Motor and method for manufacturing the same

Abstract

The present invention provides a motor and a method for manufacturing the same that can firmly fix the insulator and appropriately suppress vibrations during operation. [Solution] The motor 1 comprises a cylindrical insulator 11 having insulating properties with a plurality of winding sections 11d arranged in the circumferential direction, a cylindrical stator 3 having a plurality of winding coils 12 provided on each winding section 11d of the insulator 11, a rotor 2 rotatably arranged inside the stator 3, and an annular busbar unit 7 that supplies power to the plurality of winding coils 12. The busbar unit 7 is fixed to one end of the insulator 11.

Description

Technical Field

[0001] The present invention relates to a motor such as a so-called brushless motor and a method for manufacturing the same.

Background Art

[0002] In recent years, efforts have been made on an international scale to promote the Sustainable Development Goals (SDGs, the 2030 Agenda for Sustainable Development, adopted at the United Nations Summit on September 25, 2015, hereinafter referred to as "SDGs"). Specifically, the goals of the SDGs include "Goal 9: Build the infrastructure for industry and innovation" and "Goal 12: Take responsibility for production and consumption", and technological development aimed at solving these goals is desired.

[0003] As a technology that can contribute to the solution of these goals, the technology described in Patent Document 1 is known. In this Patent Document 1, "a bus bar holder 232A that holds a bus bar 231A has an annular holder main body portion 60A, a first leg portion 61A and a second leg portion 62A that extend downward from the holder main body portion 60A. The first leg portion 61A has a claw portion 611A that protrudes laterally. The upper surface of the claw portion 611A and the lower surface of a receiving portion 521A provided on an insulator 52A face each other in the axial direction with a gap therebetween. Therefore, the upward movement of the bus bar holder 232A is restricted by the claw portion 611A and the receiving portion 521A of the insulator 52A. On the other hand, the lower end portion of the second leg portion 62A abuts on a tooth 512A or an insulator 52A." A motor is described.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the motor described in Patent Document 1, although the claw portion 611A that protrudes laterally from the first leg portion 61A of the busbar holder 232A engages with the receiving portion 521A of the insulator 52A to restrict the upward movement of the busbar holder 232A, there are only three first legs 61 formed around the circumferential direction of the busbar holder 232A and they are located outside the inner circumferential surface of the teeth 512A. As a result, the insulator cannot be firmly fixed, and there is a problem that vibrations that may occur when the motor is driven cannot be properly suppressed.

[0006] This invention was made to solve the above-mentioned problems, and aims to provide a motor and a method for manufacturing the same that can firmly fix the insulator and appropriately suppress vibrations during operation. [Means for solving the problem]

[0007] The present invention relates to a motor comprising: an insulating cylindrical insulator having a plurality of winding sections arranged circumferentially; a cylindrical stator having a plurality of winding coils provided in each winding section of the insulator; a rotor rotatably disposed inside the stator; and an annular busbar unit for supplying power to the plurality of winding coils, wherein the busbar unit is fixed to one end of the insulator. [Effects of the Invention]

[0008] According to the present invention, the insulator can be firmly fixed, and vibrations during operation can be appropriately suppressed. [Brief explanation of the drawing]

[0009] [Figure 1] This is a side view showing the motor of one embodiment of the present invention. [Figure 2] This diagram shows a cross-sectional view of the above motor, with a portion cut out in the axial direction. [Figure 3] This is a partial perspective view of the motor shown above. [Figure 4] This is a partial radial cross-sectional view of the motor shown above. [Figure 5] This is a partial axial cross-sectional view of the motor shown above. [Figure 6] This is a side view of the above motor with a portion cut out. [Figure 7] This is a perspective view showing the insulator for the motor mentioned above. [Figure 8] This is a perspective view showing the thermistor of the motor mentioned above. [Figure 9] The diagram above shows the leaf spring material of the motor, with (A) being an external perspective view and (B) being an internal perspective view. [Figure 10] This is a rear-view perspective showing the busbar unit of the motor mentioned above. [Figure 11] This is a front view showing the busbar unit described above. [Figure 12] This is a schematic diagram showing the above motor mounted on a side-mounted electric motorcycle. [Figure 13] This is a schematic diagram showing the above motor mounted on a center-mounted electric motorcycle. [Figure 14] This is a process diagram showing the manufacturing process of the above motor. [Modes for carrying out the invention]

[0010] (One embodiment) The following describes one embodiment of the present invention with reference to the drawings. Figure 1 is a side view showing a motor of one embodiment of the present invention. Figure 2 is a cross-sectional view showing a part of the motor cut out in the axial direction. Figure 3 is a partial perspective view of the motor. Figure 4 is a partial radial cross-sectional view of the motor. Figure 5 is a partial axial cross-sectional view of the motor. Figure 6 is a side view showing a part of the motor cut out. Figure 7 is a perspective view showing the insulator of the motor. Figure 8 is a perspective view showing the thermistor of the motor. Figure 9 shows the leaf spring material of the motor, where (A) is an external perspective view and (B) is an internal perspective view. Figure 10 is a rear perspective view showing the busbar unit of the motor. Figure 11 is a front perspective view showing the busbar unit. Figure 12 is a schematic diagram showing the motor mounted on a side-mounted electric motorcycle. Figure 13 is a schematic diagram showing the motor mounted on a center-mounted electric motorcycle. Figure 14 is a process diagram showing the motor manufacturing process.

[0011] <Overall Structure> The motor 1 according to this embodiment is a three-phase motor known as a brushless motor. This motor 1 is used, for example, as a drive motor for electric motorcycles that is driven frequently and requires high durability. For example, as shown in Figure 12, the motor 1 is used as a drive motor for a side-mounted electric motorcycle that drives alongside the drive wheel, or as shown in Figure 13, for a center-mounted electric motorcycle that drives between the front and rear wheels.

