Manufacturing and assembly methods for motor

Abstract

To provide a motor capable of improving workability in manufacturing and assembly for the motor.SOLUTION: There is provided a manufacturing method for a brushless motor, which has a magnet arranged around a rotating shaft, a cylindrical coil 3 formed by winding a wire 3a, and a motor case that accommodates the magnet and the coil 3. The coil 3 has a plurality of phases, the wire 3a shifts in a rotational direction R of the rotating shaft for each phase, and is different in color from a wire 3a of the adjacent phase in the rotational direction R. In the coil 3, a color boundary 3h is formed between the wire 3a of the adjacent phase in the rotational direction R, and the color boundary 3h is aligned with a mark on the motor case, and the coil 3 is fixed to the motor case.SELECTED DRAWING: Figure 3

Description

[Technical Field]

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

[0002] In brushless motors equipped with Hall ICs, the rotor position must be detected by the Hall IC and current must be controlled to flow to the coil at the appropriate timing.

[0003] As an example of the above-mentioned brushless motor, Patent Document 1 discloses a brushless motor in which a Hall IC is positioned opposite the rotor in the axial direction and radially aligned with the first and second claw-shaped magnetic poles. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-143858 Summary of the Invention [Problem to be solved by the invention]

[0005] In the brushless motor described in the above-mentioned Patent Document 1, for example, in the case of a three-phase (U, V, W) brushless motor, three Hall ICs are provided, and the three Hall ICs are arranged at intervals of 120° in the rotation direction of the rotating shaft.

[0006] One example of a brushless motor is a slotless brushless motor, which does not have a slot for a coil. This slotless brushless motor does not have a core with a slot. Therefore, this type of brushless motor has a cylindrical coil arranged around the rotating shaft.

[0007] In the cylindrical coil described above, multiple phases are set, and wire is bonded to each phase to form the cylinder. However, there is variation in the position where the wire is bonded, which means that it takes a lot of man-hours to align it with the Hall IC, making it difficult to manufacture and assemble the motor. An object of the present invention is to improve workability in the manufacture and assembly of a motor. [Means for solving the problem]

[0008] One embodiment of a motor manufacturing method is a method for manufacturing a motor having a rotating shaft, a magnet arranged around the rotating shaft, a cylindrical coil arranged around the rotating shaft and formed by winding wire, and a cylindrical motor case that houses the magnet and the coil, wherein the coil has multiple phases, the wire is arranged offset in the rotational direction of the rotating shaft for each phase, and is a different color from the wire of the phase arranged adjacent to it in the rotational direction, a color boundary is formed in the coil relative to the wire of the phase arranged adjacent to it in the rotational direction, and the coil is fixed to the motor case by aligning the color boundary with a mark on the motor case.

[0009] Furthermore, one embodiment of a motor assembly method is a motor assembly method for fixing a motor to a gear case, the motor including a rotating shaft, a plurality of magnets arranged around the rotating shaft and rotating together with the rotating shaft, a coil arranged around the rotating shaft and formed by winding wire, and a cylindrical motor case that houses the plurality of magnets and the coil, wherein the coil has a plurality of phases, and a board on which a plurality of sensors that detect the positions of the plurality of magnets are mounted is attached to the gear case, and the rotational position of the coil is aligned so that it corresponds to the position of the plurality of sensors, and the motor case is fixed to the gear case using a position adjustment unit that the gear case or the motor case has. [Effects of the Invention]

