Electric work machine and method for manufacturing a motor mounted on the electric work machine

Abstract

In an electric working machine equipped with an outer rotor type motor, it is possible to ensure an insulation distance between a wiring arranged between a stator and a stator base and the stator base without increasing the size of the motor. [Solution] The electric work machine comprises a stator having a stator core, an insulator, and a coil portion, a rotor having a rotor core arranged on the outer periphery of the stator and a magnet fixed to the rotor core, and rotating around a rotation axis, a work portion driven by the rotor, a stator base supporting the stator from the inner diameter side, and an insulating member arranged between the stator base and the wire.

Description

[Technical Field]

[0001] The present disclosure relates to an electric working machine and a method for manufacturing a motor mounted in the electric working machine. [Background technology]

[0002] Patent Document 1 discloses an electric work machine equipped with an outer rotor motor as a power source. In an outer rotor motor, a stator is fixed to a stator base, and a rotor surrounds the outer periphery of the stator and rotates around a rotation axis that passes through the center of the stator.

[0003] The stator includes a stator core having a cylindrical yoke through which the rotor shaft can be inserted and a plurality of teeth protruding radially from the yoke. A wire that forms a coil is wound around the teeth of the stator core via an insulator. Leads extending from the coil are then drawn outward from between the stator and the stator base. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2023-5814 Summary of the Invention [Problem to be solved by the invention]

[0005] In the motor, when current is passed through the coils of each phase, which are divided into teeth of the stator core, the rotor rotates, enabling the motor to drive an electric work machine. In the motor, numerous wires, including wires that make up the coils and leads drawn from the coils, are arranged between the stator and the stator base.

[0006] If the wiring comes into contact with the stator base when the motor is running, the motor will short-circuit. Therefore, in the motor, the distance between the stator and the stator base is widened to ensure an insulation distance between the wiring and the stator base. However, widening the distance between the stator and the stator base increases the size of the motor in the direction of the rotation axis, making it difficult to miniaturize the electric power tool.

[0007] One aspect of the present disclosure aims to ensure an insulation distance between the stator and stator base and the wiring arranged between the stator and stator base in an electric work machine equipped with an outer rotor type motor, without increasing the size of the motor. [Means for solving the problem]

[0008] An electric working machine according to one aspect of the present disclosure includes a stator, a rotor, a working part, a stator base, and an insulating member. The stator includes a stator core having a cylindrical yoke and a plurality of teeth protruding radially outward from the yoke, an insulator fixed to the stator core, and a coil portion in which a portion of wire is wound around each of the plurality of teeth via the insulator.

[0009] The rotor has a rotor core disposed on the outer periphery of the stator and a magnet fixed to the rotor core, and rotates around the rotation axis. In other words, the stator and rotor function as the above-mentioned outer rotor type motor.

[0010] The working part is then driven by the rotor of the motor. The insulating member supports the stator from the inner diameter side, and is disposed between the stator base and the wire.

[0011] Therefore, with the electric power tool disclosed herein, even if the wiring arranged between the stator and the stator base approaches the stator base, for example, when the wire wound around the teeth of the stator core becomes loose, the insulating member can prevent the wiring from coming into contact with the stator base. Therefore, with the electric power tool disclosed herein, even if the distance between the stator and the stator base is shortened, the insulating member can ensure an insulation distance between the wiring and the stator base, allowing the electric power tool to be made smaller. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a perspective view illustrating the appearance of an electric operating machine according to a first embodiment. [Figure 2] FIG. 2 is a perspective view showing the motor and controller inside the electric working machine as viewed from above. [Figure 3] FIG. 3 is an exploded perspective view of the motor shown in FIG. 2. [Figure 4] FIG. 2 is a perspective view showing the motor as viewed from below. [Figure 5] FIG. 5 is an exploded perspective view of the motor shown in FIG. 4. [Figure 6] FIG. 2 is a cross-sectional view showing the motor cut along the rotation shaft. [Figure 7] FIG. 2 is a wiring diagram showing the connection state between a plurality of coils of the motor and a controller. [Figure 8] 8A is a side view of the insulating member of the motor of the second embodiment, FIG. 8B is a perspective view of the insulating member as seen obliquely from above, and FIG. 8C is a perspective view of the insulating member as seen obliquely from below. [Figure 9] FIG. 10 is a side view of a motor according to a second embodiment. [Figure 10] FIG. 10 is a perspective view illustrating the motor shown in FIG. 9 as viewed from above. [Figure 11] FIG. 10 is a perspective view illustrating the motor shown in FIG. 9 as viewed from below. DETAILED DESCRIPTION OF THE INVENTION

[0013] [Summary of the embodiment] An embodiment may provide an electric power tool including at least one of the following: Feature 1: Stator. Feature 2: The stator includes a stator core. Feature 3: The stator core has a cylindrical yoke. Feature 4: The stator core has a plurality of teeth that protrude radially outward from the yoke. Feature 5: The stator includes an insulator fixed to the stator core. Feature 6: The stator includes a coil portion. Feature 7: The coil portion has a wire wound around each of the plurality of teeth via an insulator. Feature 8: A rotor configured to rotate around a rotation axis. Feature 9: The rotor includes a rotor core disposed on the outer periphery of the stator. Feature 10: The rotor includes a magnet fixed to the rotor core. Feature 11: A working unit configured to be driven by a rotor. Feature 12: Stator base that supports the stator from the inner diameter side. Feature 13: An insulating member disposed between the stator base and the wire.