[0012] The motor 1 is an IPM motor (Interior Permanent Magnet Motor) in which magnets (permanent magnets) are embedded in a rotor (rotor) 2. Specifically, as shown in FIG. 2, the motor 1 includes a substantially cylindrical stator (stator) 3, and has an inner rotor type configuration in which the rotor 2 is concentrically and rotatably attached inside the stator 3. The rotor 2 is rotatably supported around a rotation axis 2a. In the following description, unless otherwise specified, the circumferential direction, the axial direction, and the radial direction are defined based on the axis of the rotation axis 2a.

[0013] At both axial ends of the stator 3, a front bracket 4 and a rear bracket 5 serving as lid bodies are attached, and a case body 6 serving as a housing is attached between the front bracket 4 and the rear bracket 5. The front bracket 4 is provided with an insertion hole 4a as an opening for inserting and protruding one end of the rotation axis 2a of the rotor 2. In the following description, the side where the front bracket 4 is located is defined as the front side, and the side where the rear bracket 5 is located is defined as the rear side.

[0014] The case body 6 is formed in a roughly cylindrical shape with openings on both the front and rear sides. As shown in Figures 1 and 2, the motor 1 has a three-part structure consisting of a front bracket 4, a rear bracket 5, and the case body 6. The motor 1 has a stator 3 mounted and fixed inside the case body 6, with one end of the rotating shaft 2a protruding from the insertion hole 4a of the front bracket 4, and the rotating shaft 2a is fixed between the front bracket 4 and the rear bracket 5, allowing the rotor 2 to rotate freely within the stator 3. An annular busbar unit 7 is attached concentrically to the rear end of the stator 3. A roughly rectangular flat plate-shaped rotation sensor board 8 is attached to the rear side of the busbar unit 7, to which a wire (not shown) connected to a rotation sensor that detects the rotation speed of the rotor 2 is connected. The rotation sensor board 8 is mounted at an eccentric position from the rotation center of the rotating shaft 2a. Also, as shown in Figures 5 and 6, an output connector 9A is attached to the outer circumference of the case body 6 for drawing out the wires connected to the connector 8a of the rotation sensor board 8. Furthermore, a terminal holder 9B is mounted on the outer periphery of the case body 6, adjacent to the output connector 9A. The terminal holder 9B is electrically connected to a predetermined busbar terminal 7k of the busbar unit 7 via terminal 9D.

[0015] The stator 3 includes a stator core 3a formed by laminating a plurality of electromagnetic steel sheets. The stator core 3a is press-fitted into the case body 6. A front bracket 4 is fixed to the front side of the case body 6 with bolts 10a, and a rear bracket 5 is fixed to the rear side of the case body 6 with bolts 10b. Note that the front bracket 4 and the rear bracket 5 are fixed to the case body 6 with separate bolts 10a and 10b. The stator core 3a includes a cylindrical stator core body 3b and a plurality of teeth 3c protruding radially inward from the inner peripheral side of the stator core body 3b. For example, 12 teeth 3c are provided and are equally spaced in the circumferential direction. An insulator 11 is attached to each tooth 3c, and a winding coil 12 is wound around each tooth 3c via the insulator 11. The stator 3 is divided into 12 parts in the circumferential direction, and a part of these 12 divided stators is configured as a stator member 31. Each stator member 31 is formed in the same shape having a part obtained by dividing the stator core body 3b into 12 parts and the teeth 3c. Further, on the circumferential end faces of the portions corresponding to the stator core body 3b of each stator member 31, concave and convex surfaces 31a that fit together are formed. The stator 3 has a configuration including the insulator 11 and a total of 12 winding coils 12.

[0016] The insulator 11 is composed of two parts made of an insulating synthetic resin, and is attached to the teeth 3c from both axial ends of the motor 1. Also, the insulator 11 is formed with an outer diameter smaller than the outer diameter dimension of the stator 3. Specifically, the insulator 11 includes, for example, 24 insulator bodies 11a having a rectangular inner circumference and an oval outer circumference so as to cover the outer peripheral surface of the teeth 3c. The insulator 11 has the axial directions of these 24 insulator bodies 11a oriented in the radial direction of the motor 1 and is in a state where these insulator bodies 11a are arranged at equal intervals in the circumferential direction. And the stator core body 3b is attached so as to protrude to the outer peripheral side of each insulator body 11 of the insulator 11.

[0017] An inner flange 11b is provided around the entire circumference of the periphery of each insulator body 11a on the side facing the stator core body 3b. An outer flange 11c is provided around the entire circumference of the periphery of the insulator body 11a on the side opposite the inner flange 11b, towards the tip of the teeth 3c. The insulator body 11a, inner flange 11b, and outer flange 11c form a winding section 11d for mounting the winding coil 12. Each winding section 11d is fitted with a winding coil 12, formed by winding a wire 12a multiple times from the inner circumference to the outer circumference. The winding coil 12 is attached to the winding section 11d by winding the wire 12a with the radial direction as the central axis. As shown in Figure 7, the winding sections 11d are arranged at equal intervals in the circumferential direction.

[0018] The winding 12a is a conductive rectangular cross-section flat wire, and its surface is covered with an insulating material. The winding 12a is wound with one side of it in contact with the winding section 11d, and then further wound by stacking it with the other side of the wound winding 12a in contact with the other side of the wound winding 12a. The winding 12a is wound so as to be adjacent to and in contact with the already wound winding 12a, while alternately changing its winding direction from the outer circumference to the inner circumference and then from the inner circumference to the outer circumference of the winding section 11d. Finally, the windings 12a are arranged radially adjacent to each other and wound in an aligned manner from the inner circumference to the outer circumference or from the outer circumference to the inner circumference of the winding section 11d, forming the winding coil 12.

[0019] Of the outer peripheral flange 11c of the insulator 11, the portions on both sides that contact the stator core body 3b of the stator core 3a are flat plate-shaped stator core receiving portions 11e. In addition, of the outer peripheral flange 11c, the axial ends that do not contact the stator core body 3b are flat plate-shaped outer wall portions 11f. The outer wall portions 11f are formed to be thicker than the stator core receiving portions 11e, and the outer surface of the outer wall portions 11f is formed to protrude outward from the outer surface of the stator core receiving portions 11e, creating a flange-like shape. As a result, a stepped portion 11g is formed between the outer wall portions 11e and the stator core receiving portions 11, and the stator core body 3b is fitted between the stepped portions 11g of the outer wall portions 11f located at both ends in the axial direction.

