Motor and motor manufacturing method

Abstract

To provide a motor of which the workability is improved and the junction strength of casings is improved.SOLUTION: A motor 1 comprises: a shaft 4 extending in an axial direction; a rotor 2 which is rotated together with the shaft; a stator 3 which is opposed to the rotor in a radial direction; a first casing 5 in which the shaft, the rotor and the stator are stored; and a second casing 6 which is positioned on one side of the first casing in the axial direction. The second casing includes a flange part 62 which is spread outward in a view in the axial direction. The first casing includes a mounting part 52, which is joined to the flange part, on one side in the axial direction. The first casing and the second casing include a welding part 7 which is spread over the mounting part and a distal end of the flange part and configured by fusing and solidifying a material constituting the first casing and a material constituting the second casing. The welding part includes a fusion portion, which is configured by fusing and solidifying at least the material constituting the second casing, on an end face of the flange part of the second casing on one side in the axial direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a motor and a method for manufacturing a motor. [Background technology]

[0002] There is known a motor having a first casing that houses a stator and a second casing that is connected to the first casing in the direction in which the motor's rotation shaft extends. One such motor is disclosed in Patent Document 1, for example, in which a case housing the stator is fixed with screws to a bracket that closes the opening of the case. Another motor is disclosed in Patent Document 2, for example, in which a first gear housing portion and a second gear housing portion are permanently connected by friction stir welding. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2024-14387 [Patent Document 2] Special Publication No. 2016-509178 Summary of the Invention [Problem to be solved by the invention]

[0004] In a motor in which multiple casings are fastened together with multiple bolts, gaps may form in the areas where the casings are butted together and where no bolts are located, which may result in insufficient joining strength between the casings.

[0005] In addition, typically, multiple casings are overlapped with one another so that the flange portion of the other casing covers the opening of the other casing. Therefore, the mating surfaces of the multiple casings face each other in the axial direction. Therefore, when joining the multiple casings by friction stir welding, it is necessary to bring the friction stir tool into contact with the casings in a direction intersecting the axial direction and move it in the circumferential direction. This requires a large space to move the friction stir tool, which has led to the problem of poor workability during the joining work.

[0006] Therefore, there is a demand for a method of manufacturing a motor that can improve the joining strength between the first casing and the second casing and can also improve the workability of the joining operation.

[0007] An object of the present invention is to provide a motor that can be manufactured by a manufacturing method that can improve the workability of the joining operation, and that has improved joining strength between the first casing and the second casing. [Means for solving the problem]

[0008] A motor according to one embodiment of the present invention includes a shaft extending in the axial direction, a rotor rotating with the shaft, a stator radially opposed to the rotor, a first casing accommodating the shaft, the rotor, and the stator, and a second casing located on one axial side of the first casing. The second casing has a flange portion extending outward in the axial direction. The first casing has an attachment portion on the one axial side that is joined to the flange portion. The first casing and the second casing include a welded portion that spans the attachment portion and a tip end of the flange portion and is formed by melting and solidifying materials that constitute the first casing and the second casing. The welded portion includes a molten portion formed by melting and solidifying at least the material that constitutes the second casing, on an end surface on the one axial side of the flange portion of the second casing.

[0009] A motor manufacturing method according to one embodiment of the present invention is a method for manufacturing a motor having a shaft extending in an axial direction, a rotor rotating with the shaft, a stator radially opposed to the rotor, a first casing accommodating the shaft, the rotor, and the stator, and a second casing located on one axial side of the first casing. The motor manufacturing method includes an arrangement step of arranging a tip end of a flange portion of the second casing, the flange portion extending outward as viewed in the axial direction, on an annular mounting portion protruding in the axial direction on the one axial side of the first casing, and a joining step of friction stir welding a region including the tip end of the flange portion as viewed in the axial direction from the one axial side. [Effects of the Invention]

[0010] According to one embodiment of the present invention, a motor can be obtained that can be manufactured by a manufacturing method that can improve the workability of the joining operation and that has improved joining strength between the first casing and the second casing. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a cross-sectional view showing a schematic configuration of a motor according to a first embodiment. [Figure 2] FIG. 2 is a view of the motor viewed in the axial direction. [Figure 3] FIG. 3 is a partially enlarged view of FIG. [Figure 4] FIG. 4 is a perspective view showing a schematic configuration of a friction stir tool. [Figure 5] FIG. 5 is a diagram illustrating friction stir welding. [Figure 6] FIG. 6 is a diagram schematically showing a state in which the friction stir pin of the friction stir tool is pressed into the workpiece. [Figure 7] FIG. 7 is a top view showing how the friction stir tool is moved along the mating surfaces of the workpieces. [Figure 8] FIG. 8 is a diagram illustrating friction stir welding by a method different from that shown in FIG. [Figure 9]FIG. 9 is a diagram schematically showing a state in which the friction stir pin of the friction stir tool is pressed into the workpiece. [Figure 10] FIG. 10 is a diagram illustrating the placement step according to the first embodiment. [Figure 11] FIG. 11 is a diagram illustrating the joining step according to the first embodiment. [Figure 12] FIG. 12 is a view of the first casing and the second casing joined in the joining step, viewed in the axial direction from one axial side. [Figure 13] FIG. 13 is a view corresponding to FIG. 3 of a motor according to a first modification of the first embodiment. [Figure 14] FIG. 14 is a view corresponding to FIG. 3 of a motor according to a second modification of the first embodiment. [Figure 15] FIG. 15 is a view corresponding to FIG. 3 of a motor according to a third modification of the first embodiment. [Figure 16] FIG. 16 is a view corresponding to FIG. 3 of a motor according to a fourth modification of the first embodiment. [Figure 17] FIG. 17 is a view of the motor according to the second embodiment, which corresponds to FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the drawings. The same or corresponding parts in the drawings are designated by the same reference numerals, and their description will not be repeated. Furthermore, the dimensions of the components in each drawing do not faithfully represent the actual dimensions of the components and the dimensional ratios of the components.