[0014] In an electric operating machine having at least the features 1 to 13, even if the wiring between the stator and the stator base approaches the stator base, for example, when the wire wound around the teeth of the stator core becomes loose, the insulating member can prevent the wiring from coming into contact with the stator base. Therefore, even if the distance between the stator and the stator base is shortened, the insulating member can prevent the wiring from coming into contact with the stator base. An insulation distance from the stator base can be ensured, which contributes to the miniaturization of the electric operating machine.

[0015] Some embodiments may include the following in addition to or instead of at least one of features 1-13. Feature 14: The insulating member is fixed to the stator base.

[0016] In the above configuration, the insulating member is more stably fixed to the stator base. Some embodiments may include the following in addition to or instead of at least one of features 1-14. Feature 15: The insulating member includes a guide portion that guides the wiring on the stator side in a predetermined drawing direction.

[0017] In the above configuration, the guide portion can guide the wire in a predetermined drawing direction, so that the wire can be more effectively prevented from vibrating and coming into contact with the stator base during work. Some embodiments may include the following in addition to or instead of at least one of features 1-15. Feature 16: The guide portion is configured to guide at least the lead portion extending from the coil portion in a predetermined drawing direction.

[0018] In the above configuration, the guide portion can prevent the lead portion from vibrating and coming into contact with the stator base during work. Some embodiments may include the following in addition to or instead of at least one of features 1-16. Feature 17: The lead portions extending from the coil portion are bundled for each stator phase. Feature 18: The lead portion extending from the coil portion has a fusing terminal at the tip of the lead portion.

[0019] In the above configuration, the lead portions are bundled for each phase of the stator, which can more effectively prevent the lead portions from coming into contact with the stator base. Also, the coil portions of each phase can be connected to the controller via fusing terminals.

[0020] Some embodiments may include the following in addition to or instead of at least one of features 1-18. ·Feature 19: The stator is three-phase. Feature 20: The coil section of each phase is delta-connected with a fusing terminal.

[0021] In the above configuration, the coils of each phase of the stator are delta-connected, eliminating the need for midpoint wiring as is required with Y-connection. This makes it easy to connect the stator coils to the controller.

[0022] Some embodiments may include the following in addition to or instead of at least one of features 1-20. Feature 21: The stator base has a cylindrical support portion that is inserted into the hollow portion of the yoke. Feature 22: The insulating member is formed in a disk shape having a hollow portion through which the support portion of the stator base can be inserted.

[0023] In the above configuration, the insulating member is inserted into the support portion of the stator base, and the support portion of the stator is inserted into the hollow portion of the yoke, so that the insulating member is inserted between the stator base and the stator. Therefore, the insulating member can be fixed easily and securely.

[0024] Some embodiments may include the following in addition to or instead of at least one of features 1-22. Feature 23: The guide portion is provided on the outer periphery of the disk-shaped insulating member in a protruding manner.

[0025] In the above configuration, the guide portion is protruded from the outer peripheral edge of the disk-shaped insulating member, so that the guide portion does not get in the way when the insulating member is sandwiched and fixed between the stator base and the stator.

[0026] Some embodiments may include the following in addition to or instead of at least one of features 1-23. Feature 24: The guide portion has a gap between the outer periphery of the insulating member and the guide portion, through which the wiring can be inserted.

[0027] In the above configuration, wiring such as lead portions extending from the coil portion can be inserted into the gap between the insulating member and the guide portion and pulled out, so that the guide portion allows the wiring to be pulled out in the desired pulling direction.

[0028] Some embodiments may include the following in addition to or instead of at least one of features 1-24. Feature 25: The wiring is inserted through the gap in the guide section from the stator side to the opposite side of the stator.

[0029] In the above configuration, the wiring is inserted into the gap between the insulating member and the guide portion from the stator side, which makes it easy to insert the wiring and improves work efficiency when assembling the insulating member and stator to the stator base.

[0030] Some embodiments may include the following in addition to or instead of at least one of features 1-25. Feature 26: The wiring is drawn out from the insulating member to the radially outer side of the stator.

[0031] In the above configuration, the wiring such as the lead portion extending from the coil portion is drawn out radially outward from the stator, so that the drawn wiring can be more effectively prevented from coming into contact with the stator base.

[0032] Some embodiments may include the following in addition to or instead of at least one of features 1-26. Feature 27: A magnetic sensor is attached to the stator base to detect the magnetic flux of the magnet and detect the rotational position of the rotor. Feature 28: The insulating member is configured to prevent at least the signal line from the magnetic sensor from contacting the rotor.

[0033] In the above configuration, the insulating member can prevent the signal line from the magnetic sensor from coming into contact with the rotor, thereby improving the reliability of control of the electric working machine using the magnetic sensor. Some embodiments may include the following in addition to or instead of at least one of features 1-28. Feature 29: The magnetic sensor is mounted on a circuit board that is attached to the stator base. Feature 30: The signal line is connected to the magnetic sensor via the circuit board.

[0034] In the above configuration, the magnetic sensor and the signal line are connected via the circuit board. This can better prevent the signal line from swinging near the sensor and coming into contact with the rotor. Some embodiments may include the following in addition to or instead of at least one of features 1-30. Feature 31: The insulating member has a protective portion. Feature 32: The protective portion faces the area extending from the rotor core to the outer peripheral edge of the rotor. Feature 33: The protective portion has a fixed length along the outer periphery of the rotor. Feature 34: The insulating member includes a holding portion that holds the plate surface of the protection portion at a predetermined height between the stator base and the rotor core.