[0010] According to the present invention, the workability can be improved in the manufacture and assembly of a motor. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a perspective view of the appearance of a brushless motor. [Figure 2] FIG. 2 is a cross-sectional view of the brushless motor shown in FIG. [Figure 3] FIG. 3 is a perspective view of a coil incorporated in the brushless motor shown in FIG. [Figure 4] FIG. 4 is a top view showing a state in which coils are arranged in a motor case during assembly of the brushless motor shown in FIG. [Figure 5] FIG. 5 is a rear view showing the positional relationship between the magnet of the brushless motor shown in FIG. 1 and the Hall IC on the flexible substrate. [Figure 6] 6 is a perspective view showing screw fixing holes provided in a motor case of the brushless motor shown in FIG. 1. FIG. [Figure 7] FIG. 7 is a rear view showing the structure in which the brushless motor shown in FIG. 1 is assembled into a gear case. [Figure 8] FIG. 8 is a plan view showing that screw fixing holes provided in the motor case of the brushless motor shown in FIG. 1 and elongated holes provided in the gear case are aligned in position. [Figure 9] FIG. 9 is a perspective view showing three sets of screw fixing holes provided in the motor case of the brushless motor shown in FIG. [Figure 10] FIG. 10 is a rear view showing a structure (without misalignment) in which a brushless motor having the motor case shown in FIG. 9 is assembled to a gear case. [Figure 11] FIG. 11 is a partial rear view showing a structure (with misalignment) in which a brushless motor having the motor case shown in FIG. 9 is assembled to a gear case. [Figure 12]FIG. 12 is a plan view showing a structure (with misalignment) in which a brushless motor having the motor case shown in FIG. 9 is assembled to a gear case. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. In all drawings referred to in describing the embodiment, the same or substantially the same configurations and elements will be designated by the same reference numerals. Furthermore, as a general rule, configurations and elements that have been described once will not be described repeatedly. In the following description, unless otherwise specified, terms such as "first" and "second" are used merely to distinguish components from one another and do not represent a particular order or sequence.

[0013] Fig. 1 is an external perspective view of a brushless motor according to this embodiment, and Fig. 2 is a cross-sectional view of the brushless motor according to this embodiment. Fig. 3 is a perspective view of a coil incorporated in the brushless motor according to this embodiment. Fig. 4 is a top view showing the state in which the coil is arranged in the motor case during assembly of the brushless motor according to this embodiment. Fig. 5 is a plan view showing the positional relationship between the magnet of the brushless motor according to this embodiment and the Hall IC on the flexible substrate. <Structure of a brushless motor>

[0014] There are no particular limitations on the use of the brushless motor 10 of this embodiment. The brushless motor 10 is used, for example, to drive the joints of a robot, and is a motor for rotating a gear incorporated in a module.

[0015] Brushless motor 10 is a slotless brushless motor that does not have slots for arranging windings. In other words, brushless motor 10 does not have a core with slots for arranging windings. Therefore, it has a cylindrical coil 3 arranged around rotating shaft 1. As shown in FIGS. 1 to 5, brushless motor 10 has rotating shaft 1, which is a shaft; magnet 2 arranged around rotating shaft 1; cylindrical coil 3 arranged around rotating shaft 1 and formed by winding wire 3a; and cylindrical motor case 4 that houses magnet 2 and coil 3. In this structure, magnet 2 is a rotor that rotates together with rotating shaft 1, while cylindrical coil 3 arranged around magnet 2 is a stator that is fixed so as not to rotate.

[0016] As shown in Fig. 5, four magnets 2, each forming an arc, are arranged in a ring shape at intervals around the rotating shaft 1. As shown in Figs. 1 and 2, a portion of the rotating shaft 1, the four magnets 2, a cylindrical coil 3, and laminated steel 7 provided on the outside of the coil 3 are housed in a cylindrical motor case 4. The cylindrical coil 3 is provided on the outside of the four magnets 2 arranged in a ring shape, and is preferably arranged on the circumference of a circle centered on the rotation center 1a of the rotating shaft 1.

[0017] The motor case 4 is composed of a cylindrical main body 4a, a disk-shaped front cover 4b provided on the front side of the main body 4a, and a disk-shaped bottom cover 4c provided on the bottom side of the main body 4a. As a result, one end of the rotating shaft 1 is rotatably supported by a bearing 5 provided in the center of the front cover 4b, and the other end is rotatably supported by a bearing 6 provided in the center of the bottom cover 4c.

[0018] As shown in FIG. 1, the surface cover portion 4b of the motor case 4 is provided with screw fixing holes 4d and 4e that are used to fix the brushless motor 10 to the gear case 13 shown in FIG. 7, which will be described later.