[0013] Furthermore, in the following description, the expressions "fix," "connect," and "attach" (hereinafter referred to as "fixing") include not only cases where members are directly fixed to each other, but also cases where members are fixed via other members. In other words, in the following description, the expression "fixing" includes both direct and indirect fixing of members to each other.

[0014] In the following description, a direction parallel to the central axis P of the shaft 4 will be referred to as the axial direction, and a direction perpendicular to the central axis P will be referred to as the radial direction. In addition, in the axial direction, the side where the second casing 6 is located relative to the first casing 5 will be referred to as one axial side X1 of each component, and the opposite side will be referred to as the other axial side X2 of each component.

[0015] In this specification, the term "annular" refers to a closed shape having the same starting point and ending point, i.e., the term "annular" in this specification includes not only shapes formed by curves but also shapes formed by straight lines and corners.

[0016] (Embodiment 1) (Motor configuration) A motor 1 according to a first exemplary embodiment of the present invention will be described with reference to Figures 1 to 3. As shown in Figure 1, the motor 1 has a rotor 2, a stator 3, a shaft 4, a first casing 5, and a second casing 6. The rotor 2 rotates around a central axis P relative to the stator 3. In this embodiment, the motor 1 is a so-called inner rotor type motor in which the rotor 2 is positioned inside the cylindrical stator 3 so as to be rotatable around the central axis P.

[0017] The rotor 2 includes a rotor core 21 and a magnet 22. The rotor 2 is located radially inward of the stator 3 and is rotatable relative to the stator 3 about a central axis P.

[0018] The rotor 2 has a shaft insertion hole 2a extending along the central axis P. The shaft 4 is fixed to the rotor 2 while passing through the shaft insertion hole 2a in the axial direction. This allows the rotor 2 to rotate together with the shaft 4. The configuration of the rotor 2 is similar to that of a general rotor, and therefore a detailed description of the configuration will be omitted.

[0019] The stator 3 is cylindrical. The rotor 2 is located radially inward of the stator 3. That is, the stator 3 is located radially opposite the rotor 2. The stator 3 includes a stator core 31 and a stator coil 32. The stator coil 32 is wound around the stator core 31. The configuration of the stator 3 is similar to that of a general stator, and therefore a detailed description of the configuration will be omitted.

[0020] The first casing 5 is cylindrical and extends in the axial direction. The first casing 5 houses the rotor 2, the stator 3, and the shaft 4. In this embodiment, the first casing 5 has a bottom on the other axial side X2. The first casing 5 has an opening 5a on the one axial side X1. The first casing 5 is made of a metal material that can be friction-stirred. The metal material is, for example, an aluminum alloy.

[0021] The first casing 5 has a cylindrical main body 51 that extends in the axial direction and has a bottom. The main body 51 has an attachment portion 52 at an end on one axial side X1 that is joined to a flange portion 62 of the second casing 6, which will be described later.

[0022] In this embodiment, the attachment portion 52 is configured by an end portion on one axial side X1 of the main body portion 51. Therefore, as shown in Fig. 2, the attachment portion 52 has an annular shape surrounding the opening 5a.

[0023] The first casing 5 may also contain oil or the like that functions as a lubricant and a coolant for the motor 1, for example.

[0024] The second casing 6 is located on one axial side X1 of the first casing 5. Here, "the second casing is located on one axial side X1 of the first casing" means that the second casing is located on one axial side X1 of the first casing relative to the axial center of the first casing. In other words, part or all of the second casing may be located on the other axial side X2 of the first casing relative to the end of the one axial side X1 of the first casing.

[0025] In this embodiment, the second casing 6 covers the opening 5a of the first casing 5. The second casing 6 is made of a metal material that can be frictionally stirred. The metal material is, for example, an aluminum alloy. The metal material that makes up the second casing 6 and the metal material that makes up the first casing 5 may be different.

[0026] The second casing 6 has a bearing holding portion 61 and a flange portion 62. The bearing holding portion 61 holds a bearing 63 that rotatably supports the end portion of the shaft 4 on one axial side X1. The flange portion 62 extends radially outward from the bearing holding portion 61. The tip portion of the flange portion 62 is joined to the mounting portion 52 of the first casing 5 by friction stir welding.

[0027] That is, in this embodiment, the first casing 5 has an opening 5a on one axial side X1. The attachment portion 52 is annular and protrudes toward the one axial side X1 and surrounds the opening 5a. The second casing 6 has a tip end of a flange portion 62 joined to the attachment portion 52, covering the opening 5a of the first casing 5.

[0028] This makes it possible to prevent leakage of liquid such as oil from the opening of the first casing in a motor in which the liquid is stored inside the first casing, and also to prevent foreign matter, such as dust and water, from entering the first casing 5 from the opening 5a.

[0029] (Details of the joint between the first casing and the second casing) Next, the joint portion between the first casing 5 and the second casing 6 in the motor 1 according to this embodiment will be described in detail.

[0030] 2, the attachment portion 52 of the first casing 5 is annular and surrounds the opening 5a. The second casing 6 is located on the inner circumferential side of the attachment portion 52 of the first casing 5.

[0031] 3, the inner peripheral surface 52a of the mounting portion 52 of the first casing 5 and the outer peripheral surface 62a of the flange portion 62 of the second casing 6 face each other in the radial direction. The end face 52b on one axial side X1 of the mounting portion 52 of the first casing 5 and the end face 62b on one axial side X1 of the flange portion 62 of the second casing 6 are located on the same plane.

