Rotary electric motor

Abstract

Rotary electric machine, including: a rotor (1) and a sensor rotor (2) which are held on a rotating shaft (100) and are arranged in a shaft direction of the rotating shaft (100); a stator (5) which points towards the rotor (1) and is arranged on the inside of a housing (11) with a cylindrical shape; and a sensor stator (6) pointing towards the sensor rotor (2), which is held on sensor support components (7), characterized in that the sensor support components (7) are mounted on end regions of tooth regions of the stator (5).

Description

BACKGROUND OF THE INVENTIONTechnical field

[0001] The present invention relates to a rotating electrical machine including a sensor rotor and a sensor stator. background

[0002] In conventional rotary electric machines in which an encoder (resolver), which is a type of sensor, is included, there is a rotary electric machine having a configuration in which an encoder stator used as a sensor stator is fixed to the inside of an end plate that closes an opening of a yoke housing used as a casing having a cylindrical shape, in other words, a rotary electric machine having a type in which the sensor stator is attached to a rotary electric machine within the casing having a cylindrical shape (see, for example, Patent Document 1), or there is a rotary electric machine having a configuration in which an encoder stator used as a sensor stator is attached to the outside of a flange provided at an opening of a stator casing used as a casing having a cylindrical shape, in other words, a rotary electric machine,which has a type in which the sensor stator is attached to a rotating electric machine outside the casing having a cylindrical shape (see, for example, Patent Document 2). Conventional state of the artPatent document Patent Document 1: Japanese Patent Publication JP 5 138 489 B2 Patent Document 2: Japanese Patent Laid-Open No. JP 2013 - 225 953 A SUMMARY OF THE INVENTION

[0003] Problems to be solved by the invention

[0004] The nature of conventional rotating electric machines is as described above, so that it is required that a terminal portion of a signal line of a sensor stator is electrically connected to a terminal portion (an outside terminal portion) of a signal line of a control device positioned outside a casing having a cylindrical shape.Therefore, in a configuration in which a stator is attached to an end plate having a cylindrical shape, a flange, or the like as described in Patent Document 1 and Patent Document 2 above, it is necessary that a process in which the sensor stator is attached to the casing having a cylindrical shape, a process in which a signal line of the sensor stator is wired, a process in which a terminal portion of the sensor stator is connected to the external terminal portion, a process in which a stator is attached to the casing having a cylindrical shape, a process in which a signal line of the stator is wired, and a process in which a terminal portion of the stator is connected to the external terminal portion are performed separately, and the number of attachment processes is increased.Furthermore, in a configuration in which the sensor stator is mounted on the cylindrical-shaped housing as described above, it is necessary to provide a mounting configuration component through which the sensor stator is mounted on the cylindrical-shaped housing, so that the cylindrical-shaped housing has a complicated configuration. Furthermore, a length of the rotating electric machine in a shaft direction is increased.

[0005] The present invention has been made to solve the problems described above, and an object of the invention is to provide a rotating electric machine in which it is not necessary for a sensor stator to be mounted on a casing having a cylindrical shape and a stator is mounted on the casing having a cylindrical shape, whereby the sensor stator can be easily arranged on the inside of the casing having a cylindrical shape. Means of solving problems

[0006] This object is achieved according to the invention as defined in the main claim. Embodiments of the invention are set forth in the subclaims. Effects of the invention

[0007] According to the rotary electric machine of the present invention, the rotary electric machine can be obtained in which a sensor stator can be easily arranged on the inside of a casing having a cylindrical shape.