[0019] The brushless motor 10 of this embodiment is a three-phase motor, and as shown in FIG. 3, the cylindrical coil 3 has three phases: U-phase 3b, W-phase 3c, and V-phase 3d. In the coil 3, the wire rods 3a are arranged for each phase along the direction in which the rotating shaft 1 extends (hereinafter, this direction will also be referred to as the extension direction L of the rotating shaft 1) as shown in FIG. 2, while being offset in the rotation direction R of the rotating shaft 1. Specifically, the wire rods 3a are arranged in a dogleg shape from one end 3i along the extension direction L of the rotating shaft 1, are arranged in the rotation direction R at the other end 3j, are then turned around, and are again bent in a dogleg shape toward the one end 3i and are arranged in the extension direction L of the rotating shaft 1. In this way, the wire rods 3a corresponding to the three phases are arranged offset in the rotation direction R for each phase.

[0020] As a result, the collection of wire rods 3a for U phase 3b, the collection of wire rods 3a for W phase 3c, and the collection of wire rods 3a for V phase 3d are arranged with a shift in the rotational direction R, and as a result, the collection of wire rods 3a for U phase 3b, the collection of wire rods 3a for W phase 3c, and the collection of wire rods 3a for V phase 3d are arranged with a shift in the rotational direction R over 360°. In other words, if a collection of wire rods 3a corresponding to the three phases of U phase 3b, W phase 3c, and V phase 3d is defined as one wire group 3g, multiple wire groups 3g are arranged with a shift in the rotational direction R over 360°. In the case of the coil 3 shown in FIG. 3, four wire groups 3g of wire rods 3a corresponding to the three phases of U phase 3b, W phase 3c, and V phase 3d are arranged with a shift in the rotational direction R over 360°.

[0021] The wires 3a corresponding to each phase have a winding start end 3e and a winding end 3f. Specifically, the wires 3a for the U phase 3b have a winding start end 3e and a winding end 3f for the U phase 3b, the wires 3a for the W phase 3c have a winding start end 3e and a winding end 3f for the W phase 3c, and the wires 3a for the V phase 3d have a winding start end 3e and a winding end 3f for the V phase 3d. The winding start end 3e for each phase is located near the boundary 3h between the adjacent phases in the rotational direction R in each group of wires 3a. The winding end 3f for each phase is located at the end of one wire group 3g, with three wires gathered together.

[0022] Here, in the coil 3 of this embodiment, the wire rods 3a of the three phases are different in color from the wire rods 3a of the phases arranged adjacent to each other in the rotation direction R. That is, the wire rods 3a of the three phases are different in color from the wire rods 3a of the phases arranged adjacent to each other in the rotation direction R. Specifically, in each wire rod group 3g, of the three phases arranged offset in the rotation direction R, the color of the wire rods 3a of the phase arranged at the center is different from the color of the wire rods 3a of the phases arranged at both ends. In more detail, in each wire rod group 3g, of the U phase 3b, W phase 3c, and V phase 3d arranged offset in the rotation direction R, the color of the wire rods 3a of the W phase 3c arranged at the center is different from the colors of the wire rods 3a of the U phase 3b and V phase 3d arranged at both ends.

[0023] As a result, color boundaries 3h are formed on the coil 3 between the wire rods 3a of phases that are arranged adjacent to each other in the rotation direction R. In other words, at the ends 3i and 3j of the coil 3, color boundaries 3h are formed on the wire rods 3a of phases that are arranged adjacent to each other in the rotation direction R for each wire rod group 3g. In the case of the coil 3 shown in FIG. 3, 12 boundaries 3h are formed on the circumference of each of the ends 3i and 3j of the coil 3. <Brushless motor characteristics>

[0024] In the brushless motor 10, the magnet 2 is the rotor, and three Hall ICs (sensors) 11a, as shown in FIG. 5, are provided to detect the position of this rotor. The Hall ICs 11a are sensors that use magnetic detection elements. For example, in the case of a three-phase brushless motor 10, the Hall ICs 11a are positioned at intervals of 120° relative to the rotation direction R of the rotating shaft 1. However, if the Hall ICs 11a are misaligned, the efficiency of the motor may drop significantly or the motor may not rotate normally.

[0025] Therefore, the Hall ICs (sensors) 11a must be placed in the locations specified by the design. By placing them in the locations specified by the design, each of the three Hall ICs 11a detects the north or south pole of the magnet 2, and based on this detection result, the motor driver circuit determines which phase of the wire 3a of the coil 3 to pass current to. Then, based on a signal from the driver circuit, current is passed to the wire 3a of each phase in order, causing the motor to rotate normally. In other words, the placement of the Hall ICs 11a is extremely important for the brushless motor 10.