[0035] In the above configuration, the protective portion of the insulating member can more effectively prevent the signal line from coming into contact with the rotor. An embodiment may provide a method including at least one of the following: The method is a method for manufacturing a motor to be mounted on an electric work machine. Feature 35: The motor has a stator having a coil portion. Feature 36: The motor has a rotor disposed on the outer periphery of the stator. Feature 37: The motor has a stator base that supports the stator from the inner diameter side. · Feature 38: Fix the stator to the stator base. Feature 39: An insulating member is disposed between the stator base and the coil portion.

[0036] According to the method including at least Features 35 to 39, an insulating member is disposed between the coil portion of the stator and the stator base. Therefore, in the motor, this insulating member can ensure an insulation distance between the wiring on the coil portion side and the stator base.

[0037] Examples of the above-mentioned power work machines include equipment configured to be used at work sites such as construction, manufacturing, gardening, and civil engineering, specifically, power tools for masonry, metalworking, and woodworking, power tools for gardening, and battery-powered wheelbarrows. Examples of the above-mentioned power tools include electric blowers, electric hammers, electric hammer drills, electric drills, electric screwdrivers, electric wrenches, electric grinders, electric circular saws, electric reciprocating saws, electric jigsaws, electric cutters, electric chainsaws, electric planers, electric nail guns (including tackers), electric hedge trimmers, electric lawn mowers, electric lawn clippers, electric grass cutters, electric cleaners, electric sprayers, electric spreaders, electric dust collectors, electric trowels, electric vibrators, electric rammers, electric compactors, electric pumps, electric pile drivers, electric concrete saws, electric screeds, and electric cut-off saws.

[0038] In some embodiments, the above features 1 to 39 may be combined in any manner. In some embodiments, any of the above features 1-39 may be omitted. Specific Exemplary Embodiments A specific exemplary embodiment will be described below. This specific exemplary embodiment provides an electric implement 1 in the form of an electric chainsaw. An electric chainsaw is a type of gardening tool. However, this electric implement 1 is merely an example, and the present disclosure may be applied to any form of electric implement.

[0039] [First embodiment] <Electric work equipment> As shown in Fig. 1, the electric work machine 1 includes a housing 2. The housing 2 is made of synthetic resin. The housing 2 accommodates a motor 6 therein. The housing 2 accommodates a controller 11 therein.

[0040] The electric working machine 1 is provided with a guide bar 9. The guide bar 9 is a plate-shaped member. The guide bar 9 protrudes from the housing 2 to the front of the electric working machine 1. The electric work machine 1 is provided with a saw chain 10. The saw chain 10 is made up of a plurality of chains connected to each other. The saw chain 10 is removably attached to the periphery of the guide bar 9. The saw chain 10 is connected to the rotor shaft 50 (see FIG. 2) of the motor 6 via a power transmission mechanism (not shown). The power transmission mechanism includes a sprocket (not shown) configured to have the saw chain 10 attached thereto.

[0041] Therefore, when the motor 6 is driven, the saw chain 10 serving as a working part moves around the periphery of the guide bar 9. The electric work machine 1 can cut the workpiece with the moving saw chain 10.

[0042] The electric work machine 1 is equipped with a battery mounting portion 5. In this embodiment, the battery mounting portion 5 protrudes upward from the rear of the housing 2. A battery pack 12 is detachably mounted to the battery mounting portion 5. The battery pack 12 can be attached to the rear end face of the battery mounting portion 5. The battery pack 12 includes a secondary battery, for example, a rechargeable lithium-ion battery. When attached to the battery mounting portion 5, the battery pack 12 can supply power to the electric work machine 1. The motor 6 receives power from the battery pack 12 via the controller 11 and is driven by the power.

[0043] The electric working machine 1 is provided with a hand guard 4. The hand guard 4 protrudes upward from the front of the housing 2. The electric work machine 1 is provided with a side handle 3A and a top handle 3B behind the hand guard 4. One of the side handle 3A and the top handle 3B may be omitted. The side handle 3A and the top handle 3B are made of synthetic resin.

[0044] The side handle 3A is a pipe-shaped member that protrudes leftward from the left part of the housing 2. Therefore, the operator of the electric working machine 1 can grip the side handle 3A with his / her left hand from behind the electric working machine 1.

[0045] The top handle 3B protrudes upward from the top of the housing 2. The rear end of the top handle 3B is connected to the battery attachment section 5, which forms a space between the top handle 3B and the housing 2. Therefore, the operator can insert his or her fingers into this space to grip the top handle 3B.

[0046] The electric work machine 1 is provided with a trigger switch 7 below the top handle 3B. The trigger switch 7 is operated (for example, pulled) by the operator to drive the motor 6. When the trigger switch 7 is pulled upward by the operator, the motor 6 is driven. When the operation of the trigger switch 7 is released, the driving of the motor 6 is stopped.

[0047] The electric work machine 1 is provided with a trigger lock lever 8 above the top handle 3B. When the trigger lock lever 8 is pressed downward by the operator, operation of the trigger switch 7 is permitted.

[0048] <Motor> In this embodiment, the motor 6 is in the form of an outer rotor brushless motor. 2, 3, 4, 5, and 6, the motor 6 includes a rotor 20. The motor 6 includes a stator 30.