[0032] The first casing 5 and the second casing 6 are joined by a weld 7 that spans the inner circumferential surface 52 a of the attachment portion 52 of the first casing 5 and the outer circumferential surface 62 a of the flange portion 62 of the second casing 6 .

[0033] The welded portion 7 is a portion where the material constituting the first casing 5 and the material constituting the second casing 6 have melted and solidified. The welded portion 7 is formed by friction stirring a portion F where the mounting portion 52 of the first casing 5 and the outer peripheral surface 62a of the flange portion 62 of the second casing 6 face each other, using a friction stir tool T. In other words, the welded portion 7 is formed by friction stir welding between the mounting portion 52 of the first casing 5 and the tip end of the flange portion 62 of the second casing 6.

[0034] Hereinafter, a portion that has undergone a process to change the structure of a material by melting and solidifying the material will be referred to as a molten portion, and a portion that has not undergone the process will be referred to as a non-molten portion. The process includes, for example, friction stir processing, laser welding, etc.

[0035] This makes it easier to increase the number of connection points between the first casing 5 and the second casing 6 compared to connecting the first casing 5 and the second casing 6 with, for example, bolts. Also, because the first casing 5 and the second casing 6 are joined by melting the material, the occurrence of gaps between the first casing 5 and the second casing 6 is suppressed. This improves the joining strength between the first casing 5 and the second casing 6.

[0036] 3, in this embodiment, the mounting portion 52 of the first casing 5 has a non-melted portion 53 on the outer periphery that is in an unmelted state. When viewed in the axial direction, the length L1 of the welded portion 7 in the width direction of the flange portion 62 is greater than the length L2 of the non-melted portion 53 in the width direction. Note that the width direction of the flange portion 62 is a direction that intersects with the direction in which the outer periphery 62a of the flange portion 62 extends when viewed in the axial direction of the flange portion 62.

[0037] In this embodiment, the cross-sectional area of ​​the welded portion 7 decreases from one axial side X1 to the other axial side X2. Note that the cross-sectional area is the cross-sectional area in a direction perpendicular to the axial direction. In this embodiment, the axial length L3 of the welded portion 7 is equal to or less than half the axial length L4 of the outer peripheral surface 62a of the flange portion 62.

[0038] 2, in this embodiment, the attachment portion 52 of the first casing 5 and the tip end portion of the flange portion 62 of the second casing 6 are joined over the entire circumference. That is, the welded portion 7 spans the entire circumference of one axial side X1 of the attachment portion 52 of the first casing 5 and the entire circumference of the tip end portion of the flange portion 62 of the second casing 6.

[0039] This improves the joining strength between the first casing 5 and the second casing 6. Furthermore, when a liquid such as oil is contained in the first casing 5, the second casing 6 can easily prevent the oil from leaking from the opening 5a of the first casing.

[0040] The motor 1 according to the first exemplary embodiment of the present invention described above includes a shaft 4 extending in the axial direction, a rotor 2 rotating together with the shaft 4, a stator 3 radially opposed to the rotor 2, a first casing 5 accommodating the shaft 4, the rotor 2, and the stator 3, and a second casing 6 located on one axial side X1 of the first casing 5. The second casing 6 has a flange portion 62 extending outward in the axial direction. The first casing 5 has an attachment portion 52 on the one axial side X1 that is joined to the flange portion 62. The first casing 5 and the second casing 6 include a welded portion 7 that spans the attachment portion 52 and the tip end of the flange portion 62 and is formed by melting and solidifying materials that constitute the first casing 5 and the second casing 6. The welded portion 7 has a fusion zone formed by melting and solidifying at least the material that constitutes the second casing 6 on the end surface of the one axial side X1 of the flange portion 62 of the second casing 6.

[0041] The welded portion 7 of the motor 1 is formed by friction stir welding between the attachment portion 52 of the first casing 5 and the tip end of the flange portion 62 of the second casing 6.

[0042] In this way, in the motor 1 having the above-described configuration, the first casing 5 and the second casing 6 are joined by friction stir welding. This makes it easier to increase the number of joining points compared to motors 1 in which the first casing 5 and the second casing 6 are connected by, for example, bolts. Furthermore, in the above-described configuration, the first casing 5 and the second casing 6 are joined by melting the material, which prevents gaps from forming between the first casing 5 and the second casing 6.

[0043] In the motor 1 having the fusion zone on one axial side X1, the second casing 6 and the first casing 5 are friction-stirred from the one axial side X1. This improves the workability of the joining operation during manufacturing compared to when the second casing and the first casing are welded from a direction intersecting the axial direction of the motor.

[0044] Therefore, the motor 1 can be manufactured by a manufacturing method that can improve the workability of the joining work, and the motor 1 can be obtained with improved joining strength between the first casing 5 and the second casing 6.

[0045] (Motor manufacturing method) 4 to 12, a method for manufacturing the above-described motor 1 will be described. As described above, in the motor 1, the mounting portion 52 of the first casing 5 and the tip end portion of the flange portion 62 of the second casing 6 are joined by friction stir welding.

[0046] First, friction stir welding will be briefly explained using Figures 4 to 9. Friction stir welding is a method for joining two base materials by softening them with frictional heat and stirring them. Friction stir welding is performed using a friction stir tool T.

[0047] As shown in Fig. 4, the friction stir tool T has a columnar rotating part T1 that extends in the axial direction along the central axis Q, and a friction stir pin T2 that extends in the axial direction and has one end in the axial direction supported by the rotating part T1. The rotating part T1 is connected to a rotating shaft of a friction stir mill (not shown). The rotating part T1 rotates around the rotating shaft.

[0048] The diameter of the friction stir pin T2 decreases from one end in the axial direction supported by the rotating part T1 to the other end. The friction stir pin T2 rotates together with the rotating part T1 around the rotation axis of the friction stir device.