[0020] Each outer wall portion 11f of the insulator 11 has a width direction A perpendicular to the axial and radial directions, respectively, and is arranged in the circumferential direction to form a dodecagonal shape when viewed in the axial direction. A pair of winding fitting grooves 11h and 11j are provided at predetermined intervals on the rear or front end face of each outer wall portion 11f. These winding fitting grooves 11h and 11j open to the end face side of the outer wall portion 11f and are formed as concave grooves that penetrate the outer wall portion 11f in the thickness direction. One of the winding fitting grooves 11h is formed to be shallower in the axial direction than the other winding fitting groove 11j, in other words, it is formed to be a smaller cutout shape.

[0021] In one winding fitting groove 11h, the starting point 12c of the winding 12a, which is the base side of the winding 12a, is fitted and temporarily fixed when winding the winding 12a onto the winding winding section 11d. In the other winding fitting groove 11j, the ending point 12b that protrudes from the outer circumference of the winding 12a, which has been wound onto the winding winding section 11d to form the winding coil 12, is fitted and temporarily fixed. In other words, the winding coil 12 is configured such that the starting point 12c of the winding 12a is temporarily fixed in the winding fitting recess 11h, the winding 12a is gradually wound onto the winding winding section 11d from the inner layer side, and then the ending point 12b of the winding 12a is temporarily fixed in the winding fitting recess 11j and pulled out to the outer circumference side of the insulator 11.

[0022] Furthermore, as shown in Figure 7, the insulator 11 is configured to be divided into two parts in the axial direction, and the rear half of this divided portion is divided into 12 parts in the circumferential direction, with some of these 12 divided portions of the insulator 11 forming the rear insulator member 51. Each of these rear insulator members 51 is configured to have the same shape, comprising the insulator body 11a, the inner circumferential flange 11b, and the rear half of the outer circumferential flange 11c. Furthermore, the front half of the insulator 11, which is divided into two parts in the axial direction, is also divided into 12 parts in the circumferential direction, with some of these 12 divided portions of the insulator 11 forming the front insulator member 61. Each of these front insulator members 61 is also configured to have the same shape, comprising the insulator body 11, the inner circumferential flange 11b, and the front half of the outer circumferential flange 11c.

[0023] <Fixed configuration of insulator 11> An inner wall portion 11k is formed at the axial end of the inner circumferential flange 11b of each rear-side insulator member 51 that faces the sensor mounting portion 15. The inner wall portion 11k is formed to be thicker than the stator core receiving portion 11e, and is formed in a flange shape with the inner surface of the inner wall portion 11k protruding inward from the inner surface of the stator core receiving portion 11e. Inside the inner wall portion 11k, an insertion receiving portion 11m is provided that protrudes inward in the diameter direction. As shown in Figures 3, 4, and 7, the insertion receiving portion 11m is formed in a tray shape with a concave cross-section and an opening on the rear side. An insertion receiving portion 11m is provided on each rear-side insulator member 51, and a total of 12 are arranged at equal intervals in the circumferential direction of the insulator 11. Furthermore, when the rotor 2 is attached to the stator 3, each insertion receiving portion 11m is provided to protrude inward in the diameter direction to a position that covers a part of the rotor 2, in other words, the outer peripheral edge of the rotor 2.

[0024] Furthermore, at both ends of the inner wall portion 11k of each rear insulator member 51 in the width direction A, these ends are cut out to form fitting steps 11n. The fitting steps 11n are provided at the rear corners of the inner wall portion 11k, and when a total of 12 rear insulator members 51 are combined, the adjacent fitting steps 11n form a concave fitting groove portion 11p. In short, the fitting groove portions 11p are located between the insertion receiving portions 11m of the insulator 11, and a total of 12 are arranged at equal intervals in the circumferential direction on the rear side of the insulator 11.

[0025] A busbar unit 7 is fixed concentrically to the rear side of the insulator 11. The busbar unit 7 supplies power to each winding coil 12 and, as shown in Figures 4, 10, and 11, has a roughly annular busbar unit body 7a. On the inner circumference of the busbar unit body 7a, near the front side, there is an insertion fixing part 7b which serves as an insulator fixing part for insertion into the insertion receiving part 11m of the insulator 11. The busbar unit body 7a is formed with an axial thickness greater than that of the insertion fixing part 7b. The insertion fixing part 7b is formed as a rectangular prism shape that protrudes to the front side and is inserted into the insertion receiving part 11m from the rear side. A total of 12 insertion fixing parts 7b are arranged at equal intervals in the circumferential direction. Furthermore, each insertion fixing part 7b is provided so as to protrude inward in a position that covers a part of the rotor 2, that is, the outer edge of the rotor 2, when the rotor 2 is arranged on the outer circumference of the stator 3.

[0026] As shown in Figure 11, a total of 12 locking protrusions 7c are provided on the bottom surface located on the front side of the busbar unit body 7a. The locking protrusions 7c are configured to fit into the fitting grooves 11p of the insulator 11 when the busbar unit 7 is fixed concentrically to the rear side of the insulator 11. The busbar unit 7 is configured such that the bottom surface on the front side of the busbar unit 7 does not come into contact with the rear surface of the winding coil 12, thus creating a predetermined clearance. The locking protrusions 7c facilitate the circumferential alignment of the busbar unit 7 with respect to the insulator 11 and restrict the rotational movement of the busbar unit 7 with respect to the insulator 11, thereby positioning and fixing it.

[0027] Furthermore, the busbar unit 7 is positioned and fixed by fitting its locking projection 7c into the fitting groove 11p of the insulator 11, and with the insertion fixing portion 7b of the busbar unit 7 inserted into the insertion receiving portion 11m of the insulator 11, a predetermined gap C, which serves as the bonding point, is formed between the front bottom surface of the insertion fixing portion 7b of the busbar unit 7 and the bottom surface of the insertion receiving portion 11m of the insulator 11, as shown in Figure 4.