[0049] The rotor 20 is disposed on the outer periphery of the stator 30 and rotates around the stator 30 . The motor 6 includes a rotor shaft 50. The rotor shaft 50 is fixed to the rotor 20. The central axis of the rotor shaft 50 coincides with the rotation axis AX of the motor 6. Therefore, the rotor 20 and the rotor shaft 50 rotate about the axis of rotation AX.

[0050] The motor 6 includes a sensor board 60. The sensor board 60 includes three magnetic sensors 62 that detect the rotation of the rotor 20. The motor 6 includes a stator base 40. The stator base 40 supports the stator 30 and the sensor board 60.

[0051] The motor 6 includes an insulating member 70. The insulating member 70 is disposed between the stator base 40 and the stator 30. The rotor shaft 50 passes through the rotor 20, the stator 30, the insulating member 70, and the stator base 40 and protrudes to the outside. The rotor shaft 50 has an output shaft 51. The output shaft 51 corresponds to a part of the rotor shaft 50 that includes a first end that protrudes to the outside from the stator base 40. The output shaft 51 is connected to a power transmission mechanism. The rotor shaft 50 moves the saw chain 10, which serves as a working unit, via the power transmission mechanism.

[0052] <Rotor> The rotor 20 includes a rotor cup 21. The rotor cup 21 is made of metal. Specifically, the rotor cup 21 contains aluminum, which is a non-magnetic material, as its main component.

[0053] The rotor cup 21 includes a plate portion 21A. The plate portion 21A has an annular shape. The plate portion 21A includes an opening 21C in its center. The rotor shaft 50 is inserted into the opening 21C and fixed therein. The rotor shaft 50 may be fixed to the rotor cup 21 by any method. In this embodiment, the rotor shaft 50 is press-fitted into the opening 21C and thereby fixed to the opening 21C (and thus to the rotor cup 21).

[0054] The rotor cup 21 includes a yoke portion 21B. The yoke portion 21B has a cylindrical shape. The yoke portion 21B surrounds the rotor shaft 50. The rotor cup 21 includes a plurality of fins 21D between the plate portion 21A and the yoke portion 21B. The yoke portion 21B is connected to the outer periphery of the plate portion 21A via the plurality of fins 21D. The plurality of fins 21D are arranged at equal intervals along the outer periphery of the plate portion 21A. The plurality of fins 21D rotate together with the plate portion 21A (in other words, the rotor 20), thereby generating wind. The wind cools the motor 6.

[0055] The rotor 20 includes a rotor core 22. The rotor core 22 includes a plurality of steel plates laminated in a direction along the rotation axis AX (hereinafter referred to as the "axial direction"). The rotor core 22 has a substantially cylindrical shape. The rotor core 22 is supported on the inner peripheral surface of the yoke portion 21B of the rotor cup 21.

[0056] The rotor 20 includes a plurality of magnets 23. Each of the plurality of magnets 23 is a permanent magnet. Each of the plurality of magnets 23 has a plate-like shape. In this embodiment, each of the plurality of magnets 23 is in the form of a sintered magnet. The plurality of magnets 23 are arranged on the inner peripheral surface of the rotor core 22 at intervals from one another along the circumferential direction. The plurality of magnets 23 are fixed to the inner peripheral surface of the rotor core 22, for example, by an adhesive. In this embodiment, the plurality of magnets 23 includes, for example, 12 magnets 23. The plurality of magnets 23 are arranged on the inner peripheral surface of the rotor core 22 so that north poles and south poles appear alternately along the circumferential direction.

[0057] <Stator> The stator 30 includes a stator core 31. The stator core 31 includes a plurality of steel plates stacked in the axial direction. The stator core 31 includes a yoke 31A. The yoke 31A has a cylindrical shape. The yoke 31A is disposed around the rotor shaft 50 via a stator base 40. The central axis of the yoke 31A coincides with the rotation axis AX.

[0058] The stator core 31 includes a plurality of teeth 31B. The plurality of teeth 31B protrude radially outward from the outer peripheral surface of the yoke 31A. The plurality of teeth 31B are arranged at intervals along the circumferential direction. In this embodiment, the plurality of teeth 31B includes nine teeth 31B. A slot is formed between two adjacent teeth 31B.

[0059] The stator 30 includes an insulator 32. The insulator 32 is made of, for example, a synthetic resin. The insulator 32 covers at least a portion of the surface of the stator core 31.

[0060] The stator 30 includes a plurality of coil portions 33. Each of the plurality of coil portions 33 includes a wire. Specifically, the insulator 32 covers the coil mounting surface of each of the plurality of teeth 31B and the outer peripheral surface of the yoke 31A. The coil mounting surface is wound with the wire of a corresponding one of the plurality of coil portions 33. The outer peripheral surface of the yoke 31A is in contact with the wire of each of the plurality of coil portions 33. Therefore, the stator core 31 is insulated from the coil portions 33 by the insulator 32.

[0061] In this embodiment, the stator core 31 and the insulator 32 are integrally molded. The insulator 32 may be fixed to the stator core 31 by insert molding. Specifically, the stator core 31 and the insulator 32 may be formed as follows. First, the stator core 31 is placed in a mold. Next, heated and melted synthetic resin is injected into the mold. When the synthetic resin solidifies, the insulator 32 is integrated (i.e., fixed) to the stator core 31.