[0049] For example, as shown in FIG. 5, a friction stir pin T2 is rotated around the rotation axis and brought into contact with a region R spanning the butted portion of two workpieces W1 and W2. As a result, the portions of the workpieces W1 and W2 that contact the friction stir pin T2 are softened by frictional heat with the friction stir pin T2. ​​Next, as shown in FIG. 6, the friction stir pin T2 is pressed into the workpieces W1 and W2 and moved along the butted portion as shown in FIG. 7. As a result, the region R and its surroundings of the workpieces W1 and W2 are friction-stirred. As a result, the workpieces W1 and W2 are joined. In FIGS. 6 and 7, the region W3 where the workpieces W1 and W2 are friction-stirred is indicated by a dot.

[0050] Friction stir welding can also be performed on two workpieces W1 and W2 that overlap in the direction in which the friction stir pin T2 is pushed in. For example, as shown in FIG. 8, the friction stir pin T2 is brought into contact with the region R of one of the workpieces W1 and W2, W1, where the workpieces W1 and W2 are to be joined. Next, as shown in FIG. 9, the tip of the friction stir pin T2 is pushed in until it reaches the other workpiece W2, and the workpieces W1 and W2 are moved along the region R where they are to be joined. This causes friction stirring in the overlapping portions of the workpieces W1 and W2 and their surroundings. In FIG. 9, the region W3 where the workpieces W1 and W2 are friction stirred is indicated by a dot.

[0051] 6 and 9, the friction-stirred portion W3 narrows in width as it moves in the pushing direction of the friction stir pin T2 when viewed in a direction intersecting the axial direction of the friction stir pin T2. ​​That is, the friction-stirred portion W3 is widest at the portion where the friction stir pin T2 first comes into contact.

[0052] In friction stir welding using the friction stir tool T, the shape of the friction-stirred portion can be changed by adjusting the rotation speed of the friction stir tool T and the dimensions of the friction stir pin T2. ​​For example, the width can be increased by increasing the rotation speed. Also, the depth can be increased by increasing the axial length of the friction stir pin T2.

[0053] Next, a description will be given of a manufacturing method of the motor 1 according to the present embodiment 1. The manufacturing method of the motor 1 includes an arrangement step and a joining step.

[0054] As shown in FIG. 10, in the arrangement step, the tip end of the flange portion 62 of the second casing 6 is arranged relative to the attachment portion 52 that protrudes from the first casing 5 toward one axial side X1.

[0055] Specifically, the inner surface 52a of the mounting portion 52 of the first casing 5 faces the outer surface 62a of the flange portion 62 of the second casing 6, and the end face 52b of one axial side X1 of the mounting portion 52 and the end face 62b of one axial side X1 of the flange portion 62 are arranged on the same plane.

[0056] Next, as shown in FIG. 11, in the joining step, a region R spanning the attachment portion 52 and the flange portion 62 of the first casing 5 as viewed in the axial direction is friction stir welded.

[0057] Specifically, a friction stir welding pin T2 is rotated and brought into contact with the region R spanning the first casing 5 and the second casing 6 from one axial side X1, and the friction stir welding pin T2 is pushed in the axial direction. Then, as shown in FIG. 12, the friction stir welding pin T2 is moved in the direction of the arrow in FIG. 12. This causes friction stirring between the mounting portion 52 of the first casing 5 and the tip end of the flange portion 62 of the second casing 6. The friction stirred portion forms the welded portion 7 of the motor 1.

[0058] In this embodiment, friction stir welding is performed over the entire circumference of the region R that straddles the first casing 5 and the second casing 6. That is, the inner circumferential surface 52a of the mounting portion 52 of the first casing 5 and the outer circumferential surface 62a of the flange portion 62 of the second casing 6 are joined together without any gaps.

[0059] This improves the joining strength between the first casing 5 and the second casing 6. Therefore, when a liquid such as oil is stored inside the first casing 5, the second casing 6 can more reliably prevent the oil from leaking from the opening 5a of the first casing 5.

[0060] In this embodiment, the rotation speed of the friction stir tool T and the dimensions of the friction stir pin T2 are adjusted to rotation speed and dimensions suitable for forming a weld 7 whose axial length L3 is equal to or less than half the axial length L4 of the outer peripheral surface 62a of the flange portion 62. That is, in this embodiment, the friction stir pin T2 is pushed in to a position shallower than half the thickness of the flange portion 62.

[0061] This allows the friction stir pin T2 to be pushed in a smaller amount than when forming a welded joint whose axial length L3 is equal to or greater than half the axial length L4 of the outer peripheral surface of the flange portion. This reduces the time required for the joining process, thereby improving the productivity of the motor 1.

[0062] In addition, in this embodiment, the rotational speed of the friction stir tool T and the dimensions of the friction stir pin T2 are adjusted to a rotational speed and dimensions suitable for forming a welded portion 7 whose width on one axial side is larger than the width of the non-melted portion 53 of the first casing 5 on one axial side X1.

[0063] This allows the volume of the welded portion 7 to be larger than when the width of the welded portion 7 is smaller than the width of the non-melted portion 53. Therefore, it is possible to manufacture a motor 1 with improved joint strength between the first casing 5 and the second casing 6.

[0064] As described above, the manufacturing method of the motor 1 according to an exemplary embodiment of the present invention includes an arrangement process in which the tip end of the flange portion 62, which extends outward in the axial direction in the second casing 6, is arranged relative to the annular mounting portion 52 protruding from one axial side X1 of the first casing 5, and a joining process in which the region including the tip end of the flange portion 62, as viewed in the axial direction, is friction stir joined from one axial side X1.