[0028] Furthermore, each insertion and fixing portion 7b of the busbar unit body 7a is provided with a leg portion 7e having a through hole 7d that penetrates into the insertion and fixing portion 7b. The leg portion 7e protrudes from the insertion and fixing portion 7b toward the inner circumference of the busbar unit body 7a. The through hole 7d penetrates from the rear side of the leg portion 7e to the front side of the insertion and fixing portion 7b and is formed in a conical shape, essentially a funnel shape, with a diameter that narrows in the insertion direction D for inserting the insertion receiving portion 11m of the insulator 11 into the insertion and fixing portion 7b. The through hole 7d has a length dimension that is the sum of the thickness dimension of the leg portion 7e and the thickness dimension of the insertion and fixing portion 7b, and is designed so that the internal volume of the through hole 7d is greater than the amount of adhesive 7f that is filled into the through hole 7d. As shown in Figure 4, the through-hole 7d functions as an adhesive filling port, where a fluid adhesive 7f is filled into the gap C between the insertion fixing part 7b and the insertion receiving part 11m from the rear side, and the side surface of the insertion fixing part 7b is immersed in the adhesive 7f, thereby bonding and fixing the insertion fixing part 7b and the insertion receiving part 11m together.

[0029] Furthermore, each leg portion 7e is connected circumferentially by a flat inner flange portion 7g, and each leg portion protrudes to the rear from these inner flange portions 7g. Each inner flange portion 7g forms a stepped portion 7h between itself and the inner surface of the busbar unit body 7a. On the outer circumference side of this stepped portion 7h, a concave stepped portion 7j is formed, which is shaped like a concave recess in the inner surface of the busbar unit body 7a.

[0030] The outer circumference of the busbar unit body 7a is provided with flange-shaped busbar terminals 7k, which serve as coil connection points for positioning and fixing the starting point 12c and ending point 12b of each winding coil 12. Each busbar terminal 7k protrudes radially outward, and a total of 12 are provided, corresponding to the number of winding coils 12, and are arranged at equal intervals in the circumferential direction. The outer edge of each busbar terminal 7k is provided with a pair of connection points 7m to which the starting point 12c or ending point 12b of the winding coil 12 is welded and electrically connected.

[0031] <Temperature detection configuration> A thermistor 13 for detecting the temperature of the winding coil 12 and a leaf spring 14 for biasing the thermistor 13 to the winding coil 12 are attached to the outer circumference of the insulator 11. These thermistor 13 and leaf spring 14 are attached to a thermistor housing 15 provided on the outside of the outer wall portion 11f located on the rear side of the insulator 11. In short, a thermistor housing 15 is provided on each of the rear insulator members 51. The thermistor housing 15 is located between a pair of winding fitting grooves 11h and 11j located on the outside of the outer wall portion 11f, and is positioned at the center in the width direction of the outer surface of the outer wall portion 11f. That is, the thermistor housing 15 is located between the starting point 12c and the ending point 12b of the winding coil 12.

[0032] Furthermore, the thermistor housing 15 is provided with a mounting recess 15a into which the thermistor 13 is fitted from the rear side. The mounting recess 15a is provided along the axial direction and is formed in a box shape that protrudes from the outer circumference of the insulator 11, in other words, from the outside of the outer wall portion 11f. The mounting recess 15a is also provided from the rear end of the outer wall portion 11f to a position along the outer circumference of the winding portion 11d. Furthermore, as shown in Figures 3 and 4, the bottom of the front side of the mounting recess 15a contacts the rear side surface of the stator core body 3b, which has the function of preventing the insulator 11 from tipping over.

[0033] A locking groove 15b is provided on the outer surface of the mounting recess 15a, penetrating the mounting recess 15a. The locking groove 15b is formed in a rectangular shape, with the rear opening edge forming a locking surface 15c perpendicular to the outer wall portion 11f. Furthermore, a recessed storage recess 15d with a concave cross-section is provided on the insulator body 11a side of the outer surface of the mounting recess 15a. The storage recess 15d is provided continuously with the locking groove 15b on the insulator body 11a side. The storage recess 15d extends from the opening edge located opposite the locking surface 15c of the storage recess 15d to the rear end in the height direction perpendicular to the width direction A.

[0034] Furthermore, the thermistor housing 15 has an opening 15e that allows the thermistor 13, mounted in the mounting recess 15a, to directly contact the winding coil 12. The opening 15e penetrates to the rear side and is formed to a width slightly smaller than the width dimension of the mounting recess 15a. The opening 15e is also shaped as a concave cutout from the rear end of the outer wall portion 11f to the outer circumferential surface of the winding portion 11d. The opening 15e is provided axially at the center of the width direction A. Therefore, the opening 15e is provided at the center of the width direction A of the winding coil 12 wound around the winding portion 11d, along the stacking direction B, which is the winding direction of the windings 12a of the winding coil 12. As a result, the thermistor 13 is mounted in the thermistor housing 15 so as to contact multiple windings 12a located in the inner layers of the winding coil 12, along the stacking direction B of the winding coil 12 from the opening 15e.

[0035] Furthermore, locking pieces 15f are provided on both sides of the opening 15e in the width direction A, with the inner piece of the mounting recess 15a protruding. The locking pieces 15f are located near both sides of the thermistor 13 mounted in the mounting recess 15a, and restrict the movement of the thermistor 13 in the width direction A.

[0036] As shown in Figure 8, the thermistor 13 comprises a thermistor body 13a with a rectangular cross-section. The thermistor 13 has a configuration in which a pair of conductors 13b are led out from one end of the thermistor body 13a in the longitudinal direction. Inside the thermistor body 13a is a detection element 13c, which serves as a base point for detecting temperature. The detection element 13c is mounted on the thermistor body 13a at a predetermined distance from the other end face toward the one end. A pair of lead wires 13d are connected to one end of the thermistor body 13a in the longitudinal direction of the detection element 13c. The ends of these pair of lead wires 13d are electrically connected to the pair of conductors 13b.