[0062] The stator 30 includes the above-described multiple coil portions 33. The multiple coil portions 33 are provided on the multiple teeth 31B, respectively. That is, in this embodiment, the multiple coil portions 33 include nine coil portions 33. The wire of the corresponding coil portion 33 is wound around each of the multiple teeth 31B. Therefore, multiple coil portions 33 are provided corresponding to the number of teeth 31B (nine in this embodiment). Note that, for each of the multiple teeth 31B, the coil mounting surface is covered with the insulator 32, but the tooth outer peripheral surface is not covered with the insulator 32. The tooth outer peripheral surface is the surface facing radially outward.

[0063] <Bearings> The motor 6 includes a plurality of bearings, which (i) have the rotor shaft 50 passing through them, and (ii) rotatably support the rotor shaft 50 (and thus the rotor 20).

[0064] In this embodiment, the plurality of bearings include a first bearing 54 and a second bearing 56. The first bearing 54 is fitted into a third support portion 41C of the stator base 40, which will be described later. The second bearing 56 is fitted into a first support portion 41A of the stator base 40, which will be described later.

[0065] In this embodiment, the first bearing 54 is in the form of a roller bearing (specifically a radial roller bearing, more specifically a needle roller bearing), and the second bearing 56 is in the form of a ball bearing (specifically a radial ball bearing).

[0066] <Stator base> The stator base 40 of this embodiment is made of aluminum and is integrally formed.

[0067] The stator base 40 includes a support portion 41. The support portion 41 (i) has a cylindrical shape and (i) has a plurality of steps along the rotation axis AX. Specifically, the support portion 41 includes a first support portion 41A, a second support portion 41B, and a third support portion 41C, all of which have a cylindrical shape. The first support portion 41A is connected to the second support portion 41B along the rotation axis AX. The second support portion 41B is connected to the third support portion 41C along the rotation axis AX. The outer diameter of the second support portion 41B is larger than the outer diameter of the third support portion 41C. The outer diameter of the first support portion 41A is larger than the outer diameter of the second support portion 41B.

[0068] The first support portion 41A has an inner diameter large enough to fit the second bearing 56. The second support portion 41B has an outer diameter large enough to fit into the hollow portion of the insulator 32 and larger than the inner diameter of the hollow portion of the stator core 31 (more specifically, the hollow portion of the yoke 31). The third support portion 41C has an inner diameter large enough to fit the first bearing 54 and an outer diameter large enough to be inserted into the hollow portion of the stator core 31.

[0069] 3 and 5 show a state in which the first and second bearings 54, 56 are inserted onto the rotor shaft 50. However, in reality, as will be described later, the first and second bearings 54, 56 are first fixed to the stator base 40. Thereafter, the rotor shaft 50 is inserted into the stator base 40 and is thereby supported by the first and second bearings 54, 56.

[0070] The first and second bearings 54, 56 may each be fixed to the stator base 40 in any manner. In this embodiment, the first bearing 54 is press-fitted into the third support portion 41C. In other words, the first bearing 54 is fixed to the third support portion 41C by a press-fitting method. The second bearing 56 is also press-fitted into the first support portion 41A in this embodiment. However, the first bearing 54 may be fixed to the third support portion 41C by a method other than the press-fitting method. The same applies to the second bearing 56.

[0071] The yoke 31A is fitted into the third support portion 41C, so that the stator base 40 supports the stator core 31 from its inner diameter side. The first bearing 54 is disposed so as to at least partially overlap with the stator core 31 and the rotor core 22 in the axial direction. The second bearing 56 does not overlap with the stator core 31 or the rotor core 22 in the axial direction.

[0072] When assembling the motor 6, the first bearing 54 and the second bearing 56 are fixed to the stator base 40. Thereafter, the rotor shaft 50 is inserted through the stator 30, the insulating member 70, and the stator base 40 in this order, and is thereby supported by the stator base 40 (more specifically, supported by the first and second bearings 54, 56). Therefore, the output shaft 51 of the motor 6 is supported by the first support portion 41A so as to be rotatable around the rotation axis AX.

[0073] The stator base 40 includes a fixed portion 42. The fixed portion 42 is integrally formed with the support portion 41. The fixed portion 42 includes a fixed portion main body 42A. The fixed portion main body 42A has a hollow disk shape. The fixed portion main body 42A is provided on the outer periphery of the first support portion 41A.

[0074] The fixing portion 42 includes a first fixing portion 42B, a second fixing portion 42C, and a third fixing portion 42D. One or two may be omitted.

[0075] The first fixed portion 42B, the second fixed portion 42C, and the third fixed portion 42D each protrude radially outward from the fixed portion main body 42A. The first fixed portion 42B, the second fixed portion 42C, and the third fixed portion 42D each have a screw hole SH at their tip portion. The tip portion corresponds to the end opposite the fixed portion main body 42A. A screw (not shown) is inserted into each screw hole SH. The motor 6 is fixed within the housing 2 by screws inserted into each of the three screw holes SH.

[0076] Substrate fixing portion 42E is provided between first fixing portion 42B and second fixing portion 42C. Substrate fixing portion 42E fixes sensor substrate 60. Substrate fixing portion 42E has a shape corresponding to the shape of sensor substrate 60, specifically, an arc shape centered on rotation axis AX.

[0077] 3 and 5, the substrate fixing portion 42E has a first hole 43 and a first pin 43A at a first end thereof. The first pin 43A is inserted into the first hole 43. Specifically, in this embodiment, the first pin 43A is press-fitted into the first hole 43.

[0078] The substrate fixing portion 42E has a second hole 44 and a second pin 44A at its second end. The second pin 44A is inserted into the second hole 44. Specifically, in this embodiment, the second pin 44A is press-fitted into the second hole 44.