[0065] In the above-described manufacturing method, the first casing 5 and the second casing 6 are joined by friction stir welding. This makes it easier to increase the number of joints between the first casing 5 and the second casing 6 compared to connecting the first casing 5 and the second casing 6 with, for example, bolts. Furthermore, in this method, the first casing 5 and the second casing 6 are joined by melting the base material, which makes it possible to prevent gaps from occurring between the first casing 5 and the second casing 6.

[0066] In the above-described manufacturing method, the friction stir process is performed from one axial direction, which improves the workability of the joining operation compared to when welding or the like is performed from a direction intersecting the axial direction of the motor.

[0067] Therefore, it is possible to provide a method for manufacturing the motor 1 that can improve the joining strength between the first casing 5 and the second casing 6 and also improve the workability of the joining operation.

[0068] In this embodiment, in the arrangement step, the inner peripheral surface 52a of the attachment portion 52 of the first casing 5 and the outer peripheral surface 62a of the flange portion 62 of the second casing 6 are opposed to each other, and the end face 52b of the attachment portion 52 on one axial side X1 and the end face on one axial side X1 of the outer peripheral side of the flange portion 62 located on the inner peripheral side with respect to the first casing 5 are arranged on the same plane. In the joining step, the region R spanning the first casing 5 and the second casing 6 is friction stir welded from the one axial side X1.

[0069] In the motor 1 manufactured by the above-described manufacturing method, the inner circumferential surface 52a of the mounting portion 52 of the first casing 5 faces the outer circumferential surface 62a of the flange portion 62 of the second casing 6. The end face 52b on one axial side X1 of the mounting portion 52 of the first casing 5 and the end face on the one axial side X1 on the outer circumferential side of the flange portion 62 located on the inner circumferential side with respect to the first casing 5 are located on the same plane. The welded portion 7 spans the inner circumferential surface 52a of the mounting portion 52 of the first casing 5 and the outer circumferential surface 62a of the flange portion 62 of the second casing 6.

[0070] In this embodiment, when joining the second casing 6 to the first casing 5, the region R where the first casing 5 and the second casing 6 face each other is exposed on one axial side X1. Therefore, the friction stir pin T2 can be brought into contact with the region R where the first casing 5 and the second casing 6 face each other from one axial side X1. This makes it possible to easily join the first casing 5 and the second casing 6.

[0071] In the motor 1 manufactured by the above-described manufacturing method, the cross-sectional area of ​​the welded portion 7 decreases from the one axial side X1 toward the other axial side X2.

[0072] The motor 1, which has a weld 7 whose cross-sectional area decreases toward the other axial side X2, is manufactured by contacting the friction stir pin T2 with the one axial side X1. Therefore, it is manufactured by a manufacturing method that allows for improved workability in the joining operation compared to a motor manufactured by contacting the friction stir pin T2 with the radially outer side of the second casing. Therefore, a motor 1 manufactured by a manufacturing method with improved workability in the joining operation can be obtained.

[0073] In the motor 1 manufactured by the above-described manufacturing method, the axial length L3 of the welded portion 7 is half or less of the axial length L4 of the outer circumferential surface 62a of the flange portion 62.

[0074] This allows for a motor 1 to be manufactured using a manufacturing method that requires less time to join the first casing 5 and the second casing 6 than when the axial length L3 of the welded portion 7 is more than half the axial length L4 of the outer surface 62a of the flange portion 62.

[0075] Furthermore, in the motor 1 manufactured by the above-described manufacturing method, the mounting portion 52 of the first casing 5 has a non-melted portion 53 in an unmelted state on the outer circumferential side of the end face on one axial side X1. When viewed in the axial direction, the length of the welded portion 7 in the width direction of the flange portion 62 is greater than the length of the non-melted portion 53 in the width direction. Note that the width direction here refers to a direction that intersects with the direction in which the outer circumferential surface 62a of the flange portion 62 extends when viewed in the axial direction of the flange portion 62.

[0076] This allows the volume of the welded portion 7 to be larger than when the length L1 of the welded portion 7 in the width direction is smaller than the length L2 of the non-melted portion 53 in the width direction. Therefore, the motor 1 has improved joining strength between the first casing 5 and the second casing 6.

[0077] (Modification 1 of Embodiment 1) 13 is a view corresponding to FIG. 3 of a motor 101 according to a first modification of the first embodiment. In the motor 101 according to this modification, the mounting portion 152 of the first casing 105 has a protrusion 154 that protrudes inward from an inner circumferential surface 152a. A surface 154b on one axial side X1 of the protrusion 154 contacts a surface 162c on the other axial side X2 of the flange portion 162 of the second casing 106.

[0078] That is, in the motor 101 according to the first modification, the mounting portion 152 of the first casing 105 has a protrusion 154 on an inner circumferential surface 152a that comes into contact with a surface 162c on the other axial side X2 of the flange portion 162 of the second casing .

[0079] This makes it possible to easily position the second casing 106 in the axial direction relative to the first casing 105. This improves the workability of the friction stir welding operation.

[0080] (Modification 2 of Embodiment 1) 14 is a view corresponding to FIG. 3 of a motor 201 according to a second modification of the first embodiment. As shown in FIG. 14, the protruding portion of the mounting portion 252 on the first casing 205 of the motor 201 may be realized by a step 254 having a surface 254b on one axial side X1. The surface 254b on the one axial side X1 of the step 254 comes into contact with a surface 262c on the other axial side X2 of the flange portion 262 on the second casing 206.

[0081] This configuration also makes it possible to easily position the second casing 206 in the axial direction relative to the first casing 205. This improves the workability of the friction stir welding operation.