[0037] The leaf spring material 14 is a biasing member that biases the thermistor 13 to the winding coil 12. As shown in Figures 9(A) and 9(B), the leaf spring material 14 comprises an elongated flat leaf spring body 14a. The leaf spring body 14a is shaped with one end bent in an L-shape and the other end bent in a V-shape in the same direction as the other end, and is configured to have elastic force for biasing the thermistor 13 to the winding coil 12. The L-shaped bent portion 14b at one end of the leaf spring body 14a is provided with a concave insertion recess 14c through which the conductor 13a protruding from the thermistor 13 is inserted. The bent portion 14b is configured to hold the base end of the thermistor body 13b of the thermistor 13, which is attached to the thermistor housing 15, by allowing the conductor 13b of the thermistor 13 to be inserted into the insertion recess 14c.

[0038] On the other hand, the U-shaped elastic piece 14d at the other end of the leaf spring body 14a is inserted together with the thermistor 13 into the mounting recess 15a of the thermistor housing 15, and locks the thermistor 13 in place. The elastic force of the elastic piece 14d biases the thermistor 13 attached to the thermistor housing 15 toward the winding coil 12. Furthermore, a retaining piece 14e is provided in the middle of the leaf spring body 14a in the longitudinal direction, protruding from the opposite side of the bending direction of the bent portion 14b. The retaining piece 14e is formed by cutting and bending a part of the leaf spring body 14a. Furthermore, when the leaf spring material 14 is fitted into the mounting recess 15a of the thermistor housing 15 together with the thermistor 13, the retaining piece 14e engages with the locking surface 15c of the thermistor housing 15, thereby preventing the thermistor 13 from coming loose and holding it in place in the thermistor housing 15, thus forming a so-called snap-fit ​​configuration.

[0039] Furthermore, as shown in Figure 2, the thermistor 13 and leaf spring material 14 are each attached one to only one thermistor housing 15 among the multiple rear insulator members 51 of the insulator 11. The thermistor 13 is configured to detect the temperature of one adjacent winding coil 12 among the multiple winding coils 12. Here, one output side of the conductor 13b of the thermistor 13 is routed to the output connector 9A and led to the outside, as shown in Figure 5. The other ground side of this conductor 13b is electrically connected to the rotation sensor board 8 via connector 8a. For this reason, the thermistor 13 is attached to the thermistor housing 15 adjacent to the connector 8a and the output connector 9A of the rotation sensor board 8, respectively, taking into consideration the routing of the conductor 13b in order to shorten the length of the conductor 13b.

[0040] Furthermore, the thermistor 13 is press-fitted into the thermistor housing 15 together with the leaf spring material 14. The thermistor 13 is then pressed towards the winding coil 12 by the elastic force of the leaf spring material 14 generated between it and the outer surface of the thermistor housing 15, and contacts the winding 12a located on the inner circumference side of the winding coil 12 through the opening 15e of the thermistor housing 15. In addition, the thermistor 13 is fixed in contact with multiple windings 12a located on the inner layer side of the winding coil 12.

[0041] <Manufacturing method> Next, the manufacturing process for the motor 1 according to the above embodiment will be described with reference to Figure 14.

[0042] (Insulator assembly process) First, the insulator 11 is attached to the stator core 3a. At this time, the rear insulator member 51 and the front insulator member 61 are combined to form one winding section 11d (S1).

[0043] (winding process) In this state, the winding 12a is wound around the winding section 11d to mount the winding coil 12 (S2).

[0044] (Stator assembly process) Next, a total of 12 units are prepared by combining the rear insulator member 51 and the front insulator member 61, attaching the winding coil 12, and fitting the stator member 31. Then, these 12 units are arranged in an arc shape with the outer wall portion 11f of each unit facing outward. At this time, the opposing concave and concave surfaces 31a of adjacent stator members 31 are fitted together to form an arc-shaped stator 3 (S3).

[0045] (Busbar unit assembly process) Next, the busbar unit 7 is assembled to the rear side of the insulator 11 (S4). At this time, each insertion fixing portion 7b of the busbar unit 7 is inserted into each insertion receiving portion 11m of the insulator 11, and each locking projection 7c of the busbar unit 7 is fitted into each fitting groove portion 11p of the insulator 11.

[0046] (Bus bar fixing process) Next, the starting point 12c and ending point 12b of each winding coil 12 attached to the insulator 11 are welded and fixed to the connection portion 7m of each busbar terminal 7k of the busbar unit 7, thereby electrically connecting the starting point 12c and ending point 12b of each winding coil 12 to the predetermined busbar terminal 7k (S5).

[0047] (Adhesion process) In this state, a predetermined amount of adhesive 7f is injected into each through-hole 7d of the busbar unit 7, and this adhesive 7f is filled into the gap C formed between the insertion fixing part 7b of the busbar unit 7 and the insertion receiving part 11m of the insulator 11 and allowed to harden, thereby bonding and fixing the insertion fixing part 7b of the busbar unit 7 and the insertion receiving part 11m of the insulator 11 with the adhesive 7f (S6).

[0048] (Circuit board mounting process) Next, the rotation sensor board 8 is attached to the busbar unit 7 (S7).

[0049] (Thermistor installation process) Next, the base end of the conductor 13b of the thermistor 13 is inserted into the insertion recess 14c of the leaf spring material 14. The leaf spring body 14a of the leaf spring material 14 is then positioned adjacent to the outside of the thermistor body 13a of the thermistor 13. In this state, with the elastic piece 14d side of the leaf spring material 14 leading, the thermistor 13 and the leaf spring material 14 are press-fitted into the mounting recess 15a of the thermistor housing 15, which is located close to the rotation sensor substrate 8. At this time, the retaining piece 14e of the leaf spring material 14 engages with the locking surface 15c of the thermistor housing 15, and the thermistor 13 is held in place in the thermistor housing 15 (S8).

[0050] Within the thermistor housing 15, the elastic piece 14f of the leaf spring material 14 is pressed between the outer surface of the mounting recess 15a and the thermistor 13, causing it to elastically deform. The elastic force of this elastic piece 14f then presses the thermistor 13 towards the winding coil 12, causing the thermistor 13 to directly contact the multiple windings 12a located on the inner circumference side of the winding coil 12 through the opening 15e of the thermistor housing 15.