[0008] An object, a characteristic and an effect of the present invention will be described more clearly by small explanations and descriptions of the drawings in the following embodiments. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view illustrating a rotating electric machine according to Embodiment 1 of the present invention; Fig. Fig. 2 is an arrow view illustrating a main mounting portion of a sensor indicated by an arrow “A” in Fig. 1 is seen to explain a first assembling process of a sensor stator provided in the rotating electric machine according to Embodiment 1 of the present invention; Fig. 3 is an arrow view illustrating a mounting main portion of the sensor, which is indicated by the arrow “A” in the direction in Fig. 1 is considered to explain a second assembling process of the sensor stator provided in the rotating electric machine according to Embodiment 1 of the present invention; Fig. Fig. 4 is an arrow view illustrating the mounting main area of ​​the sensor viewed from the arrow “A” direction in Fig. 1 to explain a third assembling process of the sensor stator provided in the rotating electric machine according to Embodiment 1 of the present invention; Fig. 5 is an arrow view illustrating the main mounting area of ​​the sensor, when viewed from the arrow “A” direction in Fig. 1 to explain a fourth assembling process of the sensor stator provided in the rotating electric machine according to Embodiment 1 of the present invention; Fig. 6 is a cross-sectional view illustrating a rotating electric machine according to Embodiment 2 of the present invention; Fig. 7 is a cross-sectional view illustrating a modification example of the rotary electric machine according to Embodiment 2 of the present invention; Fig. 8 is a cross-sectional view illustrating another modification example of the rotary electric machine according to Embodiment 2 of the present invention; Fig. 9 is a cross-sectional view illustrating a main portion of a rotary electric machine according to Embodiment 3 of the present invention; Fig. 10 is an inclined perspective view illustrating the main portion of the rotary electric machine according to Embodiment 3 of the present invention; Fig. 11 is a cross-sectional view showing a main portion of a modification example of the Rotating electric machine according to Embodiment 3 of the present invention; Fig. 12 is a cross-sectional view illustrating a rotating electric machine according to Embodiment 4 of the present invention; Fig. 13 is a cross-sectional view illustrating a rotary electric machine according to Embodiment 5 of the present invention; and Fig. 14 is a cross-sectional view illustrating a rotary electric machine according to Embodiment 6 of the present invention. MODE FOR CARRYING OUT THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, reference numerals that are the same as those in each of the drawings refer to the same or equivalent parts. Embodiment 1

[0010] Fig. 1 is a cross-sectional view illustrating a rotating electric machine according to Embodiment 1 of the present invention.

[0011] A rotor 1 and a sensor rotor (e.g., a sensor rotor) 2 are provided in parallel in a shaft direction of a rotating shaft 100 of the rotary electric machine. A stator 5 including a stator core 3 and a coil 4 is arranged inside a casing 11 having a cylindrical shape of the rotary electric machine in such a manner that the stator 5 faces a periphery of the rotor 1. A sensor stator (e.g., a sensor stator) 6 is held by rivets 13 at an end portion of the stator core 3, in other words, at end portions of sensor support components 7 (end portions of a rotating shaft 100 side) provided at an end portion in a shaft direction of the stator 5 in such a manner that the sensor stator 6 faces a periphery of the sensor rotor 2.A terminal portion of a signal line 8 of the sensor stator 6 and a terminal portion of a signal line 9 for supplying an electric current, which is connected to the coil 4 of the stator 5, are respectively connected to a first terminal block 10a and a second terminal block 10b contained in a terminal block 10 for external connection, which is attached to a lid 11a covering an opening formed at one end portion of the housing 11. Moreover, the other terminal portion of the signal line 8 of the sensor stator 6 is connected to the sensor stator 6 through a third terminal block 10c. A length of the sensor rotor 2 in a rotation shaft direction is not the same as and different from a length of the sensor stator 6 in a rotation shaft direction.

[0012] The rotating electric machine is assembled in such a manner that the rotor 1 and the sensor rotor 2 held on the rotating shaft 100, and the stator 5 in which a plurality of slots are formed and which faces the rotor 1 so as to be arranged are inserted into the casing 11 having a cylindrical shape.

[0013] The stator 5 consists of a stator core 3, the coil 4, the sensor stator 6, the sensor support components 7, the signal line 8 and the sensor stator 6, the signal line 9 of the stator 5 and the terminal block 10.

[0014] The stator core 3 in which thin electromagnetic sheets are laminated is assembled by fixing or welding the stator core 3 in such a manner that the electromagnetic sheets do not separate from each other.

[0015] The stator core 3 is composed of an integrated core or a separate core. When the stator core 3 is constructed of the integrated core, the stator core 3 is formed in a cylindrical shape by a welding method, a ring press-insertion method, a ring burn-in insertion method, or the like.