[0026] In the brushless motor 10 of this embodiment, three Hall ICs 11a are mounted on a flexible substrate 11 as shown in Fig. 5. The flexible substrate 11 is positioned relative to the motor case 4 by fitting its recess 11b into the protrusion 4j on the bottom cover 4c of the motor case 4 of the brushless motor 10. In other words, the position of the cylindrical motor case 4 in the rotation direction R is determined.

[0027] In brushless motor 10, four arc-shaped magnets 2 are arranged in a ring shape at equal intervals around rotating shaft 1 as part of the rotor. Furthermore, a cylindrical coil 3 is arranged as part of the stator outside the four arc-shaped magnets 2 arranged in a ring shape. As shown in Fig. 3, four wire groups 3g of wires 3a corresponding to three phases, U phase 3b, W phase 3c, and V phase 3d, are arranged in cylindrical coil 3, shifted by 360° in the rotation direction R.

[0028] Therefore, in order to maintain the efficiency and normal rotation of the brushless motor 10, the arrangement of the rotation direction R of the cylindrical coil 3 relative to the cylindrical motor case 4, including the positional relationship with the three Hall ICs 11a, is an important factor. <Brushless motor manufacturing method>

[0029] In assembling the brushless motor 10 of this embodiment, when the coil 3 is attached to the motor case 4, the coil 3 and the motor case 4 are aligned in the rotation direction R so that the position of the cylindrical coil 3 in the rotation direction R can be determined, and the coil 3 is fixed to the motor case 4.

[0030] In the brushless motor 10, the coil 3 is cylindrical, and the motor case 4 is also cylindrical. As shown in Fig. 4, the cylindrical coil 3 is housed inside the cylindrical motor case 4, and the coil 3 is fixed with an adhesive.

[0031] Furthermore, when attaching the flexible substrate 11 to the gear case 13 shown in FIG. 7 (described later), the position of the connector 12 is already determined, and therefore the position of the flexible substrate 11 is also already determined. Furthermore, the flexible substrate 11 and the motor case 4 are positioned by the recessed portion 11b of the flexible substrate 11 and the protruding portion 4j of the bottom cover portion 4c of the motor case 4. In other words, the position of the cylindrical motor case 4 in the direction of rotation R is determined. Therefore, the three Hall ICs 11a mounted on the flexible substrate 11 and the cylindrical motor case 4 are necessarily positioned. Therefore, when attaching the cylindrical coil 3 to the cylindrical motor case 4, it is necessary to precisely position the coil 3 in the direction of rotation R relative to the motor case 4.

[0032] 4, the color boundary 3h of the wire 3a of each phase at the end 3i of the coil 3 is aligned with a predetermined mark on the motor case 4, and the coil 3 is fixed to the motor case 4 with an adhesive. Note that in this embodiment, a case will be described in which screw fixing holes 4d, 4e formed in the motor case 4 are used as an example of the predetermined mark on the motor case 4.

[0033] That is, by aligning the color boundary 3h of the wire 3a of each phase at the end 3i of the coil 3 with the screw holes 4d and 4e formed in the motor case 4, the position of the cylindrical coil 3 relative to the cylindrical motor case 4 in the rotational direction R can be determined. In this way, the color boundary 3h of the wire 3a of each phase in the coil 3 is aligned with the holes 4d and 4e of the motor case 4 in the rotational direction R, and the coil 3 is fixed to the motor case 4. At this time, the motor case 4 and the flexible printed circuit board 11 are positioned by the recess 11b of the flexible printed circuit board 11 and the protrusion 4j of the bottom cover 4c of the motor case 4. Therefore, the positional relationship between the screw holes 4d and 4e of the motor case 4 and the three Hall ICs 11a on the flexible printed circuit board 11 is also necessarily determined.

[0034] In this embodiment, as shown in Figure 3, the wire 3a of the coil 3 is color-coded so that the phase position at the winding end 3f, which is the end of the winding of the wire 3a, can be immediately identified. Therefore, for example, the position of the coil 3 in the rotation direction R is determined so that three Hall ICs 11a are placed at the color boundary 3h of the wire 3a of the coil 3. Then, the coil 3 is fixed to the motor case 4 at this position in the rotation direction R.