[0051] (Wire connection process) Next, one output end of the thermistor 13's wire 13b is routed to the output connector 9A and led out to the outside, while the other ground end of this wire 13b is electrically connected to the rotation sensor board 8 via connector 8a (S9).

[0052] (Case assembly process) Subsequently, the stator 3 and insulator 11 are attached to the case body 6 (S10).

[0053] (Front bracket installation process) Next, the front bracket 4 is attached to the front side of the case body 6, and the front bracket 4 is fixed to the case body 6 with bolts 10a (S11).

[0054] (Rotor assembly process) Furthermore, the rotor 2 is inserted into the stator 3 from the rear side (S12).

[0055] (Rear bracket installation process) Next, the rear bracket 5 is attached to the rear side of the stator 3, and then the rear bracket 5 is fixed to the case body 6 with bolt 10b (S13).

[0056] <Effects and Effects> As described above, the motor 1 according to the above embodiment has a configuration in which the busbar unit 7 is fixed concentrically to the rear side of the insulator 11. Therefore, since the busbar unit 7 can be firmly fixed to the insulator 11, vibrations that may occur when the motor 1 is driven can be appropriately suppressed.

[0057] In particular, the insulator 11 is provided with multiple insertion receiving portions 11m on its inner circumference, and the busbar unit 7 is provided with multiple insertion fixing portions 7b on its inner circumference. These insertion fixing portions 7b are inserted into the insertion receiving portions 11m and then fixed with adhesive 7f. Therefore, the stress on the connection portion 7m between the busbar terminal 7k and the starting point 12c and ending point 12b of the winding coil 12 can be reduced, thus preventing the connection portion 7m from breaking due to stress when fixing the busbar unit 7 to the insulator 11.

[0058] Furthermore, the insulator 11 has an insertion receiving portion 11m that protrudes in the inner diameter direction, and the busbar unit 7 has an insertion fixing portion 7b that protrudes in the inner diameter direction. As a result, even if the starting point 12c, which is the beginning of the winding coil 12, and the ending point 12b, which is the end of the winding, are made to protrude outwards from the outer diameter side of the insulator 11, or if the shape of the winding 12 in the axial view is made roughly fan-shaped for the purpose of improving the space factor of the winding coil 12, the connection portion 7m between the busbar terminal 7k and the starting point 12c and ending point 12b of the winding coil 12, and the insertion receiving portion 11m of the insulator 11 and the insertion fixing portion 7b of the busbar unit 7 can be arranged without interference in terms of layout.

[0059] Furthermore, a through hole 7d is provided in the insertion and fixing portion 7b of the busbar unit 7, and adhesive 7f is allowed to flow in through this through hole 7d to bond and fix the insertion and fixing portion 7b of the busbar unit 7 to the insertion receiving portion 11m of the insulator 11. Therefore, after assembling the busbar unit 7 to the insulator 11, the starting point 12c and ending point 12b of each winding coil 12 are welded to the connection portion 7m of each busbar terminal 7k of the busbar unit 7, and then adhesive 7f is applied to the through hole 7d to fix the busbar unit 7 to the insulator 11. As a result, compared to, for example, the case where adhesive 7f is applied, and the busbar unit 7 is assembled to the insulator 11 before the adhesive 7f hardens, and then the starting point 12c and ending point 12b of the winding coil 12 are crimped and welded, it is easier to predict and control the behavior of the fluid adhesive 7f, and it is easier to prevent problems such as insufficient bonding area. Furthermore, compared to fixing the busbar unit 7 to the insulator 11 by screwing it in, the assembly time for the busbar unit 7 can be reduced, making it possible to lower the cost of the motor 1.

[0060] Furthermore, the insertion receiving portion 11m of the insulator 11 and the insertion fixing portion 7b of the busbar unit 7 are each made to protrude inward to a position that covers a part of the rotor 2. In short, these insertion receiving portion 11m and insertion fixing portion 7b are positioned so that they overlap with the rotor 2 in an axial view. As a result, since the insertion fixing portion 7b is inserted into and fixed to the insertion receiving portion 11m, the fixing structure of these insertion receiving portion 11m and insertion fixing portion 7b can be made larger in the radial direction. Therefore, the busbar unit 7 can be fixed to the insulator 11 more firmly.

[0061] Furthermore, because the insertion receiving portion 11m and the insertion fixing portion 7b are configured to protrude inward to a position that covers a part of the rotor 2, the rotor 2 cannot be assembled from the rear side of the stator 3. Therefore, the motor 1 is made into a three-part structure consisting of a front bracket 4, a rear bracket 5, and a case body 6, so that the rotor 2 can be assembled from the front side of the stator 3. As a result, without changing the configuration other than the front bracket 4, the motor 1 can be adapted to the mounting target by simply changing the structure of the front bracket 4 to suit the mounting target. Therefore, for example, even with the side-mount type shown in Figure 12 or the center-mount type electric motorcycle drive motor shown in Figure 13, it is possible to accommodate them simply by redesigning the front bracket 4, thereby greatly improving the versatility of the motor 1.

[0062] Furthermore, multiple insertion receiving portions 11m and insertion fixing portions 7b are arranged at equal intervals in the circumferential direction of the insulator 11 and the busbar unit 7. Therefore, the busbar unit 7 can be fixed to the insulator 11 at multiple points along the circumferential direction on the inner side by these insertion receiving portions 11m and insertion fixing portions 7b, thus firmly fixing the busbar unit 7 to the insulator 11 in the circumferential direction. Additionally, the insertion receiving portion 11m of the insulator 11 is concave, and the insertion fixing portion 7b of the busbar unit 7 is inserted into this insertion receiving portion 11m. This simplifies the configuration for fixing the busbar unit 7 to the insulator 11, and simplifies the work of assembling the busbar unit 7 to the insulator 11. Thus, the ease of assembly of the busbar unit 7 can be improved.

[0063] Furthermore, by forming the through-hole 7d of the busbar unit 7 in a funnel shape with a reduced diameter in the insertion direction D, the ease of demolding when manufacturing the synthetic resin busbar unit 7 by injection molding or the like can be improved. In addition, since the entrance side portion of the through-hole 7d where the adhesive 7f is applied is widened, the busbar unit 7 can be properly fixed to the insulator 11 by the dispenser that applies the adhesive 7f.