[0016] The stator core 3 includes tooth portions in which a plurality of slots are formed. A coil covered by an insulating film is wound around each of the tooth portions. Sensor support components 7 are mounted at each end portion in an axial direction of each of the tooth portions. The sensor support components 7 are constructed using a non-magnetic material.

[0017] If the sensor support components 7 have sufficient strength, it is not necessary for the sensor support components 7 to be securely mounted on all tooth areas.

[0018] The coil 4 is insulated from the tooth areas and the sensor support components 7 by the insulating film.

[0019] Fig. 2 to Fig. 5 are arrow direction views schematically indicating a mounting main portion of a sensor viewed from an arrow “A” direction in Fig. 1 is considered to explain an assembly process of the sensor stator 6. For convenience in explaining the assembly process, the rotary shaft 100 and the sensor rotor 2 are also shown.

[0020] Fig. 2 indicates a state of the sensor stator 6 in a first assembly process of the sensor stator 6.

[0021] A plurality of sensor support components 7 are mounted on the tooth portions of the above-described stator core 3. Connection holes 20 are provided on the sensor stator 6 at outer circumferential positions corresponding to the sensor support components 7, and the sensor stator 6 has a connection portion connected to the sensor support components 7. In this step, screws 21 used for a temporary connection process are inserted into the connection holes 20, and the screws 21 are screwed and fixed to the sensor support components 7, and the sensor stator 6 and the sensor support components 7 are connected, thereby temporarily fixing the sensor stator 6 and the sensor support components 7.In the rotating electric machine according to Embodiment 1, although the sensor stator 6 and the sensor support components 7 are temporarily fixed using three screws 21, the sensor stator 6 and the sensor support components 7 may be connected using at least one screw 21, and the number of screws 21 is not limited to three.

[0022] After the sensor stator 6 is temporarily fixed to the sensor support components 7 using the screws 21 used for a temporary connection process as shown in Fig. 3, and after the rivets 13 are inserted into the connecting holes 20 in a second assembly process, the rivets 13 are riveted, whereby the sensor stator 6 and the sensor support components 7 are fixed.

[0023] After the sensor stator 6 is fixed to the sensor support components 7 in the second assembly process, as shown in Fig. 4, the screws 21 used for a temporary connection process are removed from the connection holes 20 in a third assembly process. In the third assembly process, the sensor stator 6 is fixed to the sensor support components 7 by the rivets 13. In this state, the sensor stator 6 is arranged integrally with the stator 5 via the sensor support components 7.

[0024] In addition, after the screws 21 used for a temporary connection process are removed from the connection holes 20 in the third assembling process as shown in Fig. 5, and after the rivets 13 are further inserted into the connecting holes 20 in a fourth assembly process, the rivets 13 are fastened, whereby the sensor stator 6 can be fixed to the sensor support components 7. When the rivets 13 used for a fixing process are enlarged, the sensor stator 6 can be firmly fixed to the sensor support components 7.

[0025] The stator 5 is inserted into the housing 11 having a cylindrical shape from a shaft direction of the stator 5 to be assembled in a state where the sensor stator 6 is arranged integrally with the stator 5 as described above. A terminal portion of the signal line 8 of the sensor stator 6 and a terminal portion of the signal line of a feed portion of the stator 5 are fixed to the common terminal block 10, whereby a wiring process of the signal lines and a connection process of the terminal portions can be performed simultaneously. Therefore, a mounting configuration of the sensor stator 6 and an assembly process of the sensor stator 6 are not required for the housing 11 having a cylindrical shape.

[0026] In addition, the sensor support components 7 are made of a non-magnetic material so that leakage of a magnetic flux can be reduced.

[0027] Furthermore, the sensor stator 6 and the sensor support components 7 are connected by rivets 13, and the heads of the rivets 13 are pressed together when the rivets 13 are riveted, whereby a length of the heads of the rivets 13 can be reduced compared with a length of the heads of the screws 21, so that the rotating electric machine can be downsized in a rotating shaft direction.