[0082] (Modification 3 of Embodiment 1) 15 is a view corresponding to FIG. 3 of a motor 301 according to Modification 3 of Embodiment 1. In motor 301 according to this modification, axial length L33 of welded portion 307 is greater than half the axial length L34 of outer peripheral surface 362a of flange portion 362 of second casing 306.

[0083] This improves the joining strength between the first casing 305 and the second casing 306 compared to when the axial length of the welded portion is less than half the axial length of the outer surface of the flange portion.

[0084] (Fourth Modification of First Embodiment) 16 is a view corresponding to FIG. 3 of a motor 401 according to a fourth modification of the first embodiment. In the motor 401 according to this modification, the mounting portion 452 of the first casing 405 has a non-melted portion 453 in an unmelted state on the outer circumferential side of an end face 452b on one axial side X1. As viewed in the axial direction, the length L41 of the welded portion 407 in the width direction of the flange portion 462 of the second casing 406 is smaller than the length L42 of the non-melted portion 453 in the width direction.

[0085] The first casing 405 and second casing 406 of the motor 401 having the above-described configuration are friction stir welded using a friction stir welding device having friction stir pins T2 that can be used even when the welding area R is small. A friction stir welding device having such friction stir pins T2 can also perform friction stir welding on small motors. Therefore, with the friction stir welding device, it is not necessary to replace the friction stir pins T2 depending on the size of the motor when manufacturing the motor. Therefore, by manufacturing motors using the friction stir welding device, it is possible to improve the manufacturing efficiency of motors.

[0086] That is, the motor 401 having the above-described configuration can be manufactured by a manufacturing method that can improve the workability of the joining operation, thereby providing the motor 401 manufactured by a manufacturing method that improves the workability of the joining operation.

[0087] (Embodiment 2) Next, a motor 501 according to a second exemplary embodiment of the present invention will be described with reference to Fig. 17. In this embodiment, the direction in which a first casing 505 and a second casing 506 face each other is different from the direction in which a first casing 505 and a second casing 6 face each other in the first embodiment. In the following, a description of the same configuration as in the first embodiment will be omitted, and only the configuration that differs from the first embodiment will be described.

[0088] 17 , in the motor 501, one axial side X1 of the mounting portion 552 of the first casing 505 and the other axial side X2 of the tip end portion of the flange portion 562 of the second casing 506 face each other in the axial direction. The welded portion 507 joining the first casing 505 and the second casing 506 straddles the one axial side X1 of the mounting portion 552 of the first casing 505 and the other axial side X2 of the tip end portion of the flange portion 562 of the second casing 506.

[0089] The method for manufacturing the motor 501 according to this embodiment includes an arrangement step and a joining step, similar to the first embodiment.

[0090] In the arrangement step of this embodiment, the tip end portion of the flange portion 562 of the second casing 506 is arranged on one axial side X1 of the attachment portion 552 of the first casing 505.

[0091] In the joining step of this embodiment, a region R of the flange portion 562 that overlaps with the attachment portion 552 as viewed in the axial direction is friction stir welded from one axial side X1.

[0092] This results in a motor 501 that is friction stir welded to the second casing 506 from one axial side X1, with the mounting portion 552 of the first casing 505 and the tip end of the flange portion 562 of the second casing 506 overlapping in the axial direction.

[0093] In the motor 501 manufactured by this manufacturing method, the first casing 505 and the second casing 506 also include a weld 507 that spans the mounting portion 552 and the tip of the flange portion 562 and is formed by melting and solidifying the material that constitutes the first casing 505 and the material that constitutes the second casing 506. The weld 507 has a molten portion formed by melting and solidifying at least the material that constitutes the second casing 506 on the end face of one axial side X1 of the flange portion 562 of the second casing 506.

[0094] In the motor 501, the first casing 505 and the second casing 506 are joined by friction stir welding. In such a motor 501, the number of joining points between the first casing 505 and the second casing 506 can be easily increased. Also, the occurrence of a gap between the first casing 505 and the second casing 506 can be suppressed.

[0095] Furthermore, in the above-described manufacturing method, the friction stir process is performed from one axial direction, which improves the workability of the joining operation compared to when welding or the like is performed from a direction intersecting the axial direction of the motor.

[0096] Therefore, motor 501 can be obtained that can be manufactured by a manufacturing method that can improve the workability of the joining work, and that has improved joining strength between first casing 505 and second casing 506.

[0097] (Other embodiments) Although the embodiments of the present invention have been described above, the above-described embodiments are merely examples for carrying out the present invention. Therefore, the present invention is not limited to the above-described embodiments, and it is possible to appropriately modify the above-described embodiments within the scope of the spirit of the present invention.

[0098] In the first embodiment, the mounting portion 52 of the first casing 5 is configured by an end portion on one axial side X1 of the main body portion 51. However, the first casing may have a lid portion that covers the one axial side X1 of the main body portion, and the mounting portion may be configured by a portion that protrudes toward the one axial side X1 from the lid portion.

[0099] In the first embodiment, the first casing 5 has an opening 5a on one axial side X1, and the mounting portion 52 is annular and surrounds the opening 5a. The second casing 6 covers the opening 5a. However, the first casing does not have to have an opening. The second casing does not have to cover the opening. Even if the first casing does not have an opening, it may have an annular mounting portion to which the second casing is joined.

[0100] In the first embodiment, the first casing 5 has a circular opening 5a when viewed in the axial direction and an annular mounting portion 52 when viewed in the axial direction. However, the first casing may have a polygonal opening when viewed in the axial direction. The first casing may have a polygonal mounting portion when viewed in the axial direction.

[0101] In the first embodiment, the first casing 5 and the second casing 6 are joined by friction stir welding the attachment portion 52 of the first casing 5 and the tip end of the flange portion 62 of the second casing 6. However, the first casing and the second casing may also be joined by laser welding the attachment portion of the first casing and the tip end of the flange portion of the second casing.