[0035] This makes it possible to prevent misalignment between the coil 3 and the Hall IC 11a during assembly of the brushless motor 10. In other words, when the coil 3 is attached to the motor case 4, the color boundary 3h of the wire 3a of the coil 3 can be easily identified, making it possible to easily determine the position of the coil 3 in the direction of rotation R and to prevent misalignment of the coil 3 in the direction of rotation R during assembly of the brushless motor, thereby enabling the Hall IC 11a and the coil 3 to be positioned with high precision. <How to assemble a brushless motor>

[0036] Here, we will explain how to assemble the brushless motor 10 into the gear case 13 (see FIG. 7). A flexible substrate 11 on which three Hall ICs 11a as shown in FIG. 5 are mounted is attached to the gear case 13 via a connector 12. The three Hall ICs 11a are sensors that detect the magnetic flux (north pole or south pole) emanating from the magnet 2 to detect the position of the magnet 2. As shown in FIG. 7, the connector 12 is attached to a circuit board 14 provided on the back side of the gear case 13, on the back side of the gear case 13. A driver circuit for driving the brushless motor and the like are formed on the circuit board 14.

[0037] Then, the position of the coil 3 in the rotation direction R is aligned with the positions of the three Hall ICs 11a, and the motor case 4 of the brushless motor 10 is fixed to the gear case 13 using a position adjustment unit that the gear case 13 has.

[0038] For example, the position adjustment portion is two elongated holes 13b formed in the gear case 13 as shown in Fig. 8. The two elongated holes 13b are formed on the periphery of a circle whose center is the rotation center 1a of the rotating shaft 1 in the cover portion 13a on the front side of the gear case 13.

[0039] On the other hand, as shown in FIG. 6, the surface cover portion 4b of the motor case 4 of the brushless motor 10 has two screw fixing holes 4d and 4e on the circumference of a circle centered on the rotation center 1a of the rotating shaft 1.

[0040] As a result, as shown in FIG. 8 , the two holes 4d and 4e of the motor case 4 can be aligned with the two elongated holes 13b of the gear case 13. Specifically, one of the elongated holes 13b is aligned with the hole 4d, and then the other elongated hole 13b is aligned with the hole 4e. At this time, because the hole in the gear case 13 is the elongated hole 13b, the holes 4d and 4e of the motor case 4 can be easily aligned with the elongated hole 13b of the gear case 13. In other words, any misalignment in the rotational direction R of the motor case 4 that occurs when the motor case 4 is attached to the gear case 13 can be absorbed by the elongated hole 13b of the gear case 13. As a result, the motor case 4 and the gear case 13 can be easily aligned. This makes it easy to fasten the gear case 13 and the motor case 4 together with screws.

[0041] Furthermore, for example, the position adjustment portion may be six holes (first holes) 4d, 4e, 4f, 4g, 4h, and 4i formed in the motor case 4 as shown in Fig. 9. The six holes 4d, 4e, 4f, 4g, 4h, and 4i are formed in the front cover portion 4b of the motor case 4 around the rotating shaft 1, specifically, on the circumference of a circle centered on the rotation center 1a of the rotating shaft 1 as shown in Fig. 10.

[0042] On the other hand, as shown in Figure 12, the cover portion 13a on the front side of the gear case 13 has two long holes (second hole portions) 13b for screw fixing on the circumference of a circle centered on the rotation center 1a of the rotating shaft 1.

[0043] As a result, one of the six holes 4d, 4e, 4f, 4g, 4h, and 4i in the motor case 4 is aligned with the two elongated holes 13b in the gear case 13, and the motor case 4 is fixed to the gear case 13. In other words, the motor case 4 and the gear case 13 are fixed together with screws.