[0028] A length of the sensor stator 6 in a rotational shaft direction is not equal to a length of the sensor rotor 2 in the rotational shaft direction, so the rotating electric machine is not affected by a size variation in the rotational shaft direction of the stator 5 and the rotor 1, and a constant output can be obtained. Furthermore, the rotating electric machine is not affected by a deviation in the rotational shaft direction of the sensor stator 6 and the sensor rotor 2 caused by vibration, and a constant output can be obtained. Embodiment 2

[0029] Fig. 6 is a cross-sectional view illustrating a rotating electric machine according to Embodiment 2 of the present invention.

[0030] In the rotating electric machine according to Embodiment 2, the rotating electric machine has a configuration in which a sensor stator 6 is held on a sensor holding component 12, which is attached to the sensor support components 7 by riveting. The sensor support components 7 are constructed using a non-magnetic material, and the sensor holding component 12 is configured using a magnetic material such as iron. In addition, connecting portions of the sensor holding component 12 and the sensor support components 7, which are formed using the rivets 13, have a configuration in which the sensor holding component 12 and the sensor support components 7 are connected at a plurality of positions in the circumferential direction of the rotating electric machine, similarly to Embodiment 1.Furthermore, the sensor holding component 12 is temporarily fixed to the sensor support components 7 using a screw as a temporary fixing process. Similarly to Embodiment 1, the sensor holding component 12 and the sensor support components 7 are fixed by the rivets 13. The other configurations according to Embodiment 2 are similar to the configurations shown in FIG. Fig. 1, according to Embodiment 1, so explanation is omitted.

[0031] The sensor stator 6 is fixed to the sensor holding component 12, and the stator 5 is inserted from a shaft direction to the housing 11 having a cylindrical shape so as to be assembled in a state where a terminal portion of a signal line 8 of the sensor stator 6 and a terminal portion of a signal line of a stator 5 are fixed to a common terminal block 10.

[0032] The rotating electric machine is configured such that the sensor stator 6 is held by the sensor holding component 12, so that the rotating electric machine is not affected by a shape of the sensor stator 6, and the sensor stator 6 can be attached to the stator 5. Therefore, any type of sensor stator 6 can be attached in a wide range from a small-diameter rotating electric machine to a large-diameter rotating electric machine.

[0033] Furthermore, the sensor support components 7 are configured using a non-magnetic material so that leakage of a magnetic flux can be suppressed, and the sensor support component is configured using a magnetic material so that the sensor support component has high strength and can be easily processed even if the sensor holding component 12 has a complex shape.

[0034] Fig. 7 is a cross-sectional view showing a modification example of the rotating electric machine according to Embodiment 2 of the present invention. In the rotating electric machine according to Embodiment 2, the rotating electric machine has a configuration in which a connecting portion 7a of the sensor support components 7 and a connecting portion 12a of the sensor holding component 12 are formed using a polymer material, and a pin 14 (referred to as an ultrasonic welding pin) 14 fixed using an ultrasonic welding process is inserted into the connecting portion 7a and the connecting portion 12a to be connected, thereby fixing the sensor holding component 12 and the sensor support components 7.In the rotating electric machine according to Embodiment 2, after the sensor holding component 12 is temporarily fixed to the sensor support components 7 using a screw as a temporary fixing process, the sensor holding component 12 and the sensor support components 7 can be fixed by the ultrasonic welding pin 14. The other configurations are similar to the configurations shown in FIG. Fig. 2, according to Embodiment 2, so that explanation is omitted.

[0035] In the rotary electric machine according to Embodiment 2, the ultrasonic welding pin 14 is inserted into the connecting portion 7a and the connecting portion 12a while melting a polymer of a connecting portion 7a and the connecting portion 12a in a process of inserting the ultrasonic welding pin 14 into the connecting portion 7a and the connecting portion 12a.

[0036] A concave and convex portion is formed on a surface of the ultrasonic welding pin 14, and the molten polymer is engaged with the concave and convex portion, thereby fixing the joining portion 7a and the joining portion 12a.

[0037] The molten polymer is drawn to the concave and convex portions on the surface of the ultrasonic welding pin 14, and the ultrasonic welding pin 14 is fixed by a welding process using an ultrasonic wave. This allows the polymer to be drawn even when the axial deviation of the connecting portion 7a and the connecting portion 12a is large, and a constant fixing force can be obtained. Furthermore, a part corresponding to a screw head is not required on the ultrasonic welding pin 14, so the rotary electric machine can be downsized in a shaft direction in a fixing process using the ultrasonic welding pin 14 compared to a fixing process using a conventional screw.