[0079] The first pin 43A is inserted into a third hole 65 in the sensor substrate 60. The second pin 44A is inserted into a fourth hole 66 in the sensor substrate 60. FIG. 2 shows the first pin 43A inserted into the third hole 65. In this embodiment, the first pin 43A and the second pin 44A are loosely fitted into the third hole 65 and the fourth hole 66, respectively. The first pin 43A and the second pin 44A position the sensor substrate 60 at a specified position relative to the stator base 40 (and therefore relative to the stator 30).

[0080] <Sensor board> The sensor board 60 has the third hole 65 and fourth hole 66 described above. The sensor board 60 has three magnetic sensors 62 that detect the rotational position of the rotor 20. Each of the three magnetic sensors 62 detects a change in the magnetic field that accompanies the rotation of the rotor 20 and outputs a detection signal corresponding to the detected change. The sensor board 60 is supported on the stator base 40 so that each of the three magnetic sensors 62 mounted on the sensor board 60 faces a corresponding one of the multiple magnets 23 in the axial direction. The sensor board 60 is disposed radially outward of the multiple coil portions 33.

[0081] <Insulating materials> The insulating member 70 is made of synthetic resin. The insulating member 70 has a hollow disk shape. The inner hole of the insulating member 70 has an inner diameter that allows the second support portion 41B to be inserted therethrough. The outer diameter of the insulating member 70 corresponds to (i.e., is equal to or close to) the outer diameter of an imaginary circle that follows the outer periphery of the multiple coil portions 33. Therefore, when the stator 30 is viewed in the axial direction from the fixed portion 42 side of the stator base 40, most or all of the multiple coil portions 33 are hidden by the insulating member 70 and cannot be seen.

[0082] <Effects> By configuring the insulating member 70 in this manner, it is possible to ensure an insulating distance between the stator wire group and the stator base 40. The stator wire group includes wires for each of the plurality of coil portions 33 and lead wires drawn out from each of the plurality of coil portions 33.

[0083] That is, in this embodiment, the nine coil portions 33 are connected to each other in a delta configuration. Specifically, for example, two coil portions 33 adjacent to each other in the circumferential direction are connected to each other. More specifically, as shown in FIG. 7, the motor 6 includes first to ninth connection points P1 to P9. Each of the first to ninth connection points P1 to P9 corresponds to a connection point between two adjacent coil portions 33. The first, fourth, and seventh connection points P1, P4, and P7 correspond to the U phase. The second, fifth, and eighth connection points P2, P5, and P8 correspond to the V phase. The third, sixth, and ninth connection points P3, P6, and P9 correspond to the W phase.

[0084] The motor 6 includes a lead group L. In this embodiment, the lead group L includes first to ninth lead portions L1 to L9. Each of the first to ninth lead portions L1 to L9 is in the form of, for example, a flexible lead wire.

[0085] The first connection point P1 is connected to a first end of the first lead portion L1. The second connection point P2 is connected to a first end of the second lead portion L2. The third connection point P3 is connected to a first end of the third lead portion L3. The fourth connection point P4 is connected to a first end of the fourth lead portion L4. The fifth connection point P5 is connected to a first end of the fifth lead portion L5. The sixth connection point P6 is connected to a first end of the sixth lead portion L6. The seventh connection point P7 is connected to a first end of the seventh lead portion L7. The eighth connection point P8 is connected to a first end of the eighth lead portion L8. The ninth connection point P9 is connected to a first end of the ninth lead portion L9.

[0086] As shown in FIGS. 2 to 7, the motor 6 includes a first fusing terminal 35U, a second fusing terminal 35V, a third fusing terminal 35W, a first tube TBu, a second tube TBv, and a third tube TBw.

[0087] 7, the second end of the first lead portion L1, the second end of the fourth lead portion L4, and the second end of the seventh lead portion L7 are connected to the first fusing terminal 35U, which corresponds to the U phase.

[0088] The second end of the second lead portion L2, the second end of the fifth lead portion L5, and the second end of the eighth lead portion L8 are connected to a second fusing terminal 35V. The second fusing terminal 35V corresponds to the V phase.

[0089] The second end of the third lead portion L3, the second end of the sixth lead portion L6, and the second end of the ninth lead portion L9 are connected to a third fusing terminal 35W. The third fusing terminal 35W corresponds to the W phase.

[0090] The first, fourth, and seventh lead portions L1, L4, and L7 are bundled together and inserted into a first tube TBu corresponding to the U phase. The second, fifth and eighth lead portions L2, L5 and L8 are bundled together and inserted into a second tube TBv corresponding to the V phase.

[0091] The third, sixth, and ninth lead portions L3, L6, and L9 are bundled together and inserted into a third tube TBw corresponding to the W phase. 5, the stator wiring is concentratedly arranged (i) between the stator 30 and the stator base 40 and (ii) around the yoke 31A. The stator wiring includes the wires of the multiple coil portions 33 and / or the first to ninth lead portions L1 to L9.

[0092] Therefore, if the motor 6 does not have the insulating member 70, the axial distance between the stator side wiring and the stator base 40 is required to ensure the insulation distance between the stator side wiring and the stator base 40. It is necessary to widen the gap, but in this case, the motor 6 becomes longer in the axial direction, which leads to an increase in size of the motor 6.

[0093] In contrast, in this embodiment, the insulating member 70 can ensure an insulating distance between the stator side wiring and the stator base 40. Therefore, the distance between the stator 30 and the stator base 40 can be shortened, and the motor 6 can be made smaller.