[0044] Specifically, six holes 4d, 4e, 4f, 4g, 4h, and 4i are formed in the motor case 4 on the circumference of a circle centered on the rotation center 1a of the rotating shaft 1, and two elongated holes 13b are also formed in the gear case 13 on the circumference of a circle centered on the rotation center 1a of the rotating shaft 1. This makes it easy to align the position of any one of the six holes 4d, 4e, 4f, 4g, 4h, and 4i in the motor case 4 with the two elongated holes 13b in the gear case 13. Specifically, one elongated hole 13b of the gear case 13 is aligned with the position of hole 4f of the six holes 4d, 4e, 4f, 4g, 4h, and 4i of the motor case 4, and the other elongated hole 13b of the gear case 13 is aligned with the position of hole 4g ​​of the six holes 4d, 4e, 4f, 4g, 4h, and 4i of the motor case 4. At this time, because the six holes 4d, 4e, 4f, 4g, 4h, and 4i are formed in the motor case 4, it is easy to align the position of any one of the six holes 4d, 4e, 4f, 4g, 4h, and 4i of the motor case 4 with the position of the elongated hole 13b of the gear case 13. In other words, the six holes 4d, 4e, 4f, 4g, 4h, and 4i provided in the motor case 4 can absorb any misalignment in the rotational direction R of the motor case 4 when attaching the motor case 4 to the gear case 13.

[0045] 10 shows the case where there is no misalignment in the fixing of the motor case 4, as shown in part P. In other words, the figure shows the installation state of the brushless motor 10 when there is no misalignment in the alignment between any of the six holes 4d, 4e, 4f, 4g, 4h, and 4i of the motor case 4 and the long hole 13b of the gear case 13.

[0046] 11 shows a case where the arrangement of the motor case 4 in the rotation direction R is misaligned within the allowable range, as shown in part Q. Even in this case, since the motor case 4 has six holes 4d, 4e, 4f, 4g, 4h, and 4i, it is easy to align any of these holes with the elongated hole 13b of the gear case 13. As a result, even if the arrangement of the motor case 4 in the rotation direction R relative to the gear case 13 is slightly misaligned, as shown in part Q, the gear case 13 and the motor case 4 can be easily fixed together with screws. In other words, the brushless motor 10 can be easily attached to the gear case 13. <Operation of the embodiment>

[0047] In the brushless motor 10, a color boundary 3h is formed between the wires 3a of the coil 3 of phases that are adjacent to each other in the direction of rotation R, and the coil 3 is fixed to the motor case 4 by aligning the color boundary 3h of the wires 3a with holes (markers) 4d and 4e provided in the motor case 4. This allows the wires 3a of each phase of the coil 3 to be different colors, making it easy to identify the phases. In particular, the color of the wires 3a of the central phase (W-phase 3c) of the three phases in one wire group 3g is different from the color of the wires 3a of the phases located at both ends. This makes it easy to identify the position of the W-phase 3c of the coil 3 relative to the holes (markers) 4d and 4e in the motor case 4, and therefore makes it easy to determine the position of the coil 3 in the direction of rotation R relative to the motor case 4.

[0048] This also makes it easy to align the coil 3 with the Hall IC 11a in the rotational direction R. As a result, workability can be improved in manufacturing the brushless motor 10. Furthermore, because the position of the coil 3 in the rotational direction R relative to the motor case 4 can be easily determined, the assembly position of the coil 3 in the rotational direction R can be stabilized. This makes it easy to align the motor case 4 with the flexible printed circuit board 11, reducing variations in assembly between the brushless motor 10 and the flexible printed circuit board 11.

[0049] In other words, when mounting the coil 3 in the motor case 4, the position of the rotational direction R of the coil 3 can be determined in advance relative to the positions of the holes 4d, 4e of the motor case 4, thereby reducing the need to adjust the position of the rotational direction R when mounting the coil 3 in the motor case 4. In other words, by determining the position of the rotational direction R of the coil 3 when mounting the coil 3 in the motor case 4 in advance, the adjustment of the position of the rotational direction R when mounting the coil can be kept to a minimum. This improves workability when manufacturing the brushless motor 10.

[0050] Furthermore, among the three phases in one wire group 3g, the color of the wire 3a of the phase located in the center is different from the colors of the wire 3a of the phases located at both ends, making it possible to immediately identify which wire 3a of the W phase 3c at the winding end 3f of the coil 3. This makes it easy to identify the wire 3a to be reversed, eliminates mistakes when connecting the common wire, and reduces the man-hours required to identify the wire 3a that connects the common wire.