[0038] Furthermore, in the rotary electric machine according to Embodiment 2, although it is explained that the connecting portion 7a of the sensor support components 7 and the connecting portion 12a of the sensor holding component 12 are formed using a polymer material, it is not limited to the connecting portion 7a and the connecting portion 12a being formed using a polymer material, and a connecting portion of the sensor stator 6 and the sensor support components 7 may be formed using a polymer material in a configuration of the rotary electric machine according to Embodiment 1 shown in Fig. 1 is specified.

[0039] Fig. 8 is a cross-sectional view illustrating the other modification example of the rotary electric machine according to Embodiment 2 of the present invention.

[0040] In the rotating electric machine according to Embodiment 2, the rotating electric machine has a configuration in which a hole 12b is formed on the sensor holding component 12. The other configurations are similar to the configurations shown in Fig. 6, according to Embodiment 2, so that explanation is omitted.

[0041] The hole 12b is formed on the sensor support component 12, which can realize a weight reduction of the rotating electrical machine. Furthermore, the vibration resonance point can be prevented. Embodiment 3

[0042] Fig. 9 is a cross-sectional view illustrating a main portion of a rotary electric machine according to Embodiment 3 of the present invention, and Fig. 10 is an inclined perspective view showing a holding portion of a sensor stator in Fig. 9 illustrated.

[0043] In the rotating electric machine according to Embodiment 3, a signal line 8 is held by a signal line holding component 15 having a reverse L shape, which is fixed to a sensor holding component 12.

[0044] The other configurations according to Embodiment 3 are similar to the configurations shown in Fig. 2 according to Embodiment 2, so explanation is omitted.

[0045] The signal line 8 is held by the signal line holding component 15, thereby facilitating the wiring process of the signal line 8. Furthermore, deflection of the signal line 8 is reduced, and friction between the signal line 8 and a corner portion of the other component is reduced, thus reducing wire breakage.

[0046] Fig. 11 is a cross-sectional view illustrating a main portion of a modification example of the rotary electric machine according to Embodiment 3 of the present invention.

[0047] In the rotary electric machine according to Embodiment 3, the signal line holding component 15 is formed using an elastic component, for example, a thin plate-shaped component made of iron, and the signal line holding component 15 is attached to the sensor stator 6 by a screw 22 in such a manner that the signal line 8 is sandwiched between the sensor stator 6 and the signal line holding component 15. The signal line holding component 15, which is fixed to the sensor stator 6, holds the signal line 8 wired and output from the sensor stator 6 in such a manner that the signal line 8 is pressed in an arrow B direction by an elastic force of the signal line holding component 15. Embodiment 4

[0048] Fig. 12 is a cross-sectional view illustrating a rotating electric machine according to Embodiment 4 of the present invention.

[0049] In the rotating electric machine according to Embodiment 4, the rotating electric machine has a configuration in which a coil bobbin 16 is mounted on a stator core 3 (specifically, a tooth portion provided on the stator core 3). The other configurations according to Embodiment 4 are similar to the configurations shown in Fig. 6, according to Embodiment 2, so that explanation is omitted.

[0050] The coil former 16 is mounted between a coil 4 and sensor support components 7, thereby improving the insulation capacity of the coil 4 and the sensor support components 7. Furthermore, a shape of the coil former is varied in accordance with a wire diameter of the coil 4, allowing the rotating electric machine to meet various winding specifications.

[0051] The sensor support components 7 are molded onto the coil body 16, whereby the sensor support components 7 can be prevented from falling off from the coil body 16 in a temporary attachment state before the coil 4 is wound around a tooth portion of a stator core 3 and the sensor support components 7 are fixed using a tension of the coil 4. Embodiment 5

[0052] Fig. 13 is a cross-sectional view illustrating a rotating electric machine according to Embodiment 5 of the present invention.

[0053] In the rotary electric machine according to Embodiment 5, the rotary electric machine has a configuration in which an end portion 12c of a sensor holding component 12 connected to the sensor support components 7 is bent toward the inner end side in a rotating shaft direction. The other configurations according to Embodiment 5 are similar to the configurations shown in Fig. 6, according to Embodiment 2, so that explanation is omitted.