[0094] [Second embodiment] The electric operating machine 1 of this embodiment has the same basic configuration as the electric operating machine of the first embodiment, and differs from the first embodiment in the configuration of the insulating member 70. Therefore, in this embodiment, the configuration and function of the insulating member 70 will be described in detail.

[0095] As shown in FIGS. 8A, 8B, and 8C, the insulating member 70 includes a main body portion 72, a guide portion 74, and an insulating protection portion 76. The main body 72 has a hollow disk shape, similar to the insulating member 70 of the first embodiment. The inner wall of the inner hole of the main body 72 protrudes from the plate surface of the main body 72 toward the fixed portion 42 of the stator base 40. The protruding portion 72A has an annular shape and is provided with a notch 72B in a part thereof. The protruding portion 72A is fitted into a groove (not shown) provided in the fixed portion main body 42A of the stator base 40. The notch 72B engages with a protrusion provided in this groove. Therefore, the rotational position of the insulating member 70 around the rotation axis AX of the motor 6 is fixed.

[0096] The guide portion 74 has an extension portion 74A that extends radially outward from the main body portion 72 of the insulating member 70. The extension portion 74A has a predetermined width along the outer circumferential edge of the main body portion 72 of the insulating member 70, and its tip portion is thicker than the plate thickness of the main body portion 72. The tip portion of the extension portion 74A is inclined from the stator 30 side toward the opposite side from the stator 30 so that the extension length from the main body portion 72 increases.

[0097] Both widthwise ends of the extending portion 74A protrude radially outward from the insulating member 70. A first protruding portion 74B, which is one of the protruding portions protruding from both ends of the extending portion 74A, has an engaging portion 74C at its tip that extends in the widthwise direction of the extending portion 74A. The engaging portion 74C forms a gap 74D between itself and the extending portion 74A.

[0098] The gap 74D has a width that allows at least one of the first to third tubes TB(u to w) through which the first to ninth lead portions L1 to L9 are inserted, respectively. The width of the extending portion 74A is such that the first to third tubes TB(u to w) through which the first to ninth lead portions L1 to L9 are inserted can be inserted in a line along the outer periphery of the main body portion 72 relative to the gap 74D.

[0099] As a result, the first to third tubes TB (u to w) through which the first to ninth lead portions L1 to L9 are inserted can be inserted into the gap 74D by widening the gap between the engaging portion 74C and the protruding portion of the extension portion 74A on the opposite side from the first protruding portion 74B.

[0100] 9, 10, and 11, the first to ninth lead portions L1 to L9 are inserted into the gap 74D from the stator 30 side to the opposite side of the stator 30 (i.e., the stator base 40 side). The inserted first to ninth lead portions L1 to L9 are drawn out from the guide portion 74 to the radially outer side of the stator 30 together with the first to third tubes TB (u to w).

[0101] In this way, according to the electric operating machine 1 of this embodiment, the first to ninth lead portions L1 to L9 of the motor 6 can be drawn out by utilizing the guide portion 74 provided on the insulating member 70. This more effectively prevents the first to ninth lead portions L1 to L9 from coming into contact with the stator base 40. Furthermore, the first to ninth lead portions L1 to L9 are positioned by the gap 74D of the guide portion 74, which also prevents loosening of the wiring on the stator 30 side, including the wire of the coil portion 33. Furthermore, in the guide portion 74, the wall surface on the side of the gap 74D of the extension portion 74A is inclined in the direction in which the first to ninth lead portions L1 to L9 are pulled out, making it easier to pull out the first to ninth lead portions L1 to L9.

[0102] The insulating protection portion 76 is intended to prevent the signal line LS, which connects the connection terminal 64 provided on the sensor board 60 to the controller 11, from coming into contact with the rotor 20. That is, the sensor board 60 is a circuit board having a wiring pattern that connects the three magnetic sensors 62 mounted on the sensor board 60 to the connection terminals 64. As shown in Figures 9 to 11, the connection terminals 64 are provided to protrude from one end side of the arc of the sensor board 60. As shown in Figure 7, a signal line LS is connected to this protruding connection terminal 64.

[0103] This signal line LS is drawn from the sensor board 60 to the controller 11 side and connected to the controller 11. Therefore, it is conceivable that the signal line LS may come close to the rotor 20 due to the orientation or vibration of the electric operating machine 1. For this reason, the insulating protection part 76 is configured to prevent the signal line LS from coming into contact with the rotor 20 due to the rotation of the rotor 20 when the signal line LS comes close to the rotor 20.

[0104] 8A, 8B, and 8C, the insulating protection portion 76 has an extension portion 76A that extends radially outward from the main body portion 72 of the insulating member 70. The extension portion 76A extends to a position facing the rotor core 22 in the direction of the rotation axis AX of the motor 6. The extension portion 76A has a predetermined width along the outer circumferential edge of the main body portion 72 of the insulating member 70. The extension portion 76A is adjacent to the extension portion 74A of the guide portion 74.

[0105] A bent portion 76B bent toward the rotor 20 is provided at the tip of the extending portion 76A in the extending direction. This bent portion 76B is higher than the connection terminal 64 of the sensor board 60 in the direction of the rotation axis AX of the motor 6. Therefore, the bent portion 76B is disposed closer to the rotor 20 than the connection terminal 64 of the sensor board 60.