[0051] Furthermore, when assembling brushless motor 10 to gear case 13, by using elongated holes 13b as the screw fastening holes in gear case 13, even if the assembly position relative to the rotation direction R of flexible substrate 11 varies, the positions of holes 4d and 4e in motor case 4 can be aligned with the position of elongated holes 13b in gear case 13. This makes it easy to fasten motor case 4 and gear case 13 with screws, improving the workability of assembling brushless motor 10.

[0052] Furthermore, when assembling brushless motor 10 to gear case 13, motor case 4 has a plurality of holes (e.g., holes 4d, 4e, 4f, 4g, 4h, and 4i) formed on the circumference of a circle centered on rotation center 1a of rotating shaft 1, and gear case 13 has two elongated holes 13b formed on the circumference of a circle centered on rotation center 1a of rotating shaft 1. This makes it easy to align any of the plurality of holes in motor case 4 with elongated holes 13b in gear case 13. As a result, similarly to the above, motor case 4 and gear case can be easily fixed together with screws, improving the workability of assembling brushless motor 10.

[0053] Although the manufacturing and assembly methods for brushless motor 10 according to one embodiment have been described above, the present invention is not limited to the above embodiment. Other embodiments conceivable within the scope of the technical concept of the present invention are also included within the scope of the present invention.

[0054] In the above embodiment, when the brushless motor 10 is assembled to the gear case 13, six holes 4d, 4e, 4f, 4g, 4h, and 4i are provided in the motor case 4. However, the number of holes provided in the motor case 4 is not limited to six, and may be three or more, such as eight. Furthermore, the hole provided in the gear case 13 is not limited to the elongated hole 13b (position adjustment portion, second hole portion), and may be, for example, a hole having a shape such as a perfect circle. The present technology can be configured as follows.

[0055] (1) A method for manufacturing a motor having a rotating shaft, a magnet provided around the rotating shaft, a cylindrical coil arranged around the rotating shaft and formed by winding a wire, and a cylindrical motor case that houses the magnet and the coil, The coil has a plurality of phases, the wire rods are arranged so as to be shifted in a rotation direction of the rotation shaft for each phase, and have a different color from the wire rods of phases arranged adjacent to each other in the rotation direction, In the coil, a color boundary is formed between the wire rods of phases arranged adjacent to each other in the rotation direction, A method for manufacturing a motor, comprising: aligning the boundary with a mark provided on the motor case and fixing the coil to the motor case. (2) The mark is a hole formed in the motor case, The method for manufacturing a motor according to (1), wherein the boundary and the hole are aligned in the rotation direction and the coil is fixed to the motor case. (3) The motor has three phases; A method for manufacturing a motor as described in (1) or (2), wherein, when a set of wires corresponding to the three phases is considered as one wire group, the color of the wire of the phase arranged in the center of the three phases arranged with a shift in the rotation direction of the rotating shaft in the wire group is different from the color of the wire of the phases arranged at both ends. (4) The method for manufacturing a motor according to (3), wherein in the wire group, wires of three phases arranged with a shift in the rotation direction of the rotating shaft are all different in color. (5) A motor assembly method for fixing a motor to a gear case, comprising: the motor includes a rotating shaft, a plurality of magnets provided around the rotating shaft and rotating together with the rotating shaft, a coil arranged around the rotating shaft and formed by winding a wire, and a cylindrical motor case accommodating the plurality of magnets and the coil, The coil has a plurality of phases, a substrate on which a plurality of sensors for detecting the positions of the plurality of magnets are mounted is attached to the gear case; A motor assembly method comprising aligning the rotational position of the coil so that it corresponds to the positions of the multiple sensors, and fixing the motor case to the gear case using a position adjustment unit possessed by the gear case or the motor case. (6) The position adjustment portion is a plurality of elongated holes formed in the gear case, the plurality of elongated holes are formed on the circumference of a circle whose center is the rotation center of the rotation shaft, The motor case is provided with a plurality of holes, the plurality of holes are provided on the circumference of a circle centered on the rotation center of the rotation shaft, The motor assembly method described in (5) above, wherein the motor case is fixed to the gear case by aligning the positions of the plurality of holes in the motor case with the positions of the plurality of long holes in the gear case. (7) The position adjustment portion is a plurality of first holes formed in the motor case, the plurality of first holes are formed on a circumference of a circle centered on the rotation center of the rotation shaft, The gear case is provided with a plurality of second holes, the plurality of second holes are provided on a circumference of a circle centered on the rotation center of the rotation shaft, A motor assembly method as described in (5), in which the motor case is fixed to the gear case by aligning the position of one of the plurality of first hole portions of the motor case with the position of the plurality of second hole portions of the gear case. [Explanation of symbols]