[0064] Furthermore, by making the axial thickness of the busbar unit body 7a of the busbar unit 7 greater than that of the insertion and fixing portion 7b, the upper leg portion 7e of the insertion and fixing portion 7b can protrude upward, thereby securing the internal volume of the through hole 7d. And by setting the internal volume of the through hole 7d to be larger than the amount of adhesive 7f applied, it is possible to prevent the adhesive 7f from overflowing from the through hole 7d.

[0065] Furthermore, in the motor 1 according to the above embodiment, a thermistor housing 15 is provided at the center of the width direction A on the outer wall portion 11f of the insulator 11, and an opening 15e is formed in this thermistor housing 15 along the stacking direction B of the winding coil 12. By attaching the thermistor 13 to this thermistor housing 15, the thermistor 13 is configured to be in direct contact with a plurality of windings 12a on the inner layer side of the winding coil 12 at the center of the width direction B of the winding coil 12.

[0066] As a result, the temperature of the winding 12a on the inner circumference side in the stacking direction B of the winding coil 12, which is the area where heat tends to accumulate and becomes the hottest when the motor 1 is in operation, can be detected from the outside of the winding coil 12 by the thermistor 13, and the temperature of the winding coil 12 can be detected with high accuracy. Therefore, malfunctions and burnout failures caused by melting of the insulator 11 or peeling of the coating on the winding coil 12 that may occur when the motor 1 becomes hot can be appropriately suppressed, and damage to the motor 1 can be prevented.

[0067] In short, compared to conventional motors in which thermistors 13 are wound around the winding section 12 of the insulator 11 when winding the wire 12a, or thermistors 13 are placed inside the winding coil 12 or attached to the surface of the winding coil 12, motor 1 has a configuration in which thermistor housing section 15 is provided protruding from the outer circumference of the insulator 11. As a result, it is no longer necessary to wind the thermistors 13 around the winding 12a of the winding coil 12, so the radial size of the area around the winding coil 12 of motor 1 can be reduced, making motor 1 smaller in the radial direction, or in other words, thinner. Furthermore, the temperature of the winding coil 12 can be accurately detected without reducing the space for winding the winding 12a of the insulator 11.

[0068] Furthermore, the thermistor housing portion 15 is configured to protrude from the outer surface of the outer wall portion 11f of the insulator 11, and the thermistor 13 is fitted and fixed into this thermistor housing portion 15. This reduces physical interference caused by the stator 3, insulator 11, etc., when attaching and fixing the thermistor 13 to the thermistor housing portion 15. Thus, the assembly of the thermistor 13 can be made easier without reducing the ease of assembly of the stator core 3a. In addition, the thermistor housing portion 15 is configured to protrude from the outside of the outer wall portion 11f of the insulator 11 without increasing the radial thickness of the outer wall portion 11f itself. As a result, the outer wall portion 11f of the insulator 11 can be made thinner, so deformation during molding can be suppressed even if the insulator 11 is made of synthetic resin. Thus, the insulator 11 can be molded with high precision, and the ease of assembly of the thermistor 13 can be improved without reducing the ease of assembly of the stator core 3a.

[0069] Furthermore, the insulator 11 is configured such that each of the 12 winding sections 11d has a thermistor housing section 15 on its outer circumference. As a result, each of the 12 rear insulator members 51, which are divided in the circumferential direction, has a thermistor housing section 15, and these rear insulator members 15 can be made to have the same shape. Therefore, even though the insulator 11 is divided into 12 sections in the circumferential direction, the rear insulator members 51 that make up the insulator 11 can be made common, thereby improving the manufacturability of the insulator 11.

[0070] Furthermore, the insulator 11 is configured to have a thermistor housing 15 between the winding fitting grooves 11h and 11j. As a result, the thermistor housing 15 can reinforce the central position in the width direction A of the outer wall portion 11f of the insulator 11, which tends to be a weak point, i.e., the portion between the winding fitting grooves 11h and 11j. Thus, the rigidity of the outer wall portion 11f of the insulator 11, and consequently the insulator 11 itself, can be improved. Therefore, distortion of the insulator 11 that may occur when stress is applied to the outer wall portion 11f of the insulator 11 when winding the winding 12a around the winding winding portion 11d of the insulator 11 can be suppressed.

[0071] Furthermore, the winding 12a is made of flat rectangular wire, and one side of the winding 12a is brought into contact with the winding section 11d and wound around it. Then, the winding coil 12 is formed by stacking the wound windings 12a with one side of the other side of the wound winding 12a in contact with each other. As a result, compared to the case where the winding 12a is made of round bar wire, the thermistor 13 can be brought into contact with multiple windings 12a located on the inner layer side of the winding coil 12, and the contact area between the windings 12a and the thermistor 13 can be increased. Therefore, the temperature of the winding coil 12 can be accurately detected by the thermistor 13.

[0072] Furthermore, the thermistor 13 is press-fitted into the thermistor housing 15 of the insulator 11 together with the leaf spring material 14. The elastic force of the leaf spring material 14 presses the thermistor 13 against the winding coil 12, biasing the thermistor 13 into contact with the inner winding 12a of the winding coil 12 through the opening 15e of the thermistor housing 15. As a result, no space is created between the thermistor 13 and the winding coil 12, and even if it is subjected to external shocks or vibrations caused by the drive of the motor 1, these shocks and vibrations can be absorbed by the elastic force of the leaf spring material 14. Therefore, the elastic force of the leaf spring material 14 prevents a space from being created between the thermistor 13 and the winding coil 12, and prevents the thermistor 13 from shifting. Thus, the temperature of the winding coil 12 can be appropriately detected by the thermistor 13.