[0106] The tip of the bent portion 76B in the height direction is bent radially outward from the rotor 20 to form a protective portion 76C that prevents the signal line LS from contacting the rotor 20. The length of this protective portion 76C is set so that the tip of the bent portion of the protective portion 76C coincides with the outer peripheral surface of the rotor cup 21 in the direction of the rotation axis AX of the motor 6.

[0107] Therefore, protective portion 76C is a plate-like member that faces the region extending from rotor core 66 of rotor 20 to the outer peripheral edge, and has a certain length along the outer periphery of rotor 20. In addition, bent portion 76B functions as a retaining portion that retains the plate surface of protective portion 76 at a predetermined height position between stator base 40 and rotor core 22.

[0108] Therefore, even if the signal line LS connected to the connection terminal 64 of the sensor board 60 approaches the rotor 20 due to the orientation or vibration of the electric operating machine 1, the bent portion 76B and the protective portion 76C of the insulating protective portion 76 prevent the signal line LS drawn out from the sensor board 60 from coming into contact with the rotor 20 and becoming entangled in the rotor 20.

[0109] [Other embodiments] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments and can be implemented in various modifications.

[0110] For example, the insulating member 70 may be made of an insulating material such as an insulating synthetic resin, or may be made of, for example, a metal main body portion with an insulating paint applied around the main body portion.

[0111] In the second embodiment, the insulating member 70 has been described as being configured by integrally providing the guide portion 74 and the insulating protection portion 76 with the hollow disk-shaped main body portion 72. However, the insulating member 70 does not necessarily have to be hollow disk-shaped, as long as it can be fixed to the stator base 40. The insulating member 70 may have only the function as the guide portion 74, or may have only the function as the insulating protection portion 76.

[0112] In the above embodiments, multiple functions of one component may be realized by multiple components, or one function of one component may be realized by multiple components. Furthermore, multiple functions of multiple components may be realized by one component, or one function realized by multiple components may be realized by one component. Furthermore, part of the configuration of the above embodiments may be omitted. Furthermore, at least part of the configuration of the above embodiments may be added to or substituted for the configuration of another of the above embodiments. [Explanation of symbols]

[0113] 1...electric work machine, 6...motor, 10...saw chain, 20...rotor, 22...rotor core, 23...magnet, 30...stator, 31...stator core, 31A...yoke, 31B...teeth, 32...insulator, 33...coil portion, 70...insulating member

Claims

1. a stator including a stator core having a cylindrical yoke and a plurality of teeth protruding radially outward from the yoke, an insulator fixed to the stator core, and a coil portion in which a portion of a wire is wound around each of the plurality of teeth via the insulator; a rotor having a rotor core disposed on an outer periphery of the stator and a magnet fixed to the rotor core, the rotor rotating about a rotation axis; a working unit driven by the rotor; a stator base that supports the stator from an inner diameter side; an insulating member disposed between the stator base and the wire; An electric work machine equipped with:

2. The electric operating machine according to claim 1, The insulating member is fixed to the stator base.

3. The electric operating machine according to claim 1 or 2, The insulating member has a guide portion that guides the wiring on the stator side in a predetermined drawing direction.

4. The electric operating machine according to claim 3, The guide portion is configured to guide at least a lead portion extending from the coil portion as the wiring in the drawing direction.

5. The electric operating machine according to claim 4, The lead portions extending from the coil portion are bundled for each phase of the stator and have fusing terminals at their tips.

6. The electric operating machine according to claim 5, The stator is a three-phase stator, and the coil portions of the respective phases are delta-connected at the fusing terminals.

7. An electric operating machine according to any one of claims 1 to 6, the stator base includes a cylindrical support portion that is inserted into a hollow portion of the yoke, The insulating member is configured in a disk shape having a hollow portion through which the support portion of the stator base can be inserted.

8. The electric operating machine according to any one of claims 3 to 6, the stator base includes a cylindrical support portion that is inserted into a hollow portion of the yoke, the insulating member is formed in a disk shape having a hollow portion through which the support portion of the stator base can be inserted, The guide portion is provided to protrude from the outer periphery of the disk-shaped insulating member.

9. The electric operating machine according to claim 8, The guide portion has a gap between itself and the outer peripheral edge of the insulating member, through which the wiring can be inserted.

10. The electric operating machine according to claim 9, The wiring is inserted through the gap of the guide portion from the stator side to the opposite side from the stator.

11. The electric operating machine according to any one of claims 3 to 10, The wiring is drawn out from the insulating member to the radially outer side of the stator.

12. An electric operating machine according to any one of claims 1 to 11, a magnetic sensor attached to the stator base for detecting the magnetic flux of the magnet to detect the rotational position of the rotor; The insulating member is configured to prevent at least a signal line from the magnetic sensor from contacting the rotor.

13. The electric operating machine according to claim 12, the magnetic sensor is mounted on a circuit board attached to the stator base, The signal line is connected to the magnetic sensor via the circuit board.

14. The electric operating machine according to claim 12 or 13, The insulating member is a protective portion facing a region of the rotor extending from the rotor core to an outer peripheral edge thereof and having a certain length along the outer periphery of the rotor; and a holding portion that holds the plate surface of the protection portion at a predetermined height position between the stator base and the rotor core.

15. A method for manufacturing a motor to be mounted on an electric work machine, the motor includes a stator having a coil portion, a rotor disposed on an outer circumferential side of the stator, and a stator base supporting the stator from an inner diameter side; Fixing the stator to the stator base; an insulating member disposed between the stator base and the coil portion; A method for providing

Images