[0102] In this case, the first casing may be made of a laser-weldable metal material, and the second casing may be made of a laser-weldable metal material.

[0103] In the first embodiment, the welded portion 7 spans the entire circumference of one axial side X1 of the mounting portion 52 of the first casing 5 and the entire circumference of the tip end portion of the flange portion 62 of the second casing 6. However, the welded portion may also span a part of one axial side X1 of the mounting portion of the first casing and a part of the tip end portion of the flange portion of the second casing.

[0104] In each of the above-described embodiments, the end faces on the one axial side X1 and the other axial side X2 of the flange portions 62, 162, 262, 362, 462, 562 of the second casing 6, 106, 206, 306, 406, 506 are flat. However, the end faces on the one axial side X1 of the flange portions may have irregularities. The end faces on the other axial side X2 of the flange portions may have irregularities.

[0105] (Configuration example) The present technology can also be configured as follows.

[0106] (1) The motor includes a shaft extending in the axial direction, a rotor rotating together with the shaft, a stator radially opposed to the rotor, a first casing accommodating the shaft, the rotor, and the stator, and a second casing located on one axial side of the first casing. The second casing has a flange portion extending outward when viewed in the axial direction. The first casing has an attachment portion on the one axial side that is joined to the flange portion. The first casing and the second casing include a welded portion that spans the attachment portion and a tip end of the flange portion and is formed by melting and solidifying a material that constitutes the first casing and a material that constitutes the second casing. The welded portion includes a molten portion formed by melting and solidifying at least a material that constitutes the second casing, on an end surface on the one axial side of the flange portion of the second casing.

[0107] (2) In the motor described in (1), the cross-sectional area of ​​the welded portion decreases from the one axial side toward the other axial side.

[0108] (3) In the motor described in (1) or (2), the first casing has an opening on one side in the axial direction. The mounting portion is annular and protrudes on one side in the axial direction and surrounds the opening. The tip end of the flange portion of the second casing is joined to the mounting portion, covering the opening of the first casing.

[0109] (4) In the motor described in (3), the welded portion extends over the entire circumference of the one axial side of the mounting portion of the first casing and the entire circumference of the tip end of the flange portion of the second casing.

[0110] (5) In the motor described in any one of (1) to (4), the one axial side of the mounting portion of the first casing and the other axial side of the tip end of the flange portion of the second casing face each other in the axial direction, and the welded portion straddles the one axial side of the mounting portion of the first casing and the other axial side of the tip end of the flange portion of the second casing.

[0111] (6) In the motor described in (3) or (4), the inner peripheral surface of the mounting portion of the first casing faces the outer peripheral surface of the flange portion of the second casing. An end face on the one axial side of the mounting portion of the first casing and an end face on the one axial side of the outer peripheral side of the flange portion, which is located on the inner peripheral side of the first casing, are located on the same plane. The welded portion spans the inner peripheral surface of the mounting portion of the first casing and the outer peripheral surface of the flange portion of the second casing.

[0112] (7) In the motor described in (6), the mounting portion of the first casing has a protrusion on an inner circumferential surface thereof that comes into contact with the surface of the flange portion of the second casing on the other axial side.

[0113] (8) In the motor described in (6) or (7), the axial length of the welded portion is equal to or less than half the axial length of the outer circumferential surface of the flange portion.

[0114] (9) In the motor described in (6) or (7), the axial length of the welded portion is greater than half the axial length of the outer circumferential surface of the flange portion.

[0115] (10) In the motor according to any one of (6) to (9), the mounting portion of the first casing has a non-melted portion on the outer circumferential side of the end face on one side in the axial direction, and the length of the welded portion in the width direction of the flange portion as viewed in the axial direction is greater than the length of the non-melted portion in the width direction.

[0116] (11) In the motor according to any one of (6) to (9), the mounting portion of the first casing has a non-melted portion on the outer circumferential side of the end face on the one axial side, and the length of the welded portion in the width direction of the flange portion as viewed in the axial direction is smaller than the length of the non-melted portion in the width direction.

[0117] (12) In the motor described in any one of (1) to (11), the welded portion is formed by friction stir welding between the mounting portion of the first casing and the tip end of the flange portion of the second casing.

[0118] (13) A motor manufacturing method for manufacturing a motor having an axially extending shaft, a rotor rotating with the shaft, a stator radially opposed to the rotor, a first casing accommodating the shaft, the rotor, and the stator, and a second casing located on one axial side of the first casing, the motor manufacturing method comprising: an arrangement step of arranging a tip end of a flange portion of the second casing, the flange portion extending outward as viewed in the axial direction, on an annular mounting portion protruding on the one axial side of the first casing; and a joining step of friction stir welding an area including the tip end of the flange portion as viewed in the axial direction from the one axial side.

[0119] (14) In the motor manufacturing method described in (13), in the arranging step, an inner peripheral surface of the mounting portion of the first casing is opposed to an outer peripheral surface of the flange portion of the second casing, and an end face of the mounting portion on the one axial side and an end face of the flange portion on the inner peripheral side of the first casing are arranged on the same plane. In the joining step, a region spanning the first casing and the second casing is friction stir welded from the one axial side.