[0073] Furthermore, the base end of the conductor 13b of the thermistor 13 is inserted into the insertion recess 14c of the leaf spring material 14. When the thermistor 13 is press-fitted together with the leaf spring material 14 into the mounting recess 15a of the thermistor housing 15, the retaining piece 14e of the leaf spring material 14 engages with the locking surface 15c of the thermistor housing 15, creating a snap-fit ​​structure. As a result, the thermistor 13 is held in place in the thermistor housing 15 by the leaf spring material 14. Therefore, additional steps to hold the thermistor 13 in place in the thermistor housing 15, such as applying adhesive or assembling a separate component, are unnecessary. This allows the thermistor 13 to be easily attached to the insulator 11, significantly improving the ease of assembly of the thermistor 13.

[0074] In particular, the thermistor 13 is held in place by the thermistor housing 15 of the insulator 11, and a single leaf spring material 14 is used as a component to bias the thermistor 13, which is fixed to the thermistor housing 15, into contact with the winding coil 12. Therefore, the configuration of biasing the thermistor 13 to the winding coil 12 and the configuration of holding the thermistor 13 in place by the thermistor housing 15 can be appropriately realized with a single, relatively simple component, the leaf spring material 14.

[0075] As described above, the motor 1 according to the present invention contributes to achieving SDGs goals such as "Goal 9: Build resilient infrastructure, promote inclusive and sustainable industrialization and foster innovation" and "Goal 12: Ensure responsible consumption and production."

[0076] (others) It should be noted that the present invention is not limited to the embodiments described above, but includes various variations. For example, the embodiments described above were explained for the purpose of clearly illustrating the present invention, and the present invention is not necessarily limited to having all the configurations described.

[0077] For example, the motor 1 according to the above embodiment can be used as a drive motor for a side-mounted electric motorcycle shown in Figure 12 or a center-mounted electric motorcycle shown in Figure 13. In addition, it can be used as a power source for various electric devices with suitable driving force, such as in-wheel type electric motorcycles that are driven within the wheel, or small electric automobiles.

[0078] Furthermore, in the above embodiment, the motor 1 is configured such that the thermistor 13 is held in place by a leaf spring material 14 on the thermistor mounting portion 15 of the insulator 11 and pressed against the winding coil 12. However, for example, the thermistor 13 can be fixed to the thermistor mounting portion 15 using adhesive, or the thermistor 13 can be fixed to the thermistor mounting portion 15 with screws.

[0079] Furthermore, if the configuration can suppress deformation of the busbar unit 7 due to resonance, it is also possible to fix the busbar unit 7 to the insulator 11 using bolts or press-fitting without using adhesive 7f. [Explanation of Symbols]

[0080] 1 motor 2 rotors 2a Rotation axis 3 stata 3a Stator Core 3b Stator core body 3c Teeth 4 Front Bracket 4a Through hole 5 Rear Bracket 6 Case Body 7 Busbar Units 7a Busbar Unit Body 7b Insertion and fixing part (fixing part) 7c Locking protrusion 7d through hole 7e Legs 7f Adhesive 7g inner flange 7h Multilayered section 7j concave step 7k busbar terminal 7m connection section 8 Rotation Sensor Board 8a connector 9A output connector 9B Terminal Holder 9D Terminal 10a, 10b bolts 11 Insulators 11a Insulator Body 11b Inner flange 11c outer flange 11d Winding section 11e Stator core support 11f External wall 11h, 11j Winding fitting groove 11k inner wall 11m Insertion receiving part (receiving part) 11n Mating stepped part 11p Fitting groove 12-winding coil 12a winding 12b End point 12c Starting point 13. Thermistor (temperature detection sensor) 13a Thermistor body 13b Conductor 13c detection element 13d lead wire 14. Leaf spring material (biasing member) 14a Leaf spring body 14b Bend part 14c Insertion recess 14d Elastic piece 14e Retaining piece 15 Thermistor housing (housing section) 15a Mounting recess 15b Locking groove 15c Locking surface 15d Recessed area 15e opening 15f Locking piece 31 Stator component 31a Uneven surface 51 Rear side insulator component 61 Front side insulator component A Width direction B Stacking direction C Gap D Insertion direction

Claims

1. A cylindrical insulator having insulating properties with multiple winding sections arranged in the circumferential direction, and a cylindrical stator having multiple winding coils provided in each winding section of the insulator, A rotor rotatably positioned inside this stator, An annular busbar unit that supplies power to the plurality of winding coils, A motor equipped with, The busbar unit is fixed to one end of the insulator. A motor characterized by the following features.

2. The insulator has a receiving portion, The busbar unit has a fixing portion which is fixed to the receiving portion, The receiving part and the fixing part are fixed together with adhesive. The motor according to claim 1, characterized in that it is a motor.

3. The aforementioned fixing portion is provided with a through hole. The receiving portion is fixed to the fixing portion by filling the through hole with a fluid adhesive while the fixing portion is fitted into it. Motor according to feature 2

4. The receiving portion is provided on the inner circumference side of the insulator, protruding in the radial direction. The fixing portion is provided on the inner circumference side of the busbar unit. The motor according to claim 2 or 3, characterized in that it is a motor.

5. The receiving portion and the fixing portion are provided so as to protrude inward to a position that covers a part of the rotor. The motor according to feature 4.

6. The receiving portion and the fixing portion are arranged in a plurality in the circumferential direction. The motor according to feature 4.

7. The receiving portion is formed in a concave shape, The fixing portion is formed in the shape of a protrusion that fits into the receiving portion. The motor according to claim 2 or 3, characterized in that it is a motor.

8. The through hole is formed in a conical shape with a diameter that decreases in the fitting direction of the receiving portion. The motor according to claim 3, characterized in that it is as described above.

9. The stator is provided with a housing that is fixed to the inside, The housing has an opening on the side opposite to the side to which the busbar unit is attached. A cover is attached to this opening, with one end of the rotor protruding. The motor according to claim 1, characterized in that it is a motor.

10. A method for manufacturing a motor according to claim 2 or 3, A winding step of winding a winding around the insulator to form the winding coil, The assembly process involves assembling the busbar unit onto the insulator, A fixing step of fixing the end of the winding to the busbar terminal of the busbar unit, A bonding step of fixing the receiving portion of the insulator and the fixing portion of the busbar unit with an adhesive, A method for manufacturing a motor, characterized by having the following features.

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