[0056] 1 Rotating shaft, 1a Rotation center, 2 Magnet, 3 Coil, 3a Wire, 3b U phase, 3c W phase, 3d V phase, 3e Winding start end, 3f Winding end end, 3g Wire group, 3h Boundary, 3i, 3j End, 4 Motor case, 4a Main body, 4b Surface cover, 4c Bottom cover, 4d, 4e Hole (mark, position adjustment part, first hole), 4f, 4g, 4h, 4i Hole (position adjustment part, first hole), 4j Convex part, 5, 6 Bearing, 7 Laminated steel, 10 Brushless motor, 11 Flexible circuit board, 11a Hall IC (sensor), 11b Concave part, 12 Connector, 13 Gear case, 13a Cover, 13b Long hole (position adjustment part, second hole), 14 Circuit board, L Extension direction, R Rotation direction, P: no misalignment, Q: misalignment

Claims

1. A method for manufacturing a motor having a rotating shaft, a magnet provided around the rotating shaft, a cylindrical coil arranged around the rotating shaft and formed by winding a wire, and a cylindrical motor case that houses the magnet and the coil, comprising: The coil has a plurality of phases, the wire rods are arranged so as to be shifted in a rotation direction of the rotation shaft for each phase, and have a different color from the wire rods of phases arranged adjacent to each other in the rotation direction, In the coil, a color boundary is formed between the wire rods of phases arranged adjacent to each other in the rotation direction, A method for manufacturing a motor, comprising: aligning the boundary with a mark provided on the motor case and fixing the coil to the motor case.

2. 2. The method for manufacturing a motor according to claim 1, the mark is a hole formed in the motor case, A method for manufacturing a motor, wherein the boundary and the hole are aligned in the rotational direction and the coil is fixed to the motor case.

3. 3. The motor manufacturing method according to claim 1, further comprising: The motor has three phases, When a set of wires corresponding to the three phases is regarded as one wire group, the wire of the phase arranged in the middle of the three phases arranged with a shift in the rotation direction of the rotation shaft in the wire group is a different color from the wire of the phases arranged at both ends.

4. A motor assembly method for fixing a motor to a gear case, comprising: the motor includes a rotating shaft, a plurality of magnets provided around the rotating shaft and rotating together with the rotating shaft, a coil arranged around the rotating shaft and formed by winding a wire, and a cylindrical motor case accommodating the plurality of magnets and the coil, The coil has a plurality of phases, a substrate on which a plurality of sensors for detecting the positions of the plurality of magnets are mounted is attached to the gear case; A motor assembly method comprising aligning the rotational position of the coil so that it corresponds to the positions of the multiple sensors, and fixing the motor case to the gear case using a position adjustment unit possessed by the gear case or the motor case.

5. 5. The motor assembly method according to claim 4, the position adjustment portion is a plurality of elongated holes formed in the gear case, the plurality of elongated holes are formed on the circumference of a circle whose center is the rotation center of the rotation shaft, The motor case is provided with a plurality of holes, the plurality of holes are provided on the circumference of a circle centered on the rotation center of the rotation shaft, a motor assembly method including aligning the positions of the plurality of holes of the motor case with the positions of the plurality of elongated holes of the gear case, and fixing the motor case to the gear case;

6. 5. The motor assembly method according to claim 4, the position adjustment portion is a plurality of first holes formed in the motor case, the plurality of first holes are formed on a circumference of a circle centered on the rotation center of the rotation shaft, The gear case is provided with a plurality of second holes, the plurality of second holes are provided on a circumference of a circle centered on the rotation center of the rotation shaft, A motor assembly method comprising aligning one of the plurality of first hole portions of the motor case with the plurality of second hole portions of the gear case and fixing the motor case to the gear case.

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