[0054] The end portion 12c of the sensor holding component 12 is bent toward the inside in a rotation shaft direction, whereby a length of the sensor holding component 12 in a rotation shaft direction can be reduced. Embodiment 6

[0055] Fig. 14 is a cross-sectional view illustrating a rotary electric machine according to Embodiment 6 of the present invention.

[0056] In the rotary electric machine according to Embodiment 6, the rotary electric machine has a configuration in which a central portion 7b of the sensor support components 7 is bent toward the inside in a rotation shaft direction. The other configurations according to Embodiment 6 are similar to the configurations shown in Fig. 1, according to Embodiment 1, so explanation is omitted.

[0057] In the rotary electric machine according to Embodiment 6, the central portion 7b of the sensor support components 7 is bent toward the inside in a rotating shaft direction, whereby a length of the sensor support components 7 in a rotating shaft direction can be reduced.

[0058] In the present invention, it is possible within the scope of the present invention that each of the components is freely combined or each of the embodiments is appropriately modified or omitted. Description of the symbols

[0059] "1" is a rotor; "2" is a sensor rotor, "3" is a stator core, "4" is a coil, "5" is a stator, "6" is a sensor stator, "7" is a sensor support component, "8" is a signal wire, "9" is a signal wire, "11" is a housing, "12" is a sensor holding component, "13" is a rivet, "14" is a pin, "15" is a signal wire holding component, "16" is a coil body, "100" is a rotating shaft.

Claims

[1] Rotating electric machine, comprising: a rotor (1) and a sensor rotor (2) held on a rotary shaft (100) and arranged in a shaft direction of the rotary shaft (100); a stator (5) facing the rotor (1) and arranged on the inside of a housing (11) having a cylindrical shape; and a sensor stator (6) facing the sensor rotor (2) and held on sensor support components (7), characterized by that the sensor support components (7) are mounted on end regions of tooth regions of the stator (5). [2] The rotating electrical machine according to claim 1, wherein the sensor stator is held by a sensor holding component connected to the sensor support components and held on the sensor support components. [3] The rotating electrical machine according to claim 1, wherein the sensor stator and the sensor support components are fixed by riveting. [4] The rotating electrical machine according to claim 2, wherein the sensor holding component and the sensor supporting components are fixed by riveting. [5] The rotary electric machine according to claim 2, wherein a connecting portion of the sensor holding component and the sensor supporting components are molded using a polymer material, and the connecting portion is joined with an ultrasonic welding pin. [6] The rotary electric machine according to claim 1, wherein a connecting portion of the sensor stator and the sensor support components are molded using a polymer material, and the connecting portion is connected by an ultrasonic welding pin. [7] A rotating electrical machine according to claim 2, wherein a hole is provided on the sensor holding component. [8] The rotary electric machine according to claim 2, wherein a signal line holding component provided on the sensor holding component, by which a wiring of the sensor stator is held on the sensor supporting component, is included. [9] The rotary electric machine according to claim 1, wherein a signal line holding component provided on the sensor stator, by which a wiring of the sensor stator is held on the sensor stator, is included. [10] The rotary electric machine according to claim 2, wherein an end portion of the sensor holding component connected to the sensor supporting components is bent in a shaft direction of the rotary shaft. [11] The rotary electric machine according to claim 1, wherein the sensor support components to which the sensor stator is attached are bent in a shaft direction of the rotary shaft. [12] The rotating electrical machine according to claim 1, wherein the sensor support components are made of a non-magnetic material. [13] The rotating electrical machine according to claim 2, wherein at least one side of the sensor support components and the sensor holding component is made of a non-magnetic material. [14] A rotary electric machine according to claim 1, wherein a bobbin on which a coil of the stator is wound is mounted on a stator core of the stator, and the sensor support components are held between the stator body and the bobbin core. [15] A rotating electrical machine according to claim 14, wherein the coil body and the sensor support components are inserted and potted. [16] The rotary electric machine according to claim 1, wherein a length of the sensor stator in a rotation shaft direction is different from a length of the sensor rotor in the rotation shaft direction.

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