector connection part CN for the vehicle controller CR to connect to.

[0294] Therefore, the electronic components forming the seat motor 10 can be centrally arranged on the side of the motor housing 21 where the opening 25 is provided in the longitudinal direction, making it easy to perform electrical connection operations. Thus, the assemblability of the seat motor 10 can also be improved.

[0295] Furthermore, according to this embodiment, at least a portion of a sensor connector connection portion CN is disposed between the rotor 40 and the fourth corner portion 24d, and on the fourth line segment L4 that connects the rotation center C of the rotor 40 and the fourth corner portion 24d.

[0296] Therefore, the sensor connector CN can be positioned near the fourth corner 24d, and furthermore, the sensor connector CN can be positioned in the same axial direction as the positions where the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw are located. This also helps to suppress the increase in the axial dimension of the seat motor 10.

[0297] Furthermore, according to this embodiment, the cover member 13 is provided with a bearing retaining sleeve 15a that holds the second ball bearing 12 on its inner periphery, and a total of three power line retaining claws 15b that hold the U-phase power line UL, the V-phase power line VL, and the W-phase power line WL are provided on the outer periphery of the bearing retaining sleeve 15a. The U-phase power line UL, the V-phase power line VL, and the W-phase power line WL are electrically connected to the U-phase connection terminal Tu, the V-phase connection terminal Tv, and the W-phase connection terminal Tw and supply driving current to the coil 36.

[0298] Therefore, the U-phase power line UL, V-phase power line VL, and W-phase power line WL can be housed within the axial range of the bearing retainer 15a, thus suppressing the axial increase in the size of the cover component 13.

[0299] Furthermore, according to this embodiment, when the second ball bearing 12 is viewed from the radial direction of the rotor 40, at least a portion of the U-phase power line UL, the V-phase power line VL, the W-phase power line WL, and the sensor connector connection portion CN overlap with the second ball bearing 12.

[0300] Therefore, the U-phase power line UL, V-phase power line VL, W-phase power line WL and sensor connector CN are efficiently and well arranged in the designated positions of the cover body 14 forming the cover member 13, which can also suppress the axial increase of the cover member 13.

[0301] Furthermore, according to this embodiment, the electric motor section 20 forming the seat motor 10 can be tested for operation independently and easily. Therefore, after assembling the seat motor 10, it is not necessary to disassemble the seat motor 10; only the electric motor section 20 needs to be replaced. This enables energy conservation in energy production, thereby achieving, in particular, Goal 7 (ensuring access to affordable and reliable sustainable modern energy for all) and Goal 13 (taking urgent measures to mitigate climate change and its effects) of the United Nations Sustainable Development Goals (SDGs).

[0302] This invention is not limited to the described embodiments, and various modifications can be made without departing from its spirit. For example, in the described embodiment, the cross-sectional shape of the motor housing 21 in the radial direction of the rotor 40 is shown as a square (regular polygon) including the first corner 24a to the fourth corner 24d, but the invention is not limited thereto. That is, as long as the U-phase connection terminal Tu, V-phase connection terminal Tv, and W-phase connection terminal Tw can be easily soldered to the U-phase power line UL, V-phase power line VL, and W-phase power line WL respectively, the regular polygon can be an equilateral triangle, a regular pentagon, a regular hexagon, etc.

[0303] Furthermore, in the described embodiment, a structure is shown in which the wiring unit 90 is connected to the electric motor section 20 first, and then the reduction mechanism section 50 is connected when assembling the seat motor 10; however, the present invention is not limited to this. That is, the reduction mechanism section 50 may be connected to the electric motor section 20 first, and then the wiring unit 90 may be connected.

[0304] Furthermore, in the above embodiment, a seat motor 10 is shown as an example of a motor device, but the present invention is not limited thereto and can also be applied to other vehicle-mounted devices, such as power window devices or sunroof devices, as a drive source.

[0305] Furthermore, the material, shape, size, quantity, and location of each component in the embodiments are arbitrary as long as they enable the implementation of the present invention, and are not limited to the embodiments described.

Claims

1. A motor device comprising: The stator is fixed inside the motor housing; and The rotor rotates relative to the stator in the motor assembly. The cross-sectional shape of the motor housing along the radial direction of the rotor is formed as a polygon including multiple corners. The stator has: cylindrical core body; A core protrusion is disposed on the outer periphery of the core body and abuts against the corner portion; Multiple teeth are disposed on the inner periphery of the core body; as well as The coils are wound and mounted on the plurality of teeth according to each phase. The rotor includes: A rotating axis drives the object being driven. as well as A magnet is disposed on the outer periphery of the rotating shaft. In the radial direction of the rotor, between the rotor and the corner and on the first line segment connecting the rotation center of the rotor to the corner, there is a connection terminal that is electrically connected to each of the coils arranged according to each phase.

2. The motor device according to claim 1, wherein, An arc-shaped inner periphery is provided on the inner side of the corner. The protrusion is in contact with the inner peripheral surface.

3. The motor device according to claim 1 or 2, wherein, The motor housing has an opening that is closed by a bearing retainer, which holds the bearing that supports the rotating shaft for free rotation. The connection terminal is disposed near the opening. A sensor base plate is mounted on the bearing retainer. The sensor base plate has: a rotation sensor for detecting the rotation state of the rotating shaft; and a controller connection for connecting a controller.

4. The motor device according to claim 3, wherein, At least a portion of the controller connection portion is disposed in the radial direction of the rotor, between the rotor and the corner, and on the second line segment connecting the rotation center of the rotor and the corner.

5. The motor device according to claim 3, wherein, The bearing retainer is provided with a bearing retainer sleeve that holds the bearing on its inner circumference. A power line holding claw is provided on the outer periphery of the bearing retaining sleeve to hold the power line. The power line is electrically connected to the connection terminal and supplies driving current to the coil.

6. The motor device according to claim 5, wherein, When the bearing is viewed from the radial direction of the rotor, at least a portion of the power line and the controller connection overlaps with the bearing.

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