[0120] (15) In the motor manufacturing method described in (13), in the arranging step, a tip end of the flange portion of the second casing is arranged on one axial side of the mounting portion of the first casing, and in the joining step, a region of the flange portion that overlaps with the mounting portion as viewed in the axial direction is friction stir welded from the one axial side. [Industrial Applicability]

[0121] The present invention can be used to join two casings of a motor that are arranged side by side in the axial direction. [Explanation of symbols]

[0122] 1, 101, 201, 301, 401, 501 motors 2 rotors 2a Shaft insertion hole 3 Stator 4 shafts 5, 105, 205, 305, 405, 505 First casing 5a aperture 6, 106, 206, 306, 406, 506 Second casing 7, 307, 407, 507 Welds 21 Rotor core 22 Magnet 31 stator core 32 stator coil 51 Main body 52, 152, 252, 452, 552 Mounting part 52a, 152a Inner surface 52b, 452b end face 53, 453 Non-melted area 61 Bearing holder 62, 162, 262, 362, 462, 562 flange 62a Outer surface 62b End face 63 Bearing 154 Protrusion 154b, 254b Axial direction one side surface 162c, 262c Other side of the axial direction 254 steps 362a Outer surface L1, L41 Length of the weld in the width direction of the flange L2, L42 Width of flange in non-melted area L3, L33 Axial length of the weld L4, L34 Axial length of the outer periphery of the flange T Friction Stir Tool T1 Rotating part T2 Friction Stir Pin X1 One side in the axial direction X2 Other axial side

Claims

1. an axially extending shaft; a rotor that rotates with the shaft; a stator radially opposed to the rotor; a first casing that houses the shaft, the rotor, and the stator; a second casing located on one axial side of the first casing; A motor having The second casing includes: a flange portion extending outward as viewed in the axial direction, The first casing includes: a mounting portion joined to the flange portion on one side of the axial direction, The first casing and the second casing are a welded portion that spans the attachment portion and the tip end of the flange portion and is formed by melting and solidifying a material that constitutes the first casing and a material that constitutes the second casing, The welded portion is a molten portion formed by melting and solidifying at least a material constituting the second casing, on an end surface on one axial side of the flange portion of the second casing; Motor.

2. 2. The motor according to claim 1, The welded portion is The cross-sectional area becomes smaller from one axial side to the other axial side. Motor.

3. 2. The motor according to claim 1, The first casing includes: An opening is provided on one side of the axial direction. The mounting portion is an annular projection that protrudes toward one side in the axial direction and surrounds the opening; The second casing includes: the tip end of the flange portion is joined to the mounting portion to cover the opening of the first casing; Motor.

4. 4. The motor according to claim 3, The welded portion is the flange portion of the second casing extends over the entire circumference of the one axial side of the mounting portion of the first casing and the entire circumference of the tip end of the flange portion of the second casing; Motor.

5. The motor according to any one of claims 1 to 4, the one axial side of the mounting portion of the first casing and the other axial side of the tip end of the flange portion of the second casing face each other in the axial direction, The welded portion is the flange portion of the second casing extends from the first casing to the second casing. Motor.

6. 4. The motor according to claim 3, an inner circumferential surface of the mounting portion of the first casing and an outer circumferential surface of the flange portion of the second casing face each other, an end surface of the mounting portion of the first casing on the one axial side and an end surface of the flange portion on the outer circumferential side of the first casing on the one axial side are located on the same plane, The welded portion is The flange portion of the second casing is provided between the inner circumferential surface of the mounting portion of the first casing and the outer circumferential surface of the flange portion of the second casing. Motor.

7. 7. The motor according to claim 6, The mounting portion of the first casing includes: a protrusion on an inner peripheral surface thereof that comes into contact with a surface of the flange portion of the second casing on the other side in the axial direction; Motor.

8. 7. The motor according to claim 6, The axial length of the weld is The length in the axial direction of the outer peripheral surface of the flange portion is equal to or less than half of the length. Motor.

9. 7. The motor according to claim 6, The axial length of the weld is the length of the outer peripheral surface of the flange portion in the axial direction is greater than half the length of the outer peripheral surface of the flange portion in the axial direction; Motor.

10. 7. The motor according to claim 6, The mounting portion of the first casing includes: a non-melted portion in a non-melted state on an outer circumferential side of the end surface on the one axial side, When viewed in the axial direction, the length of the weld in the width direction of the flange portion is The length of the non-melted portion in the width direction is greater than the length of the non-melted portion. Motor.

11. 7. The motor according to claim 6, The mounting portion of the first casing includes: a non-melted portion in a non-melted state on an outer circumferential side of the end surface on the one axial side, When viewed in the axial direction, the length of the weld in the width direction of the flange portion is The length of the non-melted portion in the width direction is smaller than the length of the non-melted portion. Motor.

12. 2. The motor according to claim 1, The welded portion is The mounting portion of the first casing and the tip end of the flange portion of the second casing are friction stir welded together. Motor.

13. an axially extending shaft; a rotor that rotates with the shaft; a stator radially opposed to the rotor; a first casing that houses the shaft, the rotor, and the stator; a second casing located on one axial side of the first casing; A motor manufacturing method for manufacturing a motor having the following components: an arrangement step of arranging a tip end portion of a flange portion of the second casing, the flange portion extending outward as viewed in the axial direction, relative to an annular mounting portion of the first casing protruding toward one side in the axial direction; a joining step of friction stir welding a region including a tip end of the flange portion from one axial side as viewed in the axial direction; A motor manufacturing method comprising:

14. 14. The motor manufacturing method according to claim 13, In the placing step, an inner peripheral surface of the mounting portion of the first casing and an outer peripheral surface of the flange portion of the second casing are opposed to each other, and an end face of the mounting portion on the one axial side and an end face of the flange portion on the inner peripheral side of the first casing on the one axial side are arranged on the same plane; In the joining step, a region spanning the first casing and the second casing is friction stir welded from one axial side; Motor manufacturing method.

15. 14. The motor manufacturing method according to claim 13, In the placing step, a tip end portion of the flange portion of the second casing is disposed on one axial side of the mounting portion of the first casing; In the joining step, A region of the flange portion that overlaps with the mounting portion as viewed in the axial direction is friction stir welded from one axial side. Motor manufacturing